information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for

omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

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Summary of Contents for Indian Motorcycle Scout 2025

Page 1 Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by Indian Motorcycle Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Page 2: Safety Warnings
Torx®, is a registered Trademark of Textron. Garmin®, is a registered trademark of Garmin, Ltd. Some Indian Motorcycle factory publications can be downloaded from www. polarisindustries. com, purchased from www.purepolaris.com or by contacting the nearest Indian Motorcycle dealer. REVISION INDEX...
Page 3: Feedback Form
FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile device by scanning the QR code or by clicking HERE if viewing this document...
Page 4 2025 Indian Scout Service Manual Chapter Summary CHAPTER 1 : GENERAL / SPECIFICATIONS CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING / EXHAUST CHAPTER 4 : FUEL DELIVERY / EFI CHAPTER 5 : CLUTCH / PRIMARY / SHIFT CHAPTER 6 : TRANSMISSION / CRANKSHAFT CHAPTER 7 :...
Page 5: Chapter 1 General / Specifications
GENERAL / SPECIFICATIONS CHAPTER 1 GENERAL / SPECIFICATIONS VEHICLE INFORMATION................1.2 .
Page 6 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E I I N N F F O O R R M M A A T T I I O O N N M M O O D D E E L L N N U U M M B B E E R R D D E E S S I I G G N N A A T T I I O O N N Example: N25SBB71AA TYPE MODEL...
Page 7 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E I I D D E E N N T T I I F F I I C C A A T T I I O O N N N N U U M M B B E E R R / / P P R R O O D D U U C C T T I I D D E E N N T T I I F F I I C C A A T T I I O O N N N N U U M M B B E E R R ( ( V V I I N N / / P P I I N N ) ) D D E E S S I I G G N N A A T T I I O O N N Example: 56KTCAAA0E3000024 Vehicle Descriptors...
Page 8 GENERAL / SPECIFICATIONS P P O O W W E E R R T T R R A A I I N N C C H H A A R R A A C C T T E E R R I I S S T T I I C C S S NOTICE Refer to the Owner’s Manual section on “Starting the Engine”...
Page 9 GENERAL / SPECIFICATIONS G G E E N N E E R R A A L L S S P P E E C C I I F F I I C C A A T T I I O O N N S S 2 2 0 0 2 2 5 5 M M O O D D E E L L S S P P E E C C I I F F I I C C A A T T I I O O N N S S NOTICE Scout Classic Shown.
Page 10: Wheels, Tires
GENERAL / SPECIFICATIONS Gross Vehicle Weight 988 lbs. (449 kg) Rating (GVWR) Gross Axle Weight Front 371 lbs. (168 kg) Rating Rear 675 lbs. (306 kg) (GAWR) Maximum Load Capacity US: 429 lbs. (195 kg) 428 lbs. US: 433 lbs. (196 kg) (riders, International: 428 lbs.
Page 11: Model Year
GENERAL / SPECIFICATIONS Rear 2 in. (51 3 in. (76 mm) Suspen- sion Travel Swingarm Steel Front Dual/320 mm Rotor/ Single/298 mm Rotor/2-Piston Caliper Brakes 4-Piston Caliper Rear Single/298 mm Rotor/1-Piston Caliper Brakes MODEL YEAR ALL MODELS 2025 ENGINE Engine Dry Weight Approximately 184 lbs (83 kg) Engine Type Liquid Cooled V-Twin (60 degrees)
Page 12 GENERAL / SPECIFICATIONS 4th Gear 4.850:1 5th Gear 4.286:1 6th Gear 3.680:1 ELECTRICAL Alternator 660W @ 5000 RPM 12 volt, 18 amp-hour, 310 CCA (cold cranking amps), Battery Maintenance Free AGM Voltage Regulator 14.5 volts/50 amp Headlight Classic / Bobber / Super / Sport: Reflective LED 101 Scout: LED - Solid Optics Tail/Brake Light Non-serviceable LED...
Page 13 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E L L O O A A D D I I N N G G G G R R O O S S S S V V E E H H I I C C L L E E W W E E I I G G H H T T R R A A T T I I N N G G ( ( G G V V W W R R ) ) WARNING Exceeding the gross vehicle weight rating of your motorcycle can reduce stability and handling and...
Page 14 GENERAL / SPECIFICATIONS E E M M I I S S S S I I O O N N I I N N F F O O R R M M A A T T I I O O N N E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L S S Y Y S S T T E E M M S S N N O O I I S S E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L The U.S.
Page 15 GENERAL / SPECIFICATIONS E E V V A A P P O O R R A A T T I I V V E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L ( ( I I N N T T L L / / C C A A L L I I F F O O R R N N I I A A M M O O D D E E L L S S ) ) California models are equipped with an Evaporative Emissions Canister...
Page 16 Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Indian Motorcycle recommends use of the Special Tools referenced in the chapters of this service manual when servicing any Indian Motorcycle product.
Page 18 GENERAL / SPECIFICATIONS S S P P E E C C I I A A L L T T O O O O L L S S I I N N D D E E X X E E N N G G I I N N E E / / C C O O O O L L I I N N G G / / E E X X H H A A U U S S T T Oil Pressure Gauge Engine Camshaft Timing Pin Set Crankshaft Locking Pin...
Page 19 GENERAL / SPECIFICATIONS Water Pump Seal Installation Tool Output Shaft Seal Tool Main Bearing Tool PF-51608 PF-51243 PF-52726 2 Main Bearing Tool Case Splitter PF-52726 1 PF-51234-A F F U U E E L L Fuel Tank Fitting Plug 12mm Fuel Pressure Adapter Fuel Pressure Gauge PV-48656...
Page 20 GENERAL / SPECIFICATIONS F F R R A A M M E E / / B B O O D D Y Y Body Panel Tool Kit PV-49955 S S T T E E E E R R I I N N G G / / S S U U S S P P E E N N S S I I O O N N / / W W H H E E E E L L Fork Spring Compressor Fork Spring Compressor Adapter Fork Spring Holder...
Page 21 GENERAL / SPECIFICATIONS Fork Seal Installer (inverted fork) Fork Seal Saver (inverted fork) Fork Socket Adapter / Cartridge PV-47035 PF-51611 Tool PF-51664-2 Shock Spanner Wrench Swingarm Bushing Tool Bearing Removal Kit PV-46993 PF-51237 PU-51324 Belt Tension Meter PV-43532 B B R R A A K K E E S S Brake Lever Pressure Test Tool Vacuum Brake Bleeder PV-50104...
Page 22 GENERAL / SPECIFICATIONS E E L L E E C C T T R R I I C C A A L L Battery Tester MultiLink XP PU-50296 PU-52792 9941686 R01 - 2025 Indian Scout Service Manual 1.18 © Copyright Polaris Industries Inc.
Page 23 GENERAL / SPECIFICATIONS D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I G G I I T T A A L L W W R R E E N N C C H H I I I I U U S S E E R R M M A A N N U U A A L L D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I A A G G N N O O S S T T I I C C C C O O N N N N E E C C T T O O R R The diagnostic connector is located under the seat...
Page 24 GENERAL / SPECIFICATIONS R R E E F F E E R R E E N N C C E E M M A A S S T T E E R R T T O O R R Q Q U U E E T T A A B B L L E E Camshaft Carrier 88 in-lbs (10 N·m) Fasteners (short &...
Page 25 GENERAL / SPECIFICATIONS Frame Tube Bracket to Thermostat Cover 19 ft-lbs (26 N·m) 96 in-lbs (11 N·m) Frame Fastener Bracket Fasteners Frame Tube to Mid-Cast/ Thermostat Housing 37 ft-lbs (50 N·m) 62 in-lbs (7 N·m) Frame Fasteners Fasteners Head Pipe Hanger (rear) 19 ft-lbs (26 N·m) 88 in-lbs (10 N·m) Valve Cover Fasteners...
Page 26 GENERAL / SPECIFICATIONS CHAPTER 5: CLUTCH / PRIMARY / SHIFT Step 1: 71 in-lbs (8 N·m) Step 2: Back out 125 ft-lbs (170 N·m) Clutch Retainer Nut fastener 40° and re- Starter Clutch Fasteners torque to 146 in-lbs CPS (Crank Position 88 in-lbs (10 N·m) (16.5 N·m) Sensor)
Page 27: Chapter 8: Steering / Suspension
GENERAL / SPECIFICATIONS Saddlebag Dampener Drive Sprocket Cover 44 in-lbs (5 N·m) 88 in-lbs (10 N·m) Fastener Fasteners Saddlebag Mount Drive Sprocket Nut 133 ft-lbs (180 N·m) 18 ft-lbs (25 N·m) Fastener Drive Sprocket Lock 88 in-lbs (10 N·m) Seat Mount Fastener, Plate Fasteners 88 in-lbs (10 N·m) Rear...
Page 28 GENERAL / SPECIFICATIONS CHAPTER 9: BRAKES Tone Ring Fasteners, 18 ft-lbs (24 N·m) Front: non 101 Scout ABS Module Mount 88 in-lbs (10 N·m) Fasteners Tone Ring Fasteners, 88 in-lbs (10 N·m) Front: 101 Scout Banjo Fastener (Front 44 in-lbs (5 N·m) Caliper, M/C) Valve Stem Nut 18 ft-lbs (25 N·m)
Page 29 GENERAL / SPECIFICATIONS Master Cylinder Cover License Plate Mount 88 in-lbs (10 N·m) 13 in-lbs (1.5 N·m) Fasteners (front) Fasteners 88 in-lbs (10 N·m) Nacelle Fasteners Master Cylinder Cover 13 in-lbs (1.5 N·m) Fasteners (rear) Regulator/Rectifier to 88 in-lbs (10 N·m) Bracket Fasteners Pad Retaining Pin, front and rear: Scout Bobber,...
Page 30 GENERAL / SPECIFICATIONS S S A A E E T T A A P P D D R R I I L L L L S S I I Z Z E E S S M M E E T T R R I I C C T T A A P P D D R R I I L L L L S S I I Z Z E E S S THREAD SIZE / DRILL THREAD SIZE / DRILL DECIMAL...
Page 31 GENERAL / SPECIFICATIONS D D E E C C I I M M A A L L E E Q Q U U I I V V A A L L E E N N T T S S 1/64 in = .0156 in 39/64 in = .6094 in 1/32 in = .0312 in [1 mm = .0394 in] 5/8 in = .625 in [16mm=.
Page 32 GENERAL / SPECIFICATIONS F F A A H H R R E E N N H H E E I I T T T T O O C C E E L L S S I I U U S S M M E E A A S S U U R R E E M M E E N N T T C C O O N N V V E E R R S S I I O O N N C C H H A A R R T T UNIT OF MULTIPLIED...
Page 33 GENERAL / SPECIFICATIONS UNIT OF MULTIPLIED COVERTS TO MEASURE Kilograms force = Kilo pascals x 98.1 per cm (kPa) = Cylinder p (3.14159) x R x H (height) Volume 9941686 R01 - 2025 Indian Scout Service Manual 1.29 © Copyright Polaris Industries Inc.
Page 34 GENERAL / SPECIFICATIONS R R O O U U T T I I N N G G D D O O C C U U M M E E N N T T S S This manual contains detailed routing documents which can be found in the Appendix section of the HTML manual.
Page 35 GENERAL / SPECIFICATIONS To access the routing documents: 1. With the HTML manual open, select the Routing Documents Appendix from the left side navigation menu. NOTICE Image for reference only. 2. Select the routing document you would like to view by clicking on the appropriate link.
Page 37: Maintenance
........2.4 INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS .
Page 38: Service Limit
MAINTENANCE M M A A I I N N T T E E N N A A N N C C E E Q Q U U I I C C K K R R E E F F E E R R E E N N C C E E G G U U I I D D E E M M A A I I N N T T E E N N A A N N C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S GENERAL SPECIFICATIONS ITEM...
Page 39: Fluid Type
5.25 qt (4.96 L) Dry Engine Transmission Oil Scout Classic, Bobber, 10.7 oz 315 cm Super, Sport (per side) (Conventional) Indian Motorcycle Fork Fork Oil Left Hand Fork: 13.9 oz 412 Oil 2208093 101 Scout (Inverted) Right Hand Fork: 11.5 oz 340 Recommended: 91 3.4 gal (13.0 L) / Reserve 0.5...
Page 40 Crankcase Sealant (Loctite Ultra Black 598) Available Conventional Forks: Scout Bobber / Scout Classic / SS–8 Active: 2880015 Super Scout / Sport Scout Indian Motorcycle Fork quart Fork Oil Oil (PN: 2208093) Inverted Forks: Fuchs SAF 5113, Ohlins 101 Scout...
Page 41 MAINTENANCE M M A A I I N N T T E E N N A A N N C C E E I I N N T T E E R R V V A A L L S S The maintenance interval charts outline required maintenance and inspection based on vehicle miles.
Page 42: Miles (Kilometers)
MAINTENANCE E E N N G G I I N N E E MILES (KILOMETERS) ENGINE Air Filter Crankcase Ventilation System Cooling System / Radiator Drive Belt Engine Compression Engine Mount Fasteners Engine Oil* Engine Oil Filter* Evaporative Emission Control System (If Equipped) Check and Re-Torque Exhaust Joints...
Page 43 MAINTENANCE MILES (KILOMETERS) CHASSIS Rear Wheel Alignment Road Test Sidestand / Sidestand Safety Switch Steering Bearings Swing Arm, Rear Axle, Swing Arm Pivot, and Pivot Bearings Tires / Wheels When the vehicle goes beyond 40,000 miles, return to 500 mile and start the interval process over. 9941686 R01 - 2025 Indian Scout Service Manual ©...
Page 44: Tool Description
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Indian Motorcycle CAUTION parts available from your Indian Motorcycle dealer. Failure to properly follow the engine break-in procedures outlined in this manual can result in IMPORTANT serious damage to the engine.
Page 45 MAINTENANCE R R O O U U T T I I N N E E M M A A I I N N T T E E N N A A N N C C E E P P R R O O C C E E D D U U R R E E S S 4.
Page 46 MAINTENANCE E E N N G G I I N N E E O O I I L L L L E E V V E E L L C C H H E E C C K K E E N N G G I I N N E E O O I I L L & & F F I I L L T T E E R R C C H H A A N N G G E E Due to the semi-dry sump lubrication system, the Follow all instructions carefully.
Page 47 MAINTENANCE 3. Clean the area around the two drain plugs . Place 13. Inspect the oil level by looking at the oil sight a drain pan under both drain plugs. glass. The oil level should be at or near the full mark on the oil sight glass.
Page 48 MAINTENANCE C C O O O O L L A A N N T T L L E E V V E E L L I I N N S S P P E E C C T T I I O O N N CAUTION Allow the vehicle to cool before performing any maintenance on the cooling system.
Page 49 MAINTENANCE B B R R A A K K E E F F L L U U I I D D L L E E V V E E L L I I N N S S P P E E C C T T I I O O N N 1.
Page 50 MAINTENANCE R R E E A A R R B B R R A A K K E E F F L L U U I I D D I I N N S S P P E E C C T T I I O O N N 1.
Page 51 MAINTENANCE T T I I R R E E P P R R E E S S S S U U R R E E / / S S P P E E C C I I F F I I C C A A T T I I O O N N S S WARNING Indian motorcycles are produced using the designated tires listed below as original equipment.
Page 52 MAINTENANCE LOADS UP TO VEHICLE’S LOADS UP TO 200 LB (91 KG) MAXIMUM LOAD CAPACITY LOCATION RECOMMENDED PRESSURE 40 psi (276 kPa) 40 psi (276 kPa) Rear 101 Scout 36 psi (248 kPa) 36 psi (248 kPa) Front 40 psi (276 kPa) 40 psi (276 kPa) Rear 9941686 R01 - 2025 Indian Scout Service Manual...
Page 53 MAINTENANCE S S P P A A R R K K P P L L U U G G I I N N S S P P E E C C T T I I O O N N / / G G A A P P WARNING A hot engine can cause serious burns.
Page 54 MAINTENANCE B B A A T T T T E E R R Y Y C C H H A A R R G G I I N N G G B B A A T T T T E E R R Y Y S S T T O O R R A A G G E E The battery will self-discharge when disconnected Batteries which are not connected to a vehicle should from a vehicle, and will discharge at a faster rate when...
Page 55 MAINTENANCE F F U U S S E E R R E E P P L L A A C C E E M M E E N N T T CAUTION Use fuses with the recommended amperage to avoid damage to the electrical system.
Page 56 MAINTENANCE H H E E A A D D L L I I G G H H T T A A I I M M I I N N S S P P E E C C T T I I O O N N Adjust headlight aim when there is a change in load (rider, cargo, accessories, etc.) and/or after suspension adjustment.
Page 57 MAINTENANCE H H E E A A D D L L I I G G H H T T A A I I M M A A D D J J U U S S T T M M E E N N T T 1.
Page 58 MAINTENANCE S S U U S S P P E E N N S S I I O O N N A A D D J J U U S S T T M M E E N N T T G G U U I I D D E E F F R R O O N N T T F F O O R R K K A A D D J J U U S S T T M M E E N N T T G G U U I I D D E E NOTICE Turning the adjusters fully clockwise (+) will result in a “fully-closed”...
Page 59 MAINTENANCE R R E E A A R R S S H H O O C C K K A A D D J J U U S S T T M M E E N N T T G G U U I I D D E E IMPORTANT Make sure the rear shock preload is set correctly before changing compression and rebound settings below.
Page 60 MAINTENANCE Special tools are required to perform this procedure. See the INDIAN MOTORCYCLE Service Manual or your authorized INDIAN MOTORCYCLE dealer or other qualified dealer. WARNING Uneven adjustment may cause poor handling of the motorcycle, which could result in an accident. Always adjust both the left and right shock preload equally, or have your dealer perform the adjustments.
Page 61 MAINTENANCE Rear Shock Factory Setting NOTICE Turning the adjusters fully clockwise (+) will result in a “fully-closed” position, while turning the adjusters fully counter-clockwise (-) will result in a “fully-open” position. 101 SCOUT 2 clicks from closed (4 clicks total) Shock Rebound, lower end of shock 2 clicks from closed (4 clicks total) Shock Compression, reservoir end of shock...
Page 62: Maintenance Procedure
MAINTENANCE M M A A J J O O R R M M A A I I N N T T E E N N A A N N C C E E P P R R O O C C E E D D U U R R E E S S IMPORTANT Reference the Maintenance Intervals page 2.5 for details on how often to perform each procedure.
Page 63 MAINTENANCE MAINTENANCE PROCEDURE LOCATION Sprocket Inspection Sprocket Inspection page 8.78 Sidestand Inspection Side-stand Inspection page 8.79 Side-stand Removal / Installation page 8.79 Sidestand Removal / Installation Swingarm Inspection Swing Arm Inspection page 8.80 Rear Shock preload Inspection Rear Shock Preload Inspection page 8.81 Rear Shock Preload Adjustment Rear Shock Preload Adjustment page 8.82 Shock Analysis...
Page 65 ENGINE / COOLING / EXHAUST CHAPTER 3 ENGINE / COOLING / EXHAUST MAINTENANCE - ENGINE / COOLING / EXHAUST ........... 3.4 .
Page 66 ENGINE / COOLING / EXHAUST ................3.34 OIL PRESSURE INSPECTION .
Page 67 ENGINE / COOLING / EXHAUST ..............3.70 VALVE SEAT RECONDITIONING .
Page 68 ENGINE / COOLING / EXHAUST M M A A I I N N T T E E N N A A N N C C E E - - E E N N G G I I N N E E / / C C O O O O L L I I N N G G / / C C O O O O L L I I N N G G S S Y Y S S T T E E M M P P R R E E S S S S U U R R E E T T E E S S T T E E X X H H A A U U S S T T 1.
Page 69 ENGINE / COOLING / EXHAUST C C O O O O L L I I N N G G S S Y Y S S T T E E M M H H O O S S E E S S NUMBER DESCRIPTION Radiator Inlet Hose...
Page 70 ENGINE / COOLING / EXHAUST R R A A D D I I A A T T O O R R I I N N S S P P E E C C T T I I O O N N / / C C L L E E A A N N I I N N G G CAUTION Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness.
Page 71 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T D D R R A A I I N N / / F F I I L L L L 3. Remove the coolant drain plug from the radiator.
Page 72: Hot Components
10. Remove the pinch pliers from the coolant line The engine should be at room temperature to between the reservoir and thermostat housing. perform this procedure. 11. Add Indian Motorcycle Extended Life 50/50 Engine Coolant to the reservoir fill opening until the 1. Allow engine to cool.
Page 73 ENGINE / COOLING / EXHAUST S S P P A A R R K K P P L L U U G G I I N N S S T T A A L L L L A A T T I I O O N N 8.
Page 74 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E C C O O M M P P R R E E S S S S I I O O N N T T E E S S T T ( ( W W E E T T ) ) 10.
Page 75 ENGINE / COOLING / EXHAUST V V A A L L V V E E C C L L E E A A R R A A N N C C E E A A D D J J U U S S T T M M E E N N T T 7.
Page 76 ENGINE / COOLING / EXHAUST A A I I R R B B O O X X S S E E R R V V I I C C E E 6. Disconnect breather hoses and remove airbox. A A I I R R B B O O X X R R E E M M O O V V A A L L 1.
Page 77 ENGINE / COOLING / EXHAUST 3. Install left gusset cover with fastener 4. Install the fuel tank. See Fuel Tank Installation page 4.29. 5. Install seat. See Seat Installation page 7.19. 9941686 R01 - 2025 Indian Scout Service Manual 3.13 ©...
Page 78 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S –...
Page 79 ENGINE / COOLING / EXHAUST S S P P E E C C I I A A L L T T O O O O L L S S - - E E N N G G I I N N E E PART NUMBER TOOL DESCRIPTION Engine Stand...
Page 80: Part Description
ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S E E N N G G I I N N E E B B R R A A C C K K E E T T / / F F A A S S T T E E N N E E R R C C O O M M P P O O N N E E N N T T S S NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)
Page 81 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E R R E E M M O O V V A A L L 20. Disconnect starter motor at the terminal P P R R E E P P A A R R A A T T I I O O N N F F O O R R E E N N G G I I N N E E R R E E M M O O V V A A L L NOTICE Different methods can be used to remove the engine depending on the equipment available to...
Page 82 ENGINE / COOLING / EXHAUST 23. Disconnect the oil pressure switch and fuel injector connectors 24. Disconnect the chassis ground 25. Following the wires from the components disconnect crankshaft position sensor connector stator connector , gear position switch connector , and side stand switch connector located between the mid frames.
Page 83 ENGINE / COOLING / EXHAUST R R E E M M O O V V I I N N G G E E N N G G I I N N E E F F R R O O M M F F R R A A M M E E 5.
Page 84 ENGINE / COOLING / EXHAUST 9. Push engine slightly to the right-hand side to free up from alignment dowels. With an assistant, lower the engine from the frame and remove from vehicle. 9941686 R01 - 2025 Indian Scout Service Manual 3.20 ©...
Page 85 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 86 ENGINE / COOLING / EXHAUST 8. Install upper mount fasteners and bracket 10. Torque the right-hand rear engine mounting fasteners fasteners to specification. TORQUE TORQUE Bracket Fasteners Mid Frame to Engine Fasteners: 53 ft-lbs (72 N·m) 59 ft-lbs (80 N·m) TORQUE 11.
Page 87 ENGINE / COOLING / EXHAUST 14. Connect coil connectors , knock sensor 16. Connect the starter motor battery cable at the connector , and electronic throttle body terminal connector NOTE Coolant temperature sensor and knock sensor have the same plugs. The red and black wired plug connects to the knock sensor.
Page 88 ENGINE / COOLING / EXHAUST 27. Install the mufflers. See Muffler Installation page 3.91. 28. Install the radiator assembly. See Radiator Removal / Installation page 3.37. 29. Fill and bleed the cooling system. See Coolant Drain / Fill page 3.7. 30.
Page 89: Low Oil Pressure
ENGINE / COOLING / EXHAUST L L U U B B R R I I C C A A T T I I O O N N / / C C O O O O L L I I N N G G T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G - - E E N N G G I I N N E E L L U U B B R R I I C C A A T T I I O O N N S S Y Y S S T T E E M M G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N...
Page 90 Measurements must be taken with be within 20% of the kPa) specification. engine at operating temperature and specified Indian Motorcycle Engine Oil OIL PUMP CLEARANCES (SCAVENGE) Pump Gerotor OD to Oil Pump Body .003"-.007" (0.100 mm - 0.200 .011" (.300 mm) Oil Pump End Clearance .0019"-.003"...
Page 91 Test the strength of the coolant using an antifreeze IMPORTANT hydrometer. Use Indian Motorcycle 50/50 Extended Life Coolant only. Do not mix coolant types. • A 50/50 mixture of extended life antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.
Page 92 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S - - L L U U B B R R I I C C A A T T I I O O N N L L U U B B R R I I C C A A T T I I O O N N S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S PRESSURE LUBRICATION SYSTEM ASSEMBLY VIEW ITEM...
Page 93 ENGINE / COOLING / EXHAUST ITEM DESCRIPTION TORQUE (IF APPLICABLE) – Piston Rear Cooling Jet Piston Cooling Jet Fastener 62 in-lbs (7 N·m) Oil Filter seal Oil Pump Pickup screen Oil Pump Pickup Screen Fastener 88 in-lbs (10 N·m) 9941686 R01 - 2025 Indian Scout Service Manual 3.29 ©...
Page 94 ENGINE / COOLING / EXHAUST SCAVENGE LUBRICATION SYSTEM ASSEMBLY VIEW ITEM DESCRIPTION TORQUE (IF APPLICABLE) Scavenge Oil Pump Fasteners 88 in-lbs (10 N·m) Engine Oil Scavenge Pump Engine Oil Drain Plugs 15 ft-lbs (20 N·m) Oil Drain Plug Sealing Washer Inlet Scavenge Engine Oil Screen Oil Scavenge Inlet Screen Fastener 88 in-lbs (10 N·m)
Page 95 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S - - C C O O O O L L I I N N G G C C O O O O L L I I N N G G S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION...
Page 96 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T F F L L O O W W D D I I A A G G R R A A M M Cooling System Flow Thermostat Closed (Bypass) Cooling System Flow Thermostat Open 9941686 R01 - 2025 Indian Scout Service Manual...
Page 97 ENGINE / COOLING / EXHAUST W W A A T T E E R R P P U U M M P P C C O O M M P P O O N N E E N N T T S S TORQUE (IF ITEM DESCRIPTION...
Page 98 ENGINE / COOLING / EXHAUST O O I I L L P P R R E E S S S S U U R R E E I I N N S S P P E E C C T T I I O O N N O O I I L L P P U U M M P P S S E E R R V V I I C C E E S S C C A A V V E E N N G G E E O O I I L L P P U U M M P P R R E E M M O O V V A A L L CAUTION...
Page 99 ENGINE / COOLING / EXHAUST S S C C A A V V E E N N G G E E O O I I L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N P P R R E E S S S S U U R R E E O O I I L L P P U U M M P P R R E E M M O O V V A A L L 1.
Page 100 ENGINE / COOLING / EXHAUST P P R R E E S S S S U U R R E E O O I I L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 101 ENGINE / COOLING / EXHAUST C C O O O O L L I I N N G G S S Y Y S S T T E E M M S S E E R R V V I I C C E E 10.
Page 102 ENGINE / COOLING / EXHAUST 5. Disconnect the cooling fan electrical connector 6. Remove the upper radiator hoses 7. Remove the lower coolant hose from the radiator. 8. Remove the radiator and store in a location to prevent damage. 9. Reverse removal procedure for installation. 10.
Page 103 ENGINE / COOLING / EXHAUST W W A A T T E E R R P P U U M M P P S S E E R R V V I I C C E E 6. Remove water pump impeller WATER PUMP SEAL REMOVAL AND INSTALLATION NOTICE Coolant may be present at the water pump weep...
Page 104 ENGINE / COOLING / EXHAUST WATER PUMP SHAFT OIL SEAL 9. Install new water pump seal in engine case by hand. Thread water pump seal installation tool PF- 1. Remove water pump seal. Refer to Water Pump 51608 on the water pump shaft. Seal Removal and Installation.
Page 105 ENGINE / COOLING / EXHAUST 5. Use a suitable driver to install the seal so the outer face is flush with the step on the engine case. 6. Install new water pump seal. Refer to Water Pump Seal Removal and Installation. 9941686 R01 - 2025 Indian Scout Service Manual 3.41 ©...
Page 106 ENGINE / COOLING / EXHAUST T T H H E E R R M M O O S S T T A A T T S S E E R R V V I I C C E E 7. Remove two fasteners WARNING Never remove pressure cap when engine is warm or hot.
Page 107 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G - - C C O O O O L L I I N N G G S S Y Y S S T T E E M M R R E E P P L L A A C C E E M M E E N N T T Overheating...
Page 108 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D / / V V A A L L V V E E S S •...
Page 109: Specification
ENGINE / COOLING / EXHAUST S S P P E E C C I I A A L L T T O O O O L L S S - - C C Y Y L L I I N N D D E E R R H H E E A A D D S S / / V V A A L L V V E E S S TOOL DESCRIPTION PART NUMBER Crankshaft Rotation Tool...
Page 110 ENGINE / COOLING / EXHAUST CYLINDER HEAD & VALVE TRAIN DATA ITEM STANDARD SERVICE LIMIT Cam Chain Tensioner Hydraulic / Self-Adjusting MIN: 1.0257" (26.053 mm) INTAKE MAX: 1.0335" (26.247 mm) Lobe Height MIN: 1.0198" (25.903 mm) EXHAUST MAX: 1.0274" (26.097 mm) Cam Shaft MIN: 1.0207”(25.926 mm) Journal O.D.
Page 111 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S C C A A M M C C H H A A I I N N S S C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION ITEM...
Page 112 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D / / C C A A M M S S H H A A F F T T S S C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 113 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 114 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T T T I I M M I I N N G G M M A A R R K K S S Camshaft Timing Front Cylinder 9941686 R01 - 2025 Indian Scout Service Manual 3.50...
Page 116 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N S S E E R R V V I I C C E E 7. Install cam tensioner with new sealing washer .
Page 117 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T R R E E M M O O V V A A L L C C A A M M D D R R I I V V E E G G E E A A R R R R E E M M O O V V A A L L 1.
Page 118 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S H H A A F F T T R R E E M M O O V V A A L L 6.
Page 119 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N G G U U I I D D E E R R E E M M O O V V A A L L C C A A M M C C H H A A I I N N R R E E M M O O V V A A L L 1.
Page 120 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 121 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N G G U U I I D D E E I I N N S S T T A A L L L L A A T T I I O O N N C C A A M M D D R R I I V V E E G G E E A A R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 122 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N / / T T I I M M I I N N G G 5.
Page 123 ENGINE / COOLING / EXHAUST 8. Install upper chain guide 11. Check that there is a gap between the sprocket fasteners, pin, and the edge of the sprocket TORQUE holes . If there is no gap, do the procedure again with the sprocket in a different position.
Page 124 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D S S E E R R V V I I C C E E 13.
Page 125 3. Lubricate the camshaft bearing journal surfaces with Indian Motorcycle engine oil prior to installation. 4. Carefully install the camshafts into the cylinder 2. Install NEW spark plug tube seal on cylinder head.
Page 126 ENGINE / COOLING / EXHAUST 6. Install the camshaft carrier fasteners . Follow the 8. Measure the valve clearance using a thickness torque sequence and tighten fasteners evenly to (feeler) gauge . Record the measurement if specification. clearance is out of specification. 9.
Page 127 ENGINE / COOLING / EXHAUST 12. Record the 3 digit number on the bottom of the tappet 13. Reference the valve clearance measurement recorded for that valve, along with the 3-digit tappet number. 14. Refer to the appropriate tappet selection matrix (Intake or Exhaust) on the following pages and select the proper tappet.
Page 128 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T I I N N S S P P E E C C T T I I O O N N For the following camshaft inspection procedure, refer to the camshaft service specifications section.
Page 129 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D R R E E M M O O V V A A L L 8.
Page 130 ENGINE / COOLING / EXHAUST 11. Remove the cylinder head assembly and cylinder 3. Using valve spring compressor PV-1253 remove head gasket by carefully lifting off of cylinder. keepers , upper spring retainer and valve spring from valves. 4. Slide valve out through the bottom of the C C Y Y L L I I N N D D E E R R H H E E A A D D D D I I S S A A S S S S E E M M B B L L Y Y cylinder head.
Page 131 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D I I N N S S P P E E C C T T I I O O N N V V A A L L V V E E S S P P R R I I N N G G F F R R E E E E L L E E N N G G T T H H I I N N S S P P E E C C T T I I O O N N 1.
Page 132 ENGINE / COOLING / EXHAUST V V A A L L V V E E I I N N S S P P E E C C T T I I O O N N b. Position dial indicator as shown. Measure deflection in two directions perpendicular to NOTE each other (X &...
Page 133 ENGINE / COOLING / EXHAUST V V A A L L V V E E I I N N S S P P E E C C T T I I O O N N - - Q Q U U I I C C K K R R E E F F E E R R E E N N C C E E CONDITION ILLUSTRATION POSSIBLE CAUSE...
Page 134 ENGINE / COOLING / EXHAUST V V A A L L V V E E S S E E A A T T I I N N S S P P E E C C T T I I O O N N V V A A L L V V E E S S E E A A T T R R E E C C O O N N D D I I T T I I O O N N I I N N G G NOTE IMPORTANT...
Page 135 2. Install valve in head before installing seal. Hold valve against seat wipe off the portion that extends above the guide. 3. Apply Indian Motorcycle engine oil to valve guide seal and install seal on valve, rotating the seal as you install it.
Page 136 / Installation page 3.87. 2. Install Cylinder. See Cylinder Inspection / Installation page 3.87. 7. Apply a thin coat of Indian Motorcycle engine oil to 3. Verify that locating dowels are in position on the the threads and head of the cylinder head fasteners cylinder deck.
Page 137 88 in-lbs (10 N·m) 13. Temporarily install the upper cam chain guide and torque the carrier fasteners per the specified 10. Apply a thin coat of Indian Motorcycle engine oil to sequence. each of the tappets and install them in the same position from which they were removed.
Page 139 ENGINE / COOLING / EXHAUST V V A A L L V V E E L L A A S S H H - - T T A A P P P P E E T T S S E E L L E E C C T T I I O O N N A 440 tappet means the thickness of the tappet is 4.40 mm.
Page 140 ENGINE / COOLING / EXHAUST T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G C C Y Y L L I I N N D D E E R R H H E E A A D D A A N N D D V V A A L L V V E E T T R R A A I I N N NOTICE Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test.
Page 141 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Piston Rings or Piston Ring Replace Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Chain Tensioner and / or Guide Replace Worn Bottom End Area Main Bearings...
Page 142: Tool Description
ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N S S P P E E C C I I A A L L T T O O O O L L S S G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N TOOL DESCRIPTION PART NUMBER...
Page 143 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N NOTE Measure parts at 68°...
Page 144 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 145 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N S S E E R R V V I I C C E E P P I I S S T T O O N N R R I I N N G G P P R R O O F F I I L L E E A A N N D D O O R R I I E E N N T T A A T T I I O O N N NUMBER DESCRIPTION...
Page 146 ENGINE / COOLING / EXHAUST ITEM DESCRIPTION Top Compression Ring End Gap Piston Arrow points towards front of Engine C C Y Y L L I I N N D D E E R R R R E E M M O O V V A A L L C C Y Y L L I I N N D D E E R R B B O O R R E E M M E E A A S S U U R R E E M M E E N N T T 1.
Page 147 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N T T O O C C Y Y L L I I N N D D E E R R C C L L E E A A R R A A N N C C E E W W O O R R K K S S H H E E E E T T FRONT CYLINDER RECORDED MEASUREMENT SPECIFICATION...
Page 148 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R W W A A R R P P A A G G E E M M E E A A S S U U R R E E M M E E N N T T 5.
Page 149 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N P P I I N N / / P P I I N N B B O O R R E E I I N N S S P P E E C C T T I I O O N N 4.
Page 150 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N I I N N S S T T A A L L L L A A T T I I O O N N 8.
Page 151 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R I I N N S S P P E E C C T T I I O O N N / / I I N N S S T T A A L L L L A A T T I I O O N N 8.
Page 152 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
Page 153 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Wrist Pin, Wrist Pin Replace Bore and / or Connecting Worn Piston Rings or Replace Piston Ring Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Chain Tensioner and / or...
Page 154 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T A A S S S S E E M M B B L L Y Y V V I I E E W W S S E E X X H H A A U U S S T T S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S NUMBER DESCRIPTION...
Page 155 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T S S E E R R V V I I C C E E M M U U F F F F L L E E R R I I N N S S T T A A L L L L A A T T I I O O N N M M U U F F F F L L E E R R R R E E M M O O V V A A L L 1.
Page 156 ENGINE / COOLING / EXHAUST H H E E A A D D P P I I P P E E R R E E M M O O V V A A L L 5. Disconnect downstream oxygen sensor 1.
Page 157 ENGINE / COOLING / EXHAUST 8. Remove old exhaust Gaskets from front and rear 3. Install Rear Head Pipe to engine and secure with exhaust tube. two Head Pipe Nuts 4. Torque Head Pipe fasteners to specification. Follow torque sequence shown. H H E E A A D D P P I I P P E E I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 158 ENGINE / COOLING / EXHAUST 6. Connect Rear Oxygen Sensor located under the battery tray. 7. Connect Downstream Oxygen Sensor located under the swing arm. 9941686 R01 - 2025 Indian Scout Service Manual 3.94 © Copyright Polaris Industries Inc.
Page 159 FUEL DELIVERY / EFI CHAPTER 4 FUEL DELIVERY / EFI GENERAL INFORMATION ................4.3 .
Page 160 FUEL DELIVERY / EFI .................4.40 FUEL INJECTOR O-RINGS .
Page 161 FUEL DELIVERY / EFI G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N F F U U E E L L I I N N J J E E C C T T I I O O N N S S Y Y S S T T E E M M - - O O V V E E R R V V I I E E W W O O F F The locations of sensors and other EFI system related O O P P E E R R A A T T I I O O N N...
Page 162 FUEL DELIVERY / EFI C C Y Y L L I I N N D D E E R R M M I I S S F F I I R R E E D D E E T T E E C C T T I I O O N N The ECU monitors crankshaft speed via the crankshaft position sensor.
Page 163: Troubleshooting
FUEL DELIVERY / EFI TROUBLESHOOTING • Ignition Coil and connections are good • Spark plugs wires are secure • The correct spark plugs are installed and the plugs are not fouled • Crankshaft Position Sensor tests good • Wiring to the Crankshaft Position Sensor, ECU and Ignition Coil are not damaged. Chassis ground is clean and tight •...
Page 164 FUEL DELIVERY / EFI S S E E R R V V I I C C E E N N O O T T E E S S - - F F U U E E L L D D E E L L I I V V E E R R Y Y / / E E F F I I When replacing fuel lines, always use genuine Indian Motorcycle replacement parts.
Page 165 FUEL DELIVERY / EFI S S P P E E C C I I A A L L T T O O O O L L S S - - F F U U E E L L D D E E L L I I V V E E R R Y Y / / E E F F I I TOOL DESCRIPTION PART NUMBER Fuel Pressure Adapter...
Page 166 FUEL DELIVERY / EFI M M A A I I N N T T E E N N A A N N C C E E - - F F U U E E L L D D E E L L I I V V E E R R Y Y / / E E F F I I E E V V A A P P O O R R A A T T I I V V E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L S S Y Y S S T T E E M M ( ( C C A A L L I I F F O O R R N N I I A A A A N N D D I I N N T T E E R R N N A A T T I I O O N N A A L L I I D D L L E E S S P P E E E E D D / / F F A A S S T T I I D D L L E E S S P P E E E E D D...
Page 167 Always investigate The fuel lines exiting fuel pump are subjected to high the cause of the problem and repair before replacing pressure. Replace with genuine Indian Motorcycle the fuse. replacement parts to reduce the possibility of fuel line failure.
Page 168 FUEL DELIVERY / EFI A A S S S S E E M M B B L L Y Y V V I I E E W W S S F F U U E E L L L L I I N N E E R R O O U U T T I I N N G G ( ( 4 4 9 9 S S T T A A T T E E M M O O D D E E L L S S ) ) ITEM DESCRIPTION Fuel Tank Separator...
Page 169 FUEL DELIVERY / EFI F F U U E E L L L L I I N N E E R R O O U U T T I I N N G G ( ( 5 5 0 0 S S T T A A T T E E / / I I N N T T L L ) ) ITEM DESCRIPTION Vent Connector...
Page 170 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 171 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 172 FUEL DELIVERY / EFI A A I I R R B B O O X X C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE) Air Filter Fasteners (QTY.4) 14 in-lbs (1.6 N·m) –...
Page 173: Sensor Location
FUEL DELIVERY / EFI S S E E N N S S O O R R S S - - P P O O W W E E R R T T R R A A I I N N M M A A N N A A G G E E M M E E N N T T C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM SENSOR / LOCATION...
Page 174 FUEL DELIVERY / EFI F F U U E E L L D D E E L L I I V V E E R R Y Y S S E E R R V V I I C C E E I I N N T T A A K K E E M M A A N N I I F F O O L L D D R R E E M M O O V V A A L L 1.
Page 175 FUEL DELIVERY / EFI I I N N T T A A K K E E M M A A N N I I F F O O L L D D I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 176 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P P P R R E E S S S S U U R R E E I I N N S S P P E E C C T T I I O O N N 4.
Page 177 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M D D E E P P R R E E S S S S U U R R I I Z Z A A T T I I O O N N •...
Page 178 FUEL DELIVERY / EFI • Option 2: Use your fingers to pull rearward on the release tabs at the bottom of the connector and at the same time, slide the lock tab up while pulling the connector gently away from the fuel rail.
Page 179 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K R R E E M M O O V V A A L L 6. Remove the rear tank cover .
Page 180 FUEL DELIVERY / EFI 9. There are two ways to disconnect the quick • Option 2: Use your fingers to pull rearward on connect: the release tabs at the bottom of the connector and at the same time, slide the lock tab up while •...
Page 181 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P R R E E M M O O V V A A L L 12. Lift the fuel tank off of the motorcycle. IMPORTANT WARNING During removal, make sure the fuel line does not get...
Page 182 FUEL DELIVERY / EFI 4. Disconnect the fuel line hose . Squeeze both release buttons on each side of fitting and hold. Gently slide fitting straight off fuel pump port. STOP! Do not use anything other than fingers to remove the quick connection.
Page 183 FUEL DELIVERY / EFI F F U U E E L L F F I I L L T T E E R R R R E E P P L L A A C C E E M M E E N N T T 7.
Page 184 FUEL DELIVERY / EFI 3. Install fuel pump baffle on the pickup assembly and secure with the 7080138 cable tie. Ensure baffle is properly positioned onto fuel pump by pushing the baffle retention feature against the fuel pump filter retainer. Pulling the baffle too far toward the fuel pump will cause the filter to be incorrectly positioned in the fuel tank.
Page 185 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 186 FUEL DELIVERY / EFI 5. Install fuel pump fasteners in sequence. Torque to specification. TORQUE Fuel Pump Fasteners: 44 in-lbs (5 N·m) 6. Install the fuel tank. See Fuel Tank Installation page 4.29. 7. Prime the fuel system and verify fuel pump operation.
Page 187 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K I I N N S S T T A A L L L L A A T T I I O O N N 4.
Page 188 FUEL DELIVERY / EFI P P R R I I M M I I N N G G T T H H E E F F U U E E L L S S Y Y S S T T E E M M 9.
Page 189 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T E E S S T T S S 3. On the fuel pump side of the connector, measure resistance across the level sender and compare to F F U U E E L L L L E E V V E E L L S S E E N N S S O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T the table.
Page 190: Wire Color
FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P S S U U P P P P L L Y Y V V O O L L T T A A G G E E T T E E S S T T 8.
Page 191 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P C C U U R R R R E E N N T T D D R R A A W W T T E E S S T T 5.
Page 192 FUEL DELIVERY / EFI E E F F I I S S E E R R V V I I C C E E E E C C M M R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 193 FUEL DELIVERY / EFI E E C C M M C C O O N N N N E E C C T T O O R R R R E E M M O O V V A A L L A A N N D D I I N N S S T T A A L L L L A A T T I I O O N N E E C C M M C C O O N N N N E E C C T T O O R R R R E E M M O O V V A A L L 1.
Page 194 FUEL DELIVERY / EFI T T E E M M P P E E R R A A T T U U R R E E M M A A N N I I F F O O L L D D A A B B S S O O L L U U T T E E T T M M A A P P S S E E N N S S O O R R R R E E P P L L A A C C E E M M E E N N T T P P R R E E S S S S U U R R E E S S E E N N S S O O R R ( ( T T M M A A P P ) ) R R E E P P L L A A C C E E M M E E N N T T REMOVAL...
Page 195 FUEL DELIVERY / EFI INSTALLATION 1. INSTALLATION is performed by reversing the removal procedure. 2. Install the TMAP sensor on the intake manifold 3. Install the TMAP sensor fastener TORQUE TMAP Sensor Fastener: 48 in-lbs (6 N·m) 4. Reconnect the vehicle harness to the TMAP sensor 5.
Page 196 FUEL DELIVERY / EFI C C O O O O L L A A N N T T T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R ( ( C C T T S S ) ) , , T T E E S S T T / / R R E E P P L L A A C C E E CHT TEST OVERVIEW INDICATES...
Page 197 FUEL DELIVERY / EFI F F U U E E L L I I N N J J E E C C T T O O R R R R E E M M O O V V A A L L F F U U E E L L I I N N J J E E C C T T O O R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 198 FUEL DELIVERY / EFI F F U U E E L L I I N N J J E E C C T T O O R R O O - - R R I I N N G G S S 5.
Page 199 FUEL DELIVERY / EFI T T H H R R O O T T T T L L E E B B O O D D Y Y ( ( E E T T C C ) ) R R E E M M O O V V A A L L 4.
Page 200 FUEL DELIVERY / EFI C C R R A A N N K K S S H H A A F F T T P P O O S S I I T T I I O O N N S S E E N N S S O O R R ( ( C C P P S S ) ) I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 201 FUEL DELIVERY / EFI E E F F I I T T E E S S T T S S E E C C M M C C O O N N N N E E C C T T O O R R M M A A P P PIN ECM COLOR FUNCTION...
Page 202 FUEL DELIVERY / EFI PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION NOT USED NOT USED NOT USED PK / RD ETC MOTOR (+) NOT USED CPS POSITIVE SIGNAL NOT USED CPS NEGATIVE SIGNAL NOT USED OG / DG INTAKE AIR TEMPERATURE (IAT) SENSOR OUTPUT NOT USED OG / BN...
Page 203 FUEL DELIVERY / EFI PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION NOT USED BK / WH ECM GROUND NOT USED BK / WH ECM GROUND NOT USED REAR COIL SIGNAL NOT USED FRONT COIL SIGNAL GY / YE FRONT HEATED OXYGEN SENSOR NOT USED (H02) SENSOR CONTROL VT-PK...
Page 204 FUEL DELIVERY / EFI D D I I A A G G N N O O S S T T I I C C T T R R O O U U B B L L E E C C O O D D E E S S COMPONENT CONDITION CODE...
Page 205 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Circuit Fault P0914 Voltage Too High P0917 Gear Sensor Signal Voltage Too Low P0916 Signal Fault P0915 Cruise Control Message Fault Cruise Control P0575 Brake Switch Fault C10B9 ABS Brake Switch Update Error Brake Switch C0040 ABS Brake Switch Message Error...
Page 206 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Driver Circuit Too Low P0231 Driver Circuit Low or Open P0230 Lamp Current Low or Open Circuit C232D High Beam Lamp 2348 Lamp Current High or Shorted Circuit C232C Lamp Current Low or Open Circuit C2332 Low Beam Lamp 2350...
Page 207 FUEL DELIVERY / EFI COMPONENT CONDITION CODE VCM1 Abnormal Update Rate C236D Vehicle Speed 516120 WCM1 Abnormal Update Rate U260F CAN Bus Communication Error U0010 Low Speed CAN Bus 516125 CAN Bus Communications Failure U2321 VCM1 CAN Root Cause Unknown C2341 516132 Horn Switch...
Page 208 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Torque Limit Request Message Fault U1065 Torque Target Request Message Fault U1066 Torque Target Request Message Fault U1066 516811 Torque Target Request Message Fault U1066 Torque Target Request Message Fault U1066 Battery Internal Battery Failure 516865 C10B5 Internal Fault...
Page 209 FUEL DELIVERY / EFI COMPONENT CONDITION CODE RH Control Internal Reference Voltage Incorrect C1442 520186 Hand Control LH Control Internal Reference Voltage Incorrect C1452 RH Control EEPROM CRC Fault Incorrect C1443 LH Control EEPROM CRC Fault Incorrect C1453 520187 Hand Control RH Control EEPROM CRC Fault Damaged Component C1444 LH Control EEPROM CRC Fault Damaged Component...
Page 210 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Minimum P152D Throttle Body Control - Position 520284 Condition Exists P152E Deviation Fault 520285 Brake Switch Correlation Fault P153E ECU Monitoring Error (Level 3) 520287 Condition Exists P1541 ECU Monitoring of Injection Cut Off 520288 Condition Exists P1542...
Page 211 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Data Valid But Below Normal Operating Range - Least P2180 Severe Level (System Too Lean) Feature Memory Object Not Configured 520379 C1169 Monitoring Keep Alive Error 520382 P154A Monitoring Memory Error 520383 P154B Monitoring T15 Error 520384 P154C...
Page 212 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Abnormal Update Rate B1019 Switch Message Error B1018 Right Turn Signal 524053 Abnormal Update Rate B1018 Switch Message Error B1017 Left Turn Signal 524054 Abnormal Update Rate B1017 Input CAN Message Fault C117B High Beam Switch 524056 Status Incorrect Data...
Page 213 FUEL DELIVERY / EFI ABS Trouble Codes TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Bad Intelligent Device Replace Module 520140 ABS ECU C2437 ABS Valve Relay Replace Module 520131 Condition Exists C2420 ABS Solenoid (Front In) Replace Module...
Page 214 FUEL DELIVERY / EFI TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Check Supply/ Voltage Below Normal Signal Line C123D Voltage Check Tone Wheel Speed Sensor Wheel Speed Sensor Wheel Alignment 520135 C2430 Signal Error...
Page 215 FUEL DELIVERY / EFI TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Check wiring and PGN 61441 Missing connection to 516136 Condition Exists U1112 EBC1–Lamp Info Gauge and ABS Check wiring and connections for PGN 65265 Missing Abnormal Update Rate...
Page 216 FUEL DELIVERY / EFI S S E E N N S S O O R R D D I I A A G G N N O O S S T T I I C C S S E E C C M M P P I I N N O O U U T T T T E E S S T T I I N N G G If a sensor fails or reads outside a “normal”...
Page 217 FUEL DELIVERY / EFI C C R R A A N N K K S S H H A A F F T T P P O O S S I I T T I I O O N N S S E E N N S S O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T 1.
Page 218 FUEL DELIVERY / EFI D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I G G I I T T A A L L W W R R E E N N C C H H I I I I U U S S E E R R M M A A N N U U A A L L NOTICE Digital Wrench®...
Page 219 FUEL DELIVERY / EFI T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 1 1 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
Page 220 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 2 2 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
Page 221 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 3 3 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
Page 222 Won’t Accept Non-Current Go to Dealer website and New Calibration Calibration File Set download the most current Low Battery Voltage Indian Motorcycle Calibration Attempting Re-Flash File Set Without Proper VIN/ PIN, Calibration I.D. Attach Battery Charger number, or calibration During Re-Flash, and Re-...
Page 223 CLUTCH / PRIMARY / SHIFT CHAPTER 5 CLUTCH / PRIMARY / SHIFT GENERAL INFORMATION ................5.2 .
Page 224: Specifications
Mechanism Cable • Oil additives of any kind are not recommended by Operated Indian Motorcycle. Using oil additives or oil of the Primary Reduction Ratio 1.674 : 1 wrong viscosity can have a detrimental affect on clutch performance, operation, and service life.
Page 225 CLUTCH / PRIMARY / SHIFT M M A A I I N N T T E E N N A A N N C C E E - - C C L L U U T T C C H H / / P P R R I I M M A A R R Y Y 3.
Page 226 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H L L E E V V E E R R L L U U B B R R I I C C A A T T I I O O N N C C L L U U T T C C H H L L E E V V E E R R F F R R E E E E P P L L A A Y Y 1.
Page 227 CLUTCH / PRIMARY / SHIFT 5. Verify that the safety switch activates properly. The 2. Remove shift pedal fasteners and shift linkage engine should not start in gear with the clutch lever fasteners to remove shift pedal assembly. released. NOTICE Image is for reference only.
Page 228 CLUTCH / PRIMARY / SHIFT 6. Assemble foot pedal bushing with fastener Torque to specification. TORQUE Shift Pedal Pivot Bushing Fastener: 26 ft-lbs (35 N·m) 7. Install shift pedal assembly with fastener TORQUE Footpeg Mount Fasteners 53 ft-lbs (72 N·m) TORQUE Shift Linkage Fasteners 88 in-lbs (10 N·m)
Page 229 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T P P E E D D A A L L A A D D J J U U S S T T M M E E N N T T 2.
Page 230 CLUTCH / PRIMARY / SHIFT 3. Tighten jam nuts to specification. TORQUE Shift Rod Jam Nuts: 96 in-lbs (11 N·m) CAUTION Do not remove and reposition the shift arm on the shift shaft to adjust gear shift pedal height. Dots on shift shaft and shift arm must be aligned for gears to shift correctly.
Page 231 CLUTCH / PRIMARY / SHIFT A A S S S S E E M M B B L L Y Y V V I I E E W W S S P P R R I I M M A A R R Y Y C C O O V V E E R R C C O O M M P P O O N N E E N N T T S S NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
Page 232 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION Primary Cover...
Page 233: Item Description
CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y C C O O M M P P O O N N E E N N T T S S TORQUE TORQUE ITEM...
Page 234 CLUTCH / PRIMARY / SHIFT S S E E R R V V I I C C E E P P R R O O C C E E D D U U R R E E S S P P R R I I M M A A R R Y Y D D R R I I V V E E C C O O V V E E R R R R E E M M O O V V A A L L P P R R I I M M A A R R Y Y D D R R I I V V E E C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 235 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T 5. Install hose routing with fasteners C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T R R E E M M O O V V A A L L 1.
Page 236 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T S S E E A A L L R R E E P P L L A A C C E E M M E E N N T T 2.
Page 237 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T R R A A T T C C H H E E T T R R E E M M O O V V A A L L / / I I N N S S P P E E C C T T I I O O N N 7.
Page 238 CLUTCH / PRIMARY / SHIFT 10. Inspect shift shaft return spring for cracks or loss of tension. The spring should have enough tension to keep the shift shaft centered. 11. Inspect shift shaft for wear or damage. 12. Inspect ratchet arm return spring for tension.
Page 239 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T R R A A T T C C H H E E T T I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 241 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T A A R R M M R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 2.
Page 242 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T S S H H A A F F T T S S E E A A L L R R E E P P L L A A C C E E M M E E N N T T 1.
Page 243 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H S S E E R R V V I I C C E E C C L L U U T T C C H H R R E E M M O O V V A A L L C C L L U U T T C C H H R R A A C C K K R R E E M M O O V V A A L L 1.
Page 244 CLUTCH / PRIMARY / SHIFT 10. Remove crankshaft nut and washer 13. Use a punch to align crankshaft split gear holes Remove clutch assembly and thrust washer. IMPORTANT A new stake nut must be installed upon assembly. 11. Use a punch to align Camshaft split gear holes Remove crank drive gear 12.
Page 245 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H D D I I S S A A S S S S E E M M B B L L Y Y CAUTION Clutch is under spring pressure.
Page 246 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H I I N N S S P P E E C C T T I I O O N N 8. Inspect surface of steel plate guides on outer edge of hub for wear, grooves, or damage.
Page 247 CLUTCH / PRIMARY / SHIFT 16. Inspect clutch rack for broken or damaged teeth. 17. Inspect lifter bearing visually for any signs or wear or discoloration. Rotate bearing inner race with your finger and check for smooth movement and no play. 18.
Page 248 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y 6. install assembled hub into the basket and onto the counter shaft splines.
Page 249 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H I I N N S S T T A A L L L L A A T T I I O O N N 7.
Page 250 CLUTCH / PRIMARY / SHIFT IMPORTANT Clutch assembly installation inspection. Verify the outer face of the clutch gear is inset from the primary gear 11. Torque the stake nut to specification. TORQUE Stake Nuts: 125 ft-lbs (170 N·m) 12. Stake the stake nuts at two points with punch or similar 13.
Page 251 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L S S E E R R V V I I C C E E S S T T A A T T O O R R C C O O V V E E R R R R E E M M O O V V A A L L S S T T A A T T O O R R C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 252 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L R R E E M M O O V V A A L L 5. Install flywheel remove tool PA-49316–A on the flywheel and tighten puller to remove flywheel...
Page 253 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L I I N N S S T T A A L L L L A A T T I I O O N N CAUTION The flywheel contains powerful magnets.
Page 254 CLUTCH / PRIMARY / SHIFT T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G C C L L U U T T C C H H / / P P R R I I M M A A R R Y Y / / S S H H I I F F T T PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
Page 255 CLUTCH / PRIMARY / SHIFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Will Not Shift Broken shift drum Shift drum Replace shift drum Bent shift forks Shift fork Replace shift forks Worn shift drum Shift drum Replace shift drum Broken gears Transmission gears Replace broken gear(s)
Page 257 TRANSMISSION / CRANKSHAFT CHAPTER 6 TRANSMISSION / CRANKSHAFT GENERAL INFORMATION ................6.2 .
Page 258: Tool Description
TRANSMISSION / CRANKSHAFT G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S – – T T R R A A N N S S M M I I S S S S I I O O N N / / C C R R A A N N K K S S H H A A F F T T •...
Page 259 TRANSMISSION / CRANKSHAFT S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - T T R R A A N N S S M M I I S S S S I I O O N N / / C C R R A A N N K K S S H H A A F F T T CONNECTING ROD / CRANKSHAFT SPECIFICATIONS ITEM...
Page 260: Specifications
TRANSMISSION / CRANKSHAFT TRANSMISSION SPECIFICATIONS ITEM PART SPECIFIC STANDARD SERVICE LIMIT Shift Fork 10.000 - 10.022 mm 10.050 mm (.3957") Shift Fork I.D. (Rail) (.3937 - .3946") 6.95 - 7.00 mm 6.93 mm (.2728") Shift Fork Pin O.D. (.2736 - .2756") Shift Fork Rail 9.972 - 9.987 mm 9.942 mm (.3914")
Page 261 TRANSMISSION / CRANKSHAFT L L O O C C K K I I N N G G T T H H E E C C R R A A N N K K S S H H A A F F T T F F O O R R S S E E R R V V I I C C E E 5.
Page 262 TRANSMISSION / CRANKSHAFT A A S S S S E E M M B B L L Y Y V V I I E E W W S S C C R R A A N N K K C C A A S S E E C C O O M M P P O O N N E E N N T T S S LH CASE COMPONENTS TORQUE ITEM...
Page 263 TRANSMISSION / CRANKSHAFT RH CASE COMPONENTS TORQUE ITEM DESCRIPTION Crankshaft Bearing – Transmission Input Shaft Bearing – Transmission Output Shaft Bearing – Transmission Shift Drum Bearing – Balance Shaft Bearing – Water Pump Shaft Bearing – Shift Shaft Bearing – Camshaft Idle shaft Bearing –...
Page 264 TRANSMISSION / CRANKSHAFT C C R R A A N N K K C C A A S S E E T T O O R R Q Q U U E E P P A A T T T T E E R R N N IMPORTANT Left crankcase fasteners in tightening sequence are M8 x 1.25 x 40 all other fasteners are M8 x 1.25 x...
Page 266 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 267 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N C C O O M M P P O O N N E E N N T T S S , , 6 6 S S P P E E E E D D I I N N P P U U T T S S H H A A F F T T ITEM DESCRIPTION...
Page 268 TRANSMISSION / CRANKSHAFT O O U U T T P P U U T T S S H H A A F F T T ITEM MEASUREMENT LOCATION Shaft, Output Bushing Washer, Flat, Keyed - 30 x 38 Retaining Ring, Externa Gear, 2nd - Output Gear, 6th, Output Retaining Ring, External...
Page 269 TRANSMISSION / CRANKSHAFT S S H H I I F F T T D D R R U U M M / / S S H H I I F F T T F F O O R R K K C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION Bearing, Shift Drum - Drive Sprocket Side...
Page 270 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
Page 271 TRANSMISSION / CRANKSHAFT G G E E A A R R T T R R A A I I N N P P O O W W E E R R F F L L O O W W 1st Gear 4th Gear 2nd Gear 5th Gear...
Page 272 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T S S E E R R V V I I C C E E B B A A L L A A N N C C E E S S H H A A F F T T R R E E M M O O V V A A L L 6.
Page 273 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 274 TRANSMISSION / CRANKSHAFT S S T T A A R R T T E E R R D D R R I I V V E E S S E E R R V V I I C C E E S S T T A A R R T T E E R R D D R R I I V V E E R R E E M M O O V V A A L L S S T T A A R R T T E E R R D D R R I I V V E E I I N N S S P P E E C C T T I I O O N N 1.
Page 275 TRANSMISSION / CRANKSHAFT S S T T A A R R T T E E R R D D R R I I V V E E I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 276 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T S S E E R R V V I I C C E E C C R R A A N N K K C C A A S S E E S S E E P P A A R R A A T T I I O O N N 17.
Page 277 TRANSMISSION / CRANKSHAFT 20. Rotate the engine stand so the engine is lying flat 24. Install M6 fasteners and M12 fastener into with the output shaft pointing UP. threaded spacers and torque to specification. 21. Position the main plate assembly onto the engine case as shown.
Page 278 TRANSMISSION / CRANKSHAFT 27. Alternately turn the case splitting tool in until 4. Lift the shift drum out of the bearing. resistance is felt, then work around the upper case with a mallet until the cases are completely apart. 5. As an assembly, lift the input shaft , output shaft , shift forks and shift fork rails out of the engine...
Page 279 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N I I N N S S P P E E C C T T I I O O N N I I N N P P U U T T S S H H A A F F T T ITEM MEASUREMENT LOCATION...
Page 280 TRANSMISSION / CRANKSHAFT O O U U T T P P U U T T S S H H A A F F T T ITEM MEASUREMENT LOCATION DIAMETER SPECIFICATION Shaft, Output Bushing I.D. - 30.02 - 30.04 mm / O.D. - 33.96-33.98 Gear, 2nd - Output 34.000 - 34.025 mm Washer, Flat, Keyed - 30 x 38...
Page 281 TRANSMISSION / CRANKSHAFT 9. Temporarily install shift drum into bearing and NOTICE rotate, checking for smooth bearing operation. Refer to the Assembly View section in this chapter for component locations and exploded diagrams. See Transmission Components, 6 Speed page 6.11. Shift Drum Refer to the Service Specifications section in this chapter for complete transmission specifications.
Page 282 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T R R E E M M O O V V A A L L C C O O N N N N E E C C T T I I N N G G R R O O D D S S I I D D E E C C L L E E A A R R A A N N C C E E I I N N S S P P E E C C T T I I O O N N 1.
Page 283 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D R R E E M M O O V V A A L L / / C C O O N N N N E E C C T T I I N N G G R R O O D D I I N N S S P P E E C C T T I I O O N N ( ( B B I I G G E E N N D D ) ) I I D D E E N N T T I I F F I I C C A A T T I I O O N N IMPORTANT...
Page 284 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G I I N N S S P P E E C C T T I I O O N N 3.
Page 285 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G C C L L E E A A R R A A N N C C E E C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G S S E E L L E E C C T T I I O O N N I I N N S S P P E E C C T T I I O O N N 1.
Page 286 TRANSMISSION / CRANKSHAFT 4. Refer to the chart below to select the proper FOR EXAMPLE: If the CONNECTING ROD grade is bearing insert. RED and the CRANKSHAFT stamp is W (white) (or not stamped), use BLACK bearing inserts. CONNECTING ROD BEARING SELECTION CHART Connecting Rod Engraving Crankshaft Bearing Color...
Page 287 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T I I N N S S P P E E C C T T I I O O N N Record all measurements and compare to 4.
Page 288 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D I I N N S S T T A A L L L L A A T T I I O O N N C C R R A A N N K K S S H H A A F F T T C C L L E E A A N N I I N N G G 1.
Page 289 TRANSMISSION / CRANKSHAFT M M A A I I N N B B E E A A R R I I N N G G O O I I L L C C L L E E A A R R A A N N C C E E 2.
Page 290 TRANSMISSION / CRANKSHAFT 2. Install the new bearings into the bearing taper. 5. Orientate the bearings so they will be installed into the case half in regard to the split line as shown. 3. Use the bearing driver to push the bearings out approximately 1/16”...
Page 291 TRANSMISSION / CRANKSHAFT 6. Use the bearing driver tool to start the bearing into 8. Press the bearing once the driver touches the the case. bearing taper. 9. Inspect the bearing to validate they are orientated correctly and are pressed in evenly. If the bearings aren't orientated correctly in regard to the split line, repeat procedure.
Page 292 TRANSMISSION / CRANKSHAFT L L E E F F T T C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 4.
Page 293 TRANSMISSION / CRANKSHAFT R R I I G G H H T T C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 4.
Page 294 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 295 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 296 TRANSMISSION / CRANKSHAFT C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 7. Pull crankcase together by tightening nut holding tool 1.
Page 297 TRANSMISSION / CRANKSHAFT 19. Install the clutch assembly. See Clutch Installation page 5.27. 20. Install cylinders. See Cylinder Inspection / Installation page 3.87. 21. Install cylinder heads. See Cylinder Head Installation page 3.72. 22. Install the primary cover. See Primary Drive Cover Installation page 5.12.
Page 298 TRANSMISSION / CRANKSHAFT T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G T T R R A A N N S S M M I I S S S S I I O O N N / / C C R R A A N N K K S S H H A A F F T T PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
Page 299 TRANSMISSION / CRANKSHAFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Cam Drive Cam Chain, Cam Refer to Engine / Cooling Sprocket / Exhaust Chapter (Cylinder Head / Valves) PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Hard to Shift Improper Clutch Clutch Refer to Clutch / Primary Operation...
Page 301: Chapter 7 Frame / Body
FRAME / BODY CHAPTER 7 FRAME / BODY GENERAL INFORMATION ................7.2 .
Page 302: Tool Description
FRAME / BODY G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S - - F F R R A A M M E E / / B B O O D D Y Y This section covers the removal and installation of frame and body components, assemblies and systems.
Page 303 FRAME / BODY A A S S S S E E M M B B L L Y Y V V I I E E W W S S S S A A D D D D L L E E B B A A G G C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
Page 304 FRAME / BODY F F E E N N D D E E R R C C O O M M P P O O N N E E N N T T S S S S C C O O U U T T C C L L A A S S S S I I C C ITEM DESCRIPTION TORQUE...
Page 305 FRAME / BODY S S C C O O U U T T B B O O B B B B E E R R ITEM DESCRIPTION TORQUE Front Fender Fasteners (front) (QTY.4) 18 ft-lbs (24 N·m) Rear Fender Fasteners (rear) (QTY.4) 37 ft-lbs (50 N·m) Seat Fender Fastener (rear) 88 in-lbs (10 N·m)
Page 306 FRAME / BODY 1 1 0 0 1 1 S S C C O O U U T T ITEM DESCRIPTION TORQUE Front Fender Fasteners (front) (QTY.4) 18 ft-lbs (24 N·m) Rear Fender Fasteners (rear) (QTY.4) 37 ft-lbs (50 N·m) Seat Fender Fastener (rear) 88 in-lbs (10 N·m) 88 in-lbs (10 N·m)
Page 307 FRAME / BODY C C O O W W L L C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION — Wind Deflector 5 in-lbs (.5 N·m) Cowl Wind Deflector Fasteners Cowl Body —...
Page 308 FRAME / BODY S S E E A A T T C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION — Seat Hex Key — 88 in-lbs (10 N·m) Seat Mount Fastener, Rear 9941686 R01 - 2025 Indian Scout Service Manual ©...
Page 309: Torque Sequence
FRAME / BODY F F R R A A M M E E C C O O M M P P O O N N E E N N T T S S TORQUE TORQUE SEQUENCE ITEM DESCRIPTION – Main–Cast Frame Right Hand V Bracket –...
Page 310 FRAME / BODY F F O O O O T T P P E E G G C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE Forward Foot Control 53 ft-lbs (72 N·m) –...
Page 312 FRAME / BODY B B O O D D Y Y / / F F R R A A M M E E S S E E R R V V I I C C E E S S A A D D D D L L E E B B A A G G R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 313 FRAME / BODY I I N N S S T T A A L L L L A A T T I I O O N N 1. Align saddlebag with mounting points. 2. Install fasteners and washers and torque to specification.
Page 314 FRAME / BODY F F O O O O T T P P E E G G R R E E M M O O V V A A L L , , D D R R I I V V E E R R R R I I G G H H T T F F O O O O T T P P E E G G L L E E F F T T F F O O O O T T P P E E G G 1.
Page 315 FRAME / BODY F F O O O O T T P P E E G G I I N N S S T T A A L L L L A A T T I I O O N N , , D D R R I I V V E E R R R R I I G G H H T T F F O O O O T T P P E E G G L L E E F F T T F F O O O O T T P P E E G G 1.
Page 316 FRAME / BODY F F O O O O T T P P E E G G R R E E M M O O V V A A L L , , P P A A S S S S E E N N G G E E R R 3.
Page 317 FRAME / BODY F F O O O O T T P P E E G G I I N N S S T T A A L L L L A A T T I I O O N N , , P P A A S S S S E E N N G G E E R R 1.
Page 318 FRAME / BODY S S E E A A T T R R E E M M O O V V A A L L 2. Lift the seat and pull it slightly forward to disengage the rear grommet from the rear dart NOTICE When removing the seat, use caution to avoid contact with the fuel tank.
Page 319 FRAME / BODY S S E E A A T T I I N N S S T T A A L L L L A A T T I I O O N N 2. Grasp the front of the passenger seat and pull up to disengage the middle grommet from the middle WARNING...
Page 320 FRAME / BODY F F R R O O N N T T F F E E N N D D E E R R R R E E M M O O V V A A L L S S C C O O U U T T B B O O B B B B E E R R S S C C O O U U T T C C L L A A S S S S I I C C 1.
Page 321 FRAME / BODY F F R R O O N N T T F F E E N N D D E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1 1 0 0 1 1 S S C C O O U U T T 1.
Page 322 FRAME / BODY S S C C O O U U T T B B O O B B B B E E R R 1 1 0 0 1 1 S S C C O O U U T T 1.
Page 323 FRAME / BODY R R E E A A R R F F E E N N D D E E R R R R E E M M O O V V A A L L R R E E A A R R F F E E N N D D E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 324 FRAME / BODY 4. Install front seat fastener and rear seat fastener and torque to specification TORQUE Front Seat Fastener: 71 in-lbs (8 N·m) TORQUE Rear Seat Fasteners: 71 in-lbs (8 N·m) 5. Install seat. See Seat Installation page 7.19. 9941686 R01 - 2025 Indian Scout Service Manual 7.24 ©...
Page 325 FRAME / BODY C C O O W W L L R R E E M M O O V V A A L L S S U U P P E E R R S S C C O O U U T T 1 1 0 0 1 1 S S C C O O U U T T 1.
Page 326 FRAME / BODY C C O O W W L L I I N N S S T T A A L L L L A A T T I I O O N N S S U U P P E E R R S S C C O O U U T T 1 1 0 0 1 1 S S C C O O U U T T 1.
Page 327 FRAME / BODY I I G G N N I I T T I I O O N N C C O O V V E E R R R R E E M M O O V V A A L L I I G G N N I I T T I I O O N N C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 328 FRAME / BODY V V - - C C O O V V E E R R R R E E M M O O V V A A L L 1. Park motorcycle on a flat surface, fully extend side stand, and make sure vehicle is stable.
Page 329 FRAME / BODY F F R R A A M M E E R R E E M M O O V V A A L L 20. Remove the rear subframe fasteners subframe assembly. WARNING Care should be taken to be sure the motorcycle will not tip or fall while elevated.
Page 330 FRAME / BODY F F R R A A M M E E I I N N S S T T A A L L L L A A T T I I O O N N 32. Remove handlebar from the forks. 33.
Page 331 FRAME / BODY 6. Install the fasteners holding the right-hand and 22. Install the right-hand and left-hand mid cast frame left-hand backbone to the front frame. fasteners 7. Install the triple clamp. See Triple Clamp 23. Install the rear subframe fasteners and subframe Installation / Steering Head Bearing assembly.
Page 332 FRAME / BODY 33. Install the head pipe assembly. See Head Pipe Installation page 3.93. 34. Install passenger foot pegs (if equipped). See Foot Peg Installation, Passenger page 7.17. 35. Install the driver foot controls. See Foot Peg Installation, Driver page 7.15. 36.
Page 333 STEERING / SUSPENSION / WHEELS / TIRES CHAPTER 8 STEERING / SUSPENSION / WHEELS / TIRES FRONT WHEEL & SUSPENSION ............... . . 8.4 .
Page 334 STEERING / SUSPENSION / WHEELS / TIRES ......8.67 TRIPLE CLAMP INSTALLATION / STEERING HEAD BEARING ADJUSTMENT .
Page 335 STEERING / SUSPENSION / WHEELS / TIRES ..........8.100 SWINGARM BUSHING / BEARING REPLACEMENT .
Page 336: Tool Description
Front Axle Adapter commercially available Tubeless tires are used on certain Indian Motorcycle (16mm hex) models. Operating the motorcycle with damaged rims creates a safety hazard including air pressure PV-59000–A...
Page 337 Scout Bobber / Scout SS–8 Active: 2880015 Classic / Super Scout / Sport Scout Fork Oil Type Indian Motorcycle Fork Oil (PN: 2208093) Inverted Forks: Fuchs SAF 5113, Ohlins fork oil, or approved 101 Scout equivalent Scout Bobber / Scout Classic / Super Scout / 36 mm (1.42 in.)
Page 338 STEERING / SUSPENSION / WHEELS / TIRES ITEM STANDARD SERVICE Left-Hand (1830149): 117 mm (4.60 in.) Height Right-Hand (1830150): 42 mm (1.65 in.) Left-Hand (1830149): 412 cc (14 oz.) Volume Right-Hand (1830150): 340 cc (11.50 oz.) 9941686 R01 - 2025 Indian Scout Service Manual ©...
Page 339 STEERING / SUSPENSION / WHEELS / TIRES M M A A I I N N T T E E N N A A N N C C E E - - F F R R O O N N T T W W H H E E E E L L & & S S U U S S P P E E N N S S I I O O N N S S T T E E E E R R I I N N G G H H E E A A D D / / F F R R O O N N T T W W H H E E E E L L I I N N S S P P E E C C T T I I O O N N WARNING...
Page 340 STEERING / SUSPENSION / WHEELS / TIRES A A S S S S E E M M B B L L Y Y V V I I E E W W S S H H A A N N D D L L E E B B A A R R C C O O N N T T R R O O L L S S C C O O M M P P O O N N E E N N T T S S SCOUT CLASSIC / SUPER ITEM DESCRIPTION...
Page 341 STEERING / SUSPENSION / WHEELS / TIRES TORQUE (IF APPLICABLE) ITEM DESCRIPTION 88 in-lbs (10 N·m) Tighten Top Fastener First Brake Lever Perch Fasteners Retention Clip Mirror Jam Nut 12 ft-lbs (16 N·m) Grip Front Master Cylinder Assembly End Cap Mirror End Cap Fastener 71 in-lbs (8 N·m) (Perch Mount)
Page 342 STEERING / SUSPENSION / WHEELS / TIRES SCOUT BOBBER / SPORT / 101 ITEM DESCRIPTION TORQUE (IF APPLICABLE) 22 ft-lbs (30 N·m) Bar End Mirror Fastener Retention Clip Clutch Perch Clamp Fastener 88 in-lbs (10 N·m) Tighten Top Fastener First Grip Left-Hand Controls 35 in-lbs (4 N·m)
Page 343 STEERING / SUSPENSION / WHEELS / TIRES TORQUE (IF APPLICABLE) ITEM DESCRIPTION 88 in-lbs (10 N·m) Tighten Top Fastener First Brake Lever Perch Fasteners Retention Clip 22 ft-lbs (30 N·m) Bar End Mirror Fastener Grip Front Master Cylinder Assembly Bar End Mirror Pinch Fastener 35 in-lbs (4 N·m) (Handlebar Mount) 9941686 R01 - 2025 Indian Scout Service Manual...
Page 344 STEERING / SUSPENSION / WHEELS / TIRES H H A A N N D D L L E E B B A A R R C C O O M M P P O O N N E E N N T T S S BOBBER / CLASSIC / SUPER SCOUT MODELS ITEM DESCRIPTION...
Page 346 STEERING / SUSPENSION / WHEELS / TIRES ITEM DESCRIPTION TORQUE (IF APPLICABLE) 18 ft-lbs (25 N·m) Upper Triple Clamp to Riser Tighten front fasteners first, then rear Fasteners 18 ft-lbs (25 N·m) Instrument Cluster Mount Fasteners 79 ft-lbs (107 N·m) Steering Stem Nut (top) See Tightening Procedure Outlined in this Chapter...
Page 347 STEERING / SUSPENSION / WHEELS / TIRES T T R R I I P P L L E E C C L L A A M M P P C C O O M M P P O O N N E E N N T T S S SCOUT BOBBER / CLASSIC / SUPER SPORT SCOUT 9941686 R01 - 2025 Indian Scout Service Manual...
Page 348 STEERING / SUSPENSION / WHEELS / TIRES ITEM DESCRIPTION TORQUE (IF APPLICABLE) 79 ft-lbs (107 N·m) Steering Stem Nut (top) See Tightening Procedure Outlined in this Chapter Washer 18 ft-lbs (25 N·m) Fork Triple Clamp Fasteners (Upper) See Tightening Procedure Outlined in this Chapter Upper Triple Clamp See Tightening Procedure Outlined in this...
Page 349 STEERING / SUSPENSION / WHEELS / TIRES 101 SCOUT ITEM DESCRIPTION TORQUE (IF APPLICABLE) 79 ft-lbs (107 N·m) Steering Stem Nut (top) See Tightening Procedure Outlined in this Chapter Washer Upper Triple Clamp 18 ft-lbs (25 N·m) Fork Triple Clamp Fasteners (Upper) See Tightening Procedure Outlined in this Chapter Wire Form, Front...
Page 350 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T F F O O R R K K C C O O M M P P O O N N E E N N T T S S ( ( C C O O N N V V E E N N T T I I O O N N A A L L ) ) 9941686 R01 - 2025 Indian Scout Service Manual 8.18 ©...
Page 351 STEERING / SUSPENSION / WHEELS / TIRES ITEM DESCRIPTION TORQUE (IF APPLICABLE) Fork Leg Assembly, Left-Hand Fork Leg Assembly, Right-Hand Kit, Bushing / Seals Spacer Compression Spring Washer O-Ring Fork Cap 16 ft-lbs (22 N·m) O-Ring Cylinder Assembly Rebound Spring Kit, Oil Lock Inner Fork Tube Washer...
Page 352 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T F F O O R R K K C C O O M M P P O O N N E E N N T T S S ( ( I I N N V V E E R R T T E E D D ) ) IMPORTANT The fork cap assemblies are non-serviceable and can not be rebuilt.
Page 353 STEERING / SUSPENSION / WHEELS / TIRES ITEM DESCRIPTION TORQUE (IF APPLICABLE) Kit, Fork Seal Fork Tube, Outter Inner Tube Assembly Spring, Fork ASM, Left-Hand Cap 16 ft-lbs (22 N·m) ASM, Right-Hand Cap 16 ft-lbs (22 N·m) Reflector 18 ft-lbs (25 N·m) Fork Pinch Fastener Jam Nut (inverted) 15 ft-lbs (20 N·m)
Page 354 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T W W H H E E E E L L C C O O M M P P O O N N E E N N T T S S SCOUT BOBBER / CLASSIC / SUPER / SPORT ITEM DESCRIPTION...
Page 355 STEERING / SUSPENSION / WHEELS / TIRES 101 SCOUT ITEM DESCRIPTION TORQUE (IF APPLICABLE) Inner Bearing Spacer Wheel Bearing Seal Outer Bearing Spacer Brake Disc Bushing Wave Washer 22 ft-lbs (30 N·m) Brake Disc Fasteners Ring Tone ABS Tone Ring Fasteners, Front: 101 Scout 88 in-lbs (10 N·m) 9941686 R01 - 2025 Indian Scout Service Manual 8.23...
Page 356 STEERING / SUSPENSION / WHEELS / TIRES S S E E R R V V I I C C E E P P R R O O C C E E D D U U R R E E S S M M I I R R R R O O R R R R E E M M O O V V A A L L HANDLEBAR MOUNT MIRRORS 1.
Page 357 STEERING / SUSPENSION / WHEELS / TIRES H H A A N N D D L L E E B B A A R R R R E E M M O O V V A A L L 4. Remove clutch lever perch fasteners and front master cylinder perch fasteners .
Page 358 STEERING / SUSPENSION / WHEELS / TIRES 6. Remove right-hand switch cube: d. Using compressed air, blow air under the inner part of the hand grip, remove the ETC, switch a. Loosen the bottom electronic throttle control cube and hand grip off the handebar. (ETC) fastener.
Page 359 STEERING / SUSPENSION / WHEELS / TIRES g. Remove the retaining clip. d. Slide the switch cube toward the center of the handlebars to gain access to the retaining clip. e. Remove the retaining clip. h. Remove switch cube from the handlebar. 7.
Page 360 STEERING / SUSPENSION / WHEELS / TIRES b. Shift the cluster assembly rearward and • Remove four riser cap fasteners and riser cap. disconnect cell USB, , Antenna GPS , and electrical connector 10. Lift handlebars out of upper triple clamp. Bobber / Classic / Super Scout: a.
Page 361 STEERING / SUSPENSION / WHEELS / TIRES H H A A N N D D L L E E B B A A R R I I N N S S T T A A L L L L A A T T I I O O N N b.
Page 362 STEERING / SUSPENSION / WHEELS / TIRES b. Slide the switch cube toward the retaining clip e. Align the ETC parting line with the lower button until it locks into position. feature on the switch cube as shown. f. Install the bottom electronic throttle control c.
Page 363 STEERING / SUSPENSION / WHEELS / TIRES 2. Install the left-hand switch cube: d. Connect the electrical connector to the clutch switch. a. Install switch cube and hand grip onto the handebar. e. Connect the switch cube electrical connectors. b. Install the retaining clip into the alignment hold in the handlebar as shown.
Page 364 STEERING / SUSPENSION / WHEELS / TIRES M M I I R R R R O O R R I I N N S S T T A A L L L L A A T T I I O O N N g.
Page 365 STEERING / SUSPENSION / WHEELS / TIRES PERCH MOUNT MIRRORS 1. With jam nut pre-installed on mirror, insert mirror into perch mount. NOTE INTL MODELS ONLY - Install adapter into threaded holes on handlebar perch. Torque to specification. TORQUE Mirror Threaded Post Nut (INTL): 12 ft-lbs (16 N·m) 2.
Page 366 STEERING / SUSPENSION / WHEELS / TIRES C C L L U U T T C C H H C C A A B B L L E E R R E E M M O O V V A A L L 8.
Page 367 STEERING / SUSPENSION / WHEELS / TIRES 9. Tighten the lower cable guide jam nut specification. TORQUE Clutch Cable Guide Jam Nut: 53 in-lbs (6 N·m) 10. Adjust clutch cable free play. See Clutch Lever Free Play page 5.4. 9941686 R01 - 2025 Indian Scout Service Manual 8.35 ©...
Page 368 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T W W H H E E E E L L R R E E M M O O V V A A L L 3.
Page 369 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T W W H H E E E E L L I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 370 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T W W H H E E E E L L I I N N S S P P E E C C T T I I O O N N B B R R A A K K E E D D I I S S C C R R E E M M O O V V A A L L 1.
Page 371 STEERING / SUSPENSION / WHEELS / TIRES Position wheel with brake disc and ABS tone ring 2. Torque new brake disc fasteners and tone ring facing up. fasteners to specification in a star pattern. SCOUT BOBBER / CLASSIC / SUPER / SPORT TORQUE Brake Disc Fasteners, Front: 101 Scout: 1.
Page 372 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T W W H H E E E E L L B B E E A A R R I I N N G G I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T W W H H E E E E L L B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T REMOVAL IMPORTANT...
Page 373 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T F F O O R R K K R R E E M M O O V V A A L L INSTALLATION 1.
Page 374 STEERING / SUSPENSION / WHEELS / TIRES 5. Remove front cowl (if applicable). See Cowl 9. Slide fork leg down and remove. Removal page 7.25. 6. Remove turn signal assembly by removing fastener 7. Loosen top triple clamp pinch fastener 8.
Page 375 STEERING / SUSPENSION / WHEELS / TIRES C C O O N N V V E E N N T T I I O O N N A A L L F F O O R R K K S S E E R R V V I I C C E E 2.
Page 376 STEERING / SUSPENSION / WHEELS / TIRES 4. Place fork tube in spring compressor tool with hole 8. Remove Spacer and Washer from top of in bottom of fork slider over peg on bottom of tool. spring. 5. Place special tool (PV-49463) in soft jawed vise 9.
Page 377 STEERING / SUSPENSION / WHEELS / TIRES 12. Prevent Fork Cartridge Tool (PF-51664-2) from 15. Push inner and outer tube together, then pull apart quickly to produce a slide hammer motion to turning and remove cylinder fasteners from remove the inner tube. bottom of fork.
Page 378 STEERING / SUSPENSION / WHEELS / TIRES FRONT FORK ASSEMBLY (CONVENTIONAL) 4. Insert inner fork tube, damping rod, and oil lock in outer fork leg as an assembly. 1. Lubricate and install a new lower bushing on inner fork tube. 5.
Page 379 STEERING / SUSPENSION / WHEELS / TIRES 8. Lubricate and install new bushing onto inner 11. Install Fork Seal Saver Tool PV–47037 over the fork tube. inner tube. 12. Apply a light film of fork oil to outside edge and 9.
Page 380 17. Lift tube to top of travel range. 18. Tip fork leg at an angle to reduce air bubbles. Slowly add the correct amount of Indian Motorcycle fork oil. Reference Service Specification - Front Wheel / Suspension page 8.5.
Page 381 STEERING / SUSPENSION / WHEELS / TIRES 21. Install Spring into fork tube. 24. Slowly compress fork tube assembly with drive nut until fork cap enters the outer tube, and threads start to make contact. NOTICE Make sure the tight coils of the spring are installed 25.
Page 382 STEERING / SUSPENSION / WHEELS / TIRES I I N N V V E E R R T T E E D D F F O O R R K K S S E E R R V V I I C C E E LEFT-SIDE FORK (SPRING) FRONT FORK DISASSEMBLY (INVERTED) IMPORTANT...
Page 383 STEERING / SUSPENSION / WHEELS / TIRES 4. Empty fork oil. 7. remove circlip. 5. Place the fork in spring compressor using the spring compressor adaptor. 8. Release spring tension. 9. Remove spring stop and preload Rod. NOTICE An adapter may be needed if the fork does not have a hole in the bottom of the lug to sit on the compressor.
Page 384 STEERING / SUSPENSION / WHEELS / TIRES 11. Remove spring assembly. 14. Push upper and lower tube together, then pull apart quickly to produce a slide hammer motion to remove the inner tube. 12. Carefully Remove dust seal out of outer fork tube with a small flat screwdriver.
Page 385 STEERING / SUSPENSION / WHEELS / TIRES RIGHT-SIDE FORK (DAMPING) 5. Drain fork oil while cycling damping rod to remove oil. NOTICE 6. Loosen lock nut. inner screw = rebound, outer gold = compression. numbers indicate rebound adjustment IMPORTANT Count the lines on the preload adjuster before disassembly.
Page 386 STEERING / SUSPENSION / WHEELS / TIRES 9. Remove dust seal. 12. Remove upper bushing. 10. Remove Retaining clip. 13. Remove lower bushing, washer, and seals in order. 11. Push inner and outer tube together, then pull apart quickly to produce a slide hammer motion to remove the inner tube.
Page 387 STEERING / SUSPENSION / WHEELS / TIRES FRONT FORK ASSEMBLY (INVERTED) 4. Install Washer, lower tube bushing, and upper tube bushing IMPORTANT Clean all parts prior to assembly. RIGHT-SIDE FORK (DAMPING) 1. Install seal saver 5. Install outer tube 6. Install lower bushing and washer using seal driver. 2.
Page 388 9. Install Dust seal by hand d. Remove cap. 12. Use special tool PV-59000–A to set oil height. 10. Slowly add the correct amount of Indian Motorcycle fork oil. Reference Service Specification - Front Wheel / Suspension page 8.5. NOTICE Fork and cartridge fully compressed.
Page 389 STEERING / SUSPENSION / WHEELS / TIRES 13. Install pushrod. 17. Make sure you can select all clicker positions 1-10 and the indicator cannot be turned past position 10. 14. Rotate Adjuster counter clockwise until stop, rotate clockwise to 10 18.
Page 390 STEERING / SUSPENSION / WHEELS / TIRES LEFT-SIDE FORK (SPRING) 20. Tighten Fork Cap In tube to specification. 1. Install seal saver TORQUE 2. Lubricate and Slide Dust seal, Retaining ring, Oil Fork Cap: seals over seal saver 16 ft-lbs (22 N·m) 21.
Page 391 Install oil seal with markings facing UP (toward top of 9. Install Dust seal by hand tube and retaining ring). 10. Slowly add the correct amount of Indian Motorcycle fork oil. Reference Service Specification - Front Wheel / Suspension page 8.5.
Page 392 STEERING / SUSPENSION / WHEELS / TIRES 11. To bleed the fork of air: 14. Install the spring keeper and preload adjustment rod. a. Seal top of the fork with your hand and pull up. 15. Compress the spring and install circlip. b.
Page 393 STEERING / SUSPENSION / WHEELS / TIRES 17. Install cap to pushrod. 19. Install Cap fully, set preload to recorded setting. IMPORTANT Make sure cap is bottoming out against the pushrod and NOT the jam nut. 18. Tighten Jam nut fully to the cap. TORQUE Fork Cap: 16 ft-lbs (22 N·m)
Page 394 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T F F O O R R K K I I N N S S P P E E C C T T I I O O N N 4.
Page 395 STEERING / SUSPENSION / WHEELS / TIRES F F R R O O N N T T F F O O R R K K I I N N S S T T A A L L L L A A T T I I O O N N 2.
Page 396 STEERING / SUSPENSION / WHEELS / TIRES 4. Torque the top fastener on the lower triple clamp 8. Install turn signal and secure with fastener Torque to specification. 5. REPEAT steps 3 – 4. TORQUE Turn Signal Fasteners: 6. Torque the upper triple clamp fastener 18 ft-lbs (25 N·m) 9.
Page 397 STEERING / SUSPENSION / WHEELS / TIRES T T R R I I P P L L E E C C L L A A M M P P R R E E M M O O V V A A L L 7.
Page 398 STEERING / SUSPENSION / WHEELS / TIRES 11. Remove stem adjuster nut with a suitable spanner socket. NOTICE Support lower triple clamp while removing the adjuster nut. 12. Remove lower triple clamp, with steering stem, and lower bearing (outer race will remain in head tube).
Page 399 STEERING / SUSPENSION / WHEELS / TIRES T T R R I I P P L L E E C C L L A A M M P P I I N N S S T T A A L L L L A A T T I I O O N N / / S S T T E E E E R R I I N N G G 4.
Page 400 STEERING / SUSPENSION / WHEELS / TIRES 10. Set upper triple clamp in place on stem. Install 15. Torque the upper triple clamp pinch fasteners washer and nut and tighten top nut until it is (both sides) to specification. finger tight. CAUTION DO NOT over-torque fasteners.
Page 401 STEERING / SUSPENSION / WHEELS / TIRES T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F R R O O N N T T W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
Page 402 STEERING / SUSPENSION / WHEELS / TIRES PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Fork Tube Height Unequal Install Correctly Fork Oil Level Unequal Set Correctly Replace Fork Spring Free Length Different Between Right & Left Wheel Assembly Out-of-Balance Balance Low Tire Pressure Inflate to specification Front Suspension Too Soft Weak Fork Springs...
Page 403: Special Tool
Use only the recommended tires inflated to the recommended tire pressures. Tubeless tires are used on certain Indian Motorcycle models. Operating the motorcycle with damaged rims creates a safety hazard including air pressure loss, steering imbalance and/or reduced steering control.
Page 404 STEERING / SUSPENSION / WHEELS / TIRES S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - R R E E A A R R W W H H E E E E L L & & S S U U S S P P E E N N S S I I O O N N ITEM STANDARD SERVICE LIMIT...
Page 405 STEERING / SUSPENSION / WHEELS / TIRES S S H H O O C C K K A A N N A A L L Y Y S S I I S S Shock “misting” or “weepage” is common and should be present during normal vehicle operation. All Shock Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock.
Page 406 STEERING / SUSPENSION / WHEELS / TIRES M M A A I I N N T T E E N N A A N N C C E E - - R R E E A A R R W W H H E E E E L L & & 3.
Page 407 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E B B E E L L T T T T E E N N S S I I O O N N 7. Push up on the gauge until the o-ring just touches the tool body and compare to specification.
Page 408 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E B B E E L L T T T T E E N N S S I I O O N N - - S S P P E E C C I I F F I I C C A A T T I I O O N N S S D D R R I I V V E E B B E E L L T T A A D D J J U U S S T T M M E E N N T T IMPORTANT SPECIFICATIONS: DRIVE BELT...
Page 409 STEERING / SUSPENSION / WHEELS / TIRES DRIVE BELT ALIGNMENT 2. On right side of motorcycle, loosen the axle nut Retighten to Adjustment Specification. WARNING TORQUE Drive belt misalignment can cause drive line noise Adjustment Specification: 15 ft-lbs (20 N·m) and damage drive belt, causing possible belt failure and loss of control of motorcycle.
Page 410 STEERING / SUSPENSION / WHEELS / TIRES S S P P R R O O C C K K E E T T I I N N S S P P E E C C T T I I O O N N IMPORTANT Belt should track to center of sprocket tooth surface NOTICE...
Page 411 STEERING / SUSPENSION / WHEELS / TIRES S S I I D D E E - - S S T T A A N N D D I I N N S S P P E E C C T T I I O O N N S S I I D D E E - - S S T T A A N N D D R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 412 STEERING / SUSPENSION / WHEELS / TIRES S S W W I I N N G G A A R R M M I I N N S S P P E E C C T T I I O O N N 6.
Page 413 STEERING / SUSPENSION / WHEELS / TIRES 6. Inspect rear shock for leakage and all rear 4. Ride height should be set on both shocks. If the suspension components for damage or loose measurement differs, adjust the preload. fasteners. MODEL RIDE HEIGHT 7.
Page 414 STEERING / SUSPENSION / WHEELS / TIRES R R E E A A R R S S H H O O C C K K P P R R E E L L O O A A D D A A D D J J U U S S T T M M E E N N T T 4.
Page 415 STEERING / SUSPENSION / WHEELS / TIRES A A S S S S E E M M B B L L Y Y V V I I E E W W S S R R E E A A R R S S U U S S P P E E N N S S I I O O N N C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 416 STEERING / SUSPENSION / WHEELS / TIRES TORQUE (IF APPLICABLE) ITEM DESCRIPTION Washer Swingarm Nut 85 ft-lbs (115 N·m) Swingarm 9941686 R01 - 2025 Indian Scout Service Manual 8.84 © Copyright Polaris Industries Inc.
Page 417 STEERING / SUSPENSION / WHEELS / TIRES R R E E A A R R W W H H E E E E L L C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 418 D D R R I I V V E E B B E E L L T T I I N N S S T T A A L L L L A A T T I I O O N N 1. Inspect sprockets and verify sprocket fasteners are tight. 2. Install drive belt with the Indian Motorcycle script situated so that it reads correctly when viewed from the left-hand side of the motorcycle.
Page 419 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E S S P P R R O O C C K K E E T T S S E E R R V V I I C C E E 4.
Page 420 STEERING / SUSPENSION / WHEELS / TIRES 8. Remove Seal , spacer , and O-ring from 3. Inspect the back surface of sprocket hub where output shaft. it contacts the seal sleeve. Replace if worn or if surface is rough. 4.
Page 421 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E S S P P R R O O C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N 8.
Page 422 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E S S P P R R O O C C K K E E T T C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 423 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E N N S S P P R R O O C C K K E E T T S S E E R R V V I I C C E E D D R R I I V V E E N N S S P P R R O O C C K K E E T T I I N N S S P P E E C C T T I I O O N N D D R R I I V V E E N N S S P P R R O O C C K K E E T T R R E E M M O O V V A A L L 1.
Page 424 STEERING / SUSPENSION / WHEELS / TIRES D D R R I I V V E E N N S S P P R R O O C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 425 STEERING / SUSPENSION / WHEELS / TIRES R R E E A A R R W W H H E E E E L L S S E E R R V V I I C C E E 5. Remove rear axle nut and washer from side of swingarm.
Page 426 STEERING / SUSPENSION / WHEELS / TIRES R R E E A A R R W W H H E E E E L L I I N N S S T T A A L L L L A A T T I I O O N N R R E E A A R R A A X X L L E E I I N N S S P P E E C C T T I I O O N N 1.
Page 427 STEERING / SUSPENSION / WHEELS / TIRES INSTALLATION IMPORTANT Due to extremely close tolerances, the bearings must 1. Use the Wheel Bearing Removal / Installation Kit be inspected visually, and by feel. Look for signs of PF-51324) to install new wheel bearings. Refer to discoloration, scoring, galling, or contamination from special tool manufacturer instructions for proper moisture or dirt.
Page 428 STEERING / SUSPENSION / WHEELS / TIRES INSTALLATION 6. Install washer and rear axle nut . Torque axle nut to specification 1. Install the ABS tone ring and brake disc TORQUE 2. Install fasteners and torque to specification. Axle Nut (rear): TORQUE 66 ft-lbs (90 N·m) Brake Disc Fasteners, Rear:...
Page 429 STEERING / SUSPENSION / WHEELS / TIRES S S H H O O C C K K A A B B S S O O R R B B E E R R I I N N S S P P E E C C T T I I O O N N 5.
Page 430 STEERING / SUSPENSION / WHEELS / TIRES S S H H O O C C K K A A B B S S O O R R B B E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 431 STEERING / SUSPENSION / WHEELS / TIRES S S W W I I N N G G A A R R M M S S E E R R V V I I C C E E 4. Support the rear caliper assembly and remove the rear brake line clip fastener S S W W I I N N G G A A R R M M R R E E M M O O V V A A L L WARNING...
Page 432 STEERING / SUSPENSION / WHEELS / TIRES S S W W I I N N G G A A R R M M B B U U S S H H I I N N G G / / B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T 8.
Page 433 STEERING / SUSPENSION / WHEELS / TIRES 4. Press new outer seals into the bearing bore until 5. Install the swingarm shaft washer and nut onto seated. the end of the swingarm shaft. Torque nut to specification. 5. Install shock absorber assembly. See Shock Ab- sorber Installation page 8.98.
Page 434 STEERING / SUSPENSION / WHEELS / TIRES 7. Install upper belt guard and torque fasteners 10. Install the rear brake line clip fastener located two fasteners on the back side of guard to on the left inner surface of the swingarm. Torque specification.
Page 436 STEERING / SUSPENSION / WHEELS / TIRES T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G R R E E A A R R W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
Page 437 STEERING / SUSPENSION / WHEELS / TIRES T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F I I N N A A L L D D R R I I V V E E PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED...
Page 438 STEERING / SUSPENSION / WHEELS / TIRES T T I I R R E E S S CAUTION G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N Overloading and under-inflation lead to premature tire wear.
Page 439 STEERING / SUSPENSION / WHEELS / TIRES S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - T T I I R R E E S S Refer to Steering / Suspension Chapter (Front Wheel and Suspension) for front wheel specifications.
Page 440 STEERING / SUSPENSION / WHEELS / TIRES T T I I R R E E I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T T T I I R R E E C C U U P P P P I I N N G G Front of tread block worn more than rear of tread T T I I R R E E W W E E A A R R P P A A T T T T E E R R N N S S block:...
Page 441 • Pneumatic or electrically operated tire machine • Manually operated tire machine • Manual manipulation of tire irons Indian Motorcycle permits and recommends all three of the general methods, but realizes that careless or improper work habits can damage both the tire and rim no matter which method is used.
Page 442 STEERING / SUSPENSION / WHEELS / TIRES T T I I R R E E R R E E M M O O V V A A L L 6. Carefully work around the circumference of the upper bead with the tire lever until it is IMPORTANT completely off of the rim.
Page 443 IMPORTANT Balance Dots Indian Motorcycle does not recommend the use of liquid balancer/sealers. These are a form of temporary repair which may adversely affect ply material and mask secondary damage caused by the penetrating object.
Page 444 STEERING / SUSPENSION / WHEELS / TIRES T T I I R R E E B B A A L L A A N N C C I I N N G G • Lock assembly on mounting machine or place in safety cage before inflating to seat beads WARNING •...
Page 445 STEERING / SUSPENSION / WHEELS / TIRES W W H H E E E E L L I I N N S S P P E E C C T T I I O O N N T T I I R R E E R R E E P P A A I I R R P P R R E E C C A A U U T T I I O O N N S S V V I I S S U U A A L L I I N N S S P P E E C C T T I I O O N N / / R R U U N N O O U U T T WARNING 1.
Page 446 STEERING / SUSPENSION / WHEELS / TIRES V V A A L L V V E E S S T T E E M M 3. 90 DEGREE VALVE: V V A A L L V V E E S S T T E E M M I I N N S S P P E E C C T T I I O O N N Remove valve stem nut , valve stem and o-...
Page 447 STEERING / SUSPENSION / WHEELS / TIRES T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G T T I I R R E E S S PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
Page 449: Chapter 9 Brakes
BRAKES CHAPTER 9 BRAKES GENERAL INFORMATION ................9.3 .
Page 450 BRAKES ...............9.50 REAR MASTER CYLINDER SERVICE .
Page 451: Tool Description
S S E E R R V V I I C C E E N N O O T T E E S S NOTICE Use only genuine Indian Motorcycle replacement Brake fluid and some types of brake cleaners will parts when servicing the brake system.
Page 452 BRAKES M M A A I I N N T T E E N N A A N N C C E E - - B B R R A A K K E E S S F F R R O O N N T T B B R R A A K K E E L L E E V V E E R R L L U U B B R R I I C C A A T T I I O O N N B B R R A A K K E E L L E E V V E E R R R R E E S S E E R R V V E E F F O O R R C C E E 1.
Page 453 BRAKES B B R R A A K K E E P P E E D D A A L L I I N N S S P P E E C C T T I I O O N N 1.
Page 454 BRAKES B B R R A A K K E E P P E E D D A A L L L L U U B B R R I I C C A A T T I I O O N N ITEM TORQUE (IF APPLICABLE) DESCRIPTION...
Page 455 BRAKES Lubricate brake pedal at intervals listed on periodic 4. Remove rue pin from clevis pin maintenance table. See Maintenance Intervals page 2.5. 1. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 2.
Page 456 BRAKES 9. Assemble pedal, washer , and bushing 12. Install brake line clip and secure with fasteners footpeg bracket. and push rivet . Torque fasteners to specification. IMPORTANT Make sure the spring is installed. 10. Install pivot bushing and fastener .
Page 457 BRAKES A A S S S S E E M M B B L L Y Y V V I I E E W W S S F F R R O O N N T T B B R R A A K K E E S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S , , S S I I N N G G L L E E C C A A L L I I P P E E R R TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 458 BRAKES F F R R O O N N T T B B R R A A K K E E S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S , , D D U U A A L L C C A A L L I I P P E E R R TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 459 BRAKES R R E E A A R R B B R R A A K K E E S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 460 BRAKES B B R R A A K K E E L L I I N N E E R R O O U U T T I I N N G G Single Front Caliper ITEM DESCRIPTION TORQUE (IF APPLICABLE) Rear Brake Line (Rear Master Cylinder to ABS Module) Push Rivet Brake Line Clip Fasteners...
Page 461 BRAKES Dual Front Caliper ITEM DESCRIPTION TORQUE (IF APPLICABLE) Rear Brake Line (Rear Master Cylinder to ABS Module) Push Rivet Brake Line Clip Fasteners 88 ft-lbs (10 N·m) Brake Line Clip (front) Brake Line Clip (rear) Brake Line Clip Fastener 88 ft-lbs (10 N·m) Routing Clip Brake Line Retainer...
Page 462 BRAKES R R E E A A R R M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 463 BRAKES F F R R O O N N T T B B R R A A K K E E C C A A L L I I P P E E R R C C O O M M P P O O N N E E N N T T S S Single Front Caliper ITEM DESCRIPTION...
Page 464 BRAKES Dual Front Caliper TORQUE (IF APPLICABLE) ITEM DESCRIPTION Caliper Body Assembly Brake Pads (shims not shown) Pad Spring Pin Clip Brake Pad Retaining Pin 53 in-lbs (6 N·m) 9941686 R01 - 2025 Indian Scout Service Manual 9.16 © Copyright Polaris Industries Inc.
Page 465 BRAKES R R E E A A R R B B R R A A K K E E C C A A L L I I P P E E R R C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 466 BRAKES A A B B S S M M O O D D U U L L E E ITEM DESCRIPTION Front Master Cylinder Rear Master Cylinder Wheel Caliper Front Wheel Caliper Rear 9941686 R01 - 2025 Indian Scout Service Manual 9.18 ©...
Page 467 BRAKES FUNCTION Ground to ECU CAN High Front WSS – Signal Ignition Not Used Not Used Not Used Not Used Voltage Supply - ECU Ground for Motor CAN Low Front WSS - Voltage Rear WSS - Voltage Rear WSS - Signal Not Used Not Used Not Used...
Page 468 Digital Wrench and perform an ABS System • Always maintain the recommended tire pressure. inspection to determine the cause. • Indian Motorcycle DOT 4 Brake Fluid is • When the ABS lamp is illuminated, the anti-lock recommended. Change every 10,000 miles (16,000 brakes will not activate, but the conventional brake km) or 24 months, whichever comes first.
Page 469 BRAKES A A B B S S S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S In addition to the brake system components listed above, the following are exclusive to ABS equipped The following parts function in the same manner as the vehicles:...
Page 470 BRAKES A A B B S S O O V V E E R R V V I I E E W W O O F F O O P P E E R R A A T T I I O O N N If the surface coefficient changes (such as moving from wet pavement to dry pavement) the ABS system will The ABS system is active and available when vehicle...
Page 471 BRAKES A A B B S S S S Y Y S S T T E E M M S S E E R R V V I I C C E E W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R R R E E P P L L A A C C E E M M E E N N T T INSTALLATION F F R R O O N N T T W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R 1.
Page 472 BRAKES R R E E A A R R W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R 5.
Page 473 BRAKES INSTALLATION 4. Install the same number of shims as during removal and wheel speed sensor fastener 1. Route the speed sensor harness along the rear Torque to specification. brake line through the retainer. Connect to the plug located above the ABS module. 2.
Page 474 BRAKES W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R A A I I R R G G A A P P 4.
Page 475 BRAKES A A B B S S M M O O D D U U L L E E R R E E P P L L A A C C E E M M E E N N T T 8.
Page 476 BRAKES I I N N S S T T A A L L L L A A T T I I O O N N 11. Rotate the rear harness box out of the way. 1. Install orientation bracket to the ABS module. 12.
Page 477 BRAKES 3. Connect the electrical connector to the ABS 6. Install four fasteners securing the ABS bracket to Module. the mid-cast. Torque fasteners to specification 4. Rotate the rear harness box out into position. TORQUE ABS Bracket to Mid-Cast Fasteners: 88 in-lbs (10 N·m) 7.
Page 478 BRAKES 12. Install the seat. See Seat Installation page 7.19. 13. Bleed brake system as outlined in this chapter. 9941686 R01 - 2025 Indian Scout Service Manual 9.30 © Copyright Polaris Industries Inc.
Page 479 WARNING torque. Do not use brake fluid taken from old, used or • Always install NEW genuine Indian Motorcycle unsealed containers. Never reuse brake fluid. Brake replacement parts and rubber parts upon assembly. fluid can accumulate moisture, reducing it’s Apply special lubricant where indicated (included performance.
Page 480 BRAKES A A B B S S F F L L U U I I D D C C H H A A N N G G E E 2. Remove front fastener and loosen the rear foot control fastener so the foot control can be Review Brake Fluid Replacement and Bleeding rotated.
Page 481 BRAKES 8. Vacuum bleed approximately four reservoirs worth 11. Clean the reservoir cover, diaphragm, and of fluid through the system. reservoir sealing surface. If diaphragm is extended, return it to normal (flat) position. Install IMPORTANT diaphragm and cover. Vacuum bleed until the level in the reservoir has TORQUE been lowered to the LOW level then refill reservoir.
Page 482 BRAKES A A B B S S F F R R O O N N T T B B R R A A K K E E B B L L E E E E D D I I N N G G 6.
Page 483 BRAKES D D U U A A L L C C A A L L I I P P E E R R S S E E R R V V I I C C E E 11. Clean the reservoir cover, diaphragm, diaphragm plate and reservoir sealing surface.
Page 484 BRAKES 7. Close bleeder fastener and fill the brake fluid 11. Clean the reservoir cover, diaphragm, diaphragm reservoir appropriately per the level indications on plate and reservoir sealing surface. Install the sight glass. diaphragm, diaphragm plate, and cover. 8. Repeat procedure until lever feels firm. IMPORTANT 9.
Page 485 BRAKES B B R R A A K K E E S S Y Y S S T T E E M M S S E E R R V V I I C C E E F F R R O O N N T T B B R R A A K K E E P P A A D D I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T B B R R A A K K E E P P A A D D R R E E P P L L A A C C E E M M E E N N T T S S I I N N G G L L E E C C A A L L I I P P E E R R M M O O D D E E L L S S NOTICE...
Page 486: Installation
BRAKES 3. Remove the pin clip , brake pad pin INSTALLATION 1. Install new brake pads with friction material toward disc. 2. Insert pads into caliper until the forward ear is engaged into the channel. Push the pads up into the caliper and insert the retaining pin through the hole in both.
Page 487 BRAKES D D U U A A L L C C A A L L I I P P E E R R M M O O D D E E L L S S 6. Install speed sensor. Torque fastener to specification.
Page 488 BRAKES INSTALLATION 5. Install the brake pad retaining pin and pin clip 1. Inspect caliper piston for any sign of fluid leakage. NOTICE Clean brake caliper surfaces with brake cleaner. 2. Install shims onto new brake pads as shown. 6. Torque pad retaining pin to specification. TORQUE Pad Retaining Pin: 53 in-lbs (6 N·m)
Page 489 BRAKES R R E E A A R R B B R R A A K K E E P P A A D D I I N N S S P P E E C C T T I I O O N N R R E E A A R R B B R R A A K K E E P P A A D D R R E E P P L L A A C C E E M M E E N N T T 1.
Page 490 BRAKES I I N N S S T T A A L L L L A A T T I I O O N N 6. Remove the old pads from the caliper. 1. Install brake pad shims on the outer side of each rear brake pad as shown.
Page 491 BRAKES B B R R A A K K E E D D I I S S C C I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R S S E E R R V V I I C C E E 1.
Page 492 BRAKES 5. Remove reservoir cover , plate and diaphragm 8. Remove piston assembly out of master cylinder with spring. 6. Remove the nut and pivot pin and pull lever IMPORTANT assembly out of master cylinder. Note spring orientation for assembly of new spring (new parts) 9.
Page 493 BRAKES 15. Carefully install spring / piston assembly into 20. Using new sealing washers, connect the banjo master cylinder bore. Work both piston seals fastener securing the brake line to the front master carefully past the chamfer and into bore. Use care cylinder.
Page 494 BRAKES F F R R O O N N T T C C A A L L I I P P E E R R S S E E R R V V I I C C E E 3. Remove wheel speed sensor fastener. CAUTION Brake fluid and brake cleaners will damage paint, plastics and some rubber compounds.
Page 495 BRAKES 10. Clean all parts thoroughly with isopropyl alcohol. 20. Install the caliper to the fork and secure with two Be sure the seal bores are clean, removing all fasteners. Torque fastener to specification. traces of dirt or dried brake fluid. TORQUE 11.
Page 496 BRAKES D D U U A A L L C C A A L L I I P P E E R R S S E E R R V V I I C C E E 4. Remove the pin clip and brake pad retaining pin 1.
Page 497 BRAKES 10. Install brake pads. Torque retaining pin to 16. Before torquing caliper mounting fasteners, make specification. sure brake pads are set on the rotors by stroking the front brake lever. Torque fasteners to TORQUE specification. Pad Retaining Pin: TORQUE 53 in-lbs (6 N·m) Caliper Mounting Fasteners (front): 33 ft-lbs (45 N·m)
Page 498 BRAKES R R E E A A R R M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R S S E E R R V V I I C C E E 3.
Page 499 BRAKES 11. Carefully assemble and install the internal master 13. Install diaphragm and reservoir cover and torque cylinder components in order. to specification. IMPORTANT If diaphragm is extended, return it to the neutral position. 12. Install the master cylinder and torque the clevis nut, mounting fasteners, and brake line banjo fastener to specification.
Page 500 BRAKES R R E E A A R R C C A A L L I I P P E E R R S S E E R R V V I I C C E E 7. Remove the old pads and wear clip from the caliper.
Page 501 BRAKES 14. Apply clean DOT4 brake fluid to outer surface of 21. Install the wear clip. Insert the pad retaining pin the piston. through the caliper and the hole in both brake pads. Torque fastener to specification. 15. Install piston seal and dust seal in caliper body. TORQUE 16.
Page 502 BRAKES T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component Erratic Braking...
Page 503 / dirt on pads and / brake disc. or brake disc. Repair as Necessary. Inspect Pad Pad Not Secure in Caliper Installation Aftermarket (not genuine Indian Motorcycle) Install Genuine Indian Motorcycle Parts Parts Replace Worn or Damaged Wheel Bearing(s) Replace...
Page 505: Chapter 10 Electrical
ELECTRICAL CHAPTER 10 ELECTRICAL STARTING / CHARGING................10.5 .
Page 506 ELECTRICAL ........... . 10.48 STATOR WINDINGS TO GROUND INSPECTION .
Page 507 ELECTRICAL ..............10.89 VEHICLE CONTROL MODULE (VCM) .
Page 508 ELECTRICAL ELECTRICAL DIAGNOSTICS ................10.156 .
Page 509 ELECTRICAL S S T T A A R R T T I I N N G G / / C C H H A A R R G G I I N N G G Battery Label G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S All electrical system and component service can be performed with the engine in the frame.
Page 510: Wire Routing
ELECTRICAL WARNING CAUTION Battery electrolyte is poisonous. It contains sulfuric WIRE ROUTING acid. Serious burns can result from contact with skin, Make sure that all wires are routed correctly away eyes or clothing. Antidote: from moving parts, hot exhaust, or sharp edges. •...
Page 511 ELECTRICAL CAUTION Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last. Do not remove the battery cables while the engine is running. Doing so may damage the Electronic Control Module (ECM). Take great care NOT to reverse the battery leads when installing the battery.
Page 512 ELECTRICAL S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S – – S S T T A A R R T T I I N N G G / / C C H H A A R R G G I I N N G G ELECTRICAL SPECIFICATIONS ITEM SPECIFICATIONS...
Page 513 ELECTRICAL A A S S S S E E M M B B L L Y Y V V I I E E W W S S S S T T A A R R T T E E R R M M O O T T O O R R / / S S O O L L E E N N O O I I D D C C O O M M P P O O N N E E N N T T S S ITEM DESCRIPTION TORQUE (IF APPLICABLE)
Page 514 ELECTRICAL S S T T A A T T O O R R C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM DESCRIPTION Stator Stator Mounting Fasteners to Cover 88 in-lbs (10 N·m) Stator Wire Clip Stator Clip Fasteners...
Page 515 ELECTRICAL R R E E G G U U L L A A T T O O R R / / R R E E C C T T I I F F I I E E R R C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 516 ELECTRICAL B B A A T T T T E E R R Y Y B B O O X X C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 517 ELECTRICAL B B A A T T T T E E R R Y Y S S E E R R V V I I C C E E 3. Remove the battery cover access tool located under the seat. B B A A T T T T E E R R Y Y R R E E M M O O V V A A L L WARNING Improperly connecting or disconnecting battery...
Page 518 ELECTRICAL 6. Release the retaining tab 9. Remove the two cover fasteners and retain. 10. Disconnect the negative (-) battery terminal 7. Lift the WCM up and back to remove. fastener and cable. NOTICE Install the fastener into the battery after removal to capture the nut in the battery post.
Page 519 ELECTRICAL 11. Remove the Positive (+) Jump Start Terminal cap 14. Using the battery strap, pull the battery out of to aid in removal of the cover. battery trays. Once the battery is about 1/2 – 3/4 way out, use your other hand to grab the top of the NOTICE battery and remove it from the motorcycle.
Page 520 ELECTRICAL B B A A T T T T E E R R Y Y I I N N S S T T A A L L L L A A T T I I O O N N 3. Install Positive (+) Jump Start Terminal onto the positive battery terminal as shown.
Page 521 ELECTRICAL 6. Install the Positive (+) Jump Start Terminal cap 9. Install the two battery cover fasteners . Torque to specification. 7. Connect the negative (-) battery cable and terminal TORQUE fastener . Torque to specification. Battery Cover Fasteners: 35 in-lbs (4 N·m) 10.
Page 522 ELECTRICAL 12. Push down on the back of the WCM until it locks 15. Power on the motorcycle to verify the battery has properly in the rear retaining tab of the battery been connected properly. cover. 16. Install the battery cover access tool under the seat. 13.
Page 523 ELECTRICAL B B A A T T T T E E R R Y Y T T R R A A Y Y R R E E M M O O V V A A L L 5. If removing the left-hand battery tray, perform the steps below: 1.
Page 524 ELECTRICAL B B A A T T T T E E R R Y Y T T R R A A Y Y I I N N S S T T A A L L L L A A T T I I O O N N c.
Page 525 ELECTRICAL d. Connect the chassis harness to the left-hand 2. If installing the right-hand battery tray, Connect the battery tray connector. ECM electrical connectors . Install the battery tray into the recesses of the mid-cast. IMPORTANT Listen for audible “click” when pressing into place. Pull gently on connector once seated to ensure a proper connection has been made.
Page 526 ELECTRICAL 5. Install battery. See Battery Installation page 10.16. 6. Install the seat. See Seat Installation page 7.19. 9941686 R01 - 2025 Indian Scout Service Manual 10.22 © Copyright Polaris Industries Inc.
Page 527 B B A A T T T T E E R R Y Y C C H H A A R R G G I I N N G G A A N N D D M M A A I I N N T T E E N N A A N N C C E E INDIAN MOTORCYCLE RECOMMENDED AGM BATTERY...
Page 528 ELECTRICAL AGM BATTERY CHARGING RECOMMENDATIONS AGM BATTERY CHARGING RECOMMENDATIONS – DEEPLY DISCHARGED (BELOW 9VOLTS) The battery will self-discharge when disconnected from a vehicle, and will discharge at a faster rate when If the automatic charger's manual does not include connected. Listed below are the recommended instructions on how to charge deeply discharged battery charging schedules.
Page 529 4. Battery connections should be tightened to the jelly. correct torque during installation. This will reduce voltage drop and ensure a reliable connection 5. Test using the Indian Motorcycle recommended between the regulator/rectifier and battery. AGM battery testing procedure. See BATTERY CHARGING AND MAINTENANCE page 10.23.
Page 530 ELECTRICAL B B A A T T T T E E R R Y Y T T E E S S T T I I N N G G The recommended battery tester for all Indian Motorcycle batteries is special tool PU-50296. See Special Tools Index page 1.14.
Page 531 ELECTRICAL S S T T A A R R T T I I N N G G S S Y Y S S T T E E M M T T E E S S T T S S B B A A T T T T E E R R Y Y L L O O A A D D T T E E S S T T 1.
Page 532 ELECTRICAL S S T T A A R R T T I I N N G G S S Y Y S S T T E E M M D D I I A A G G N N O O S S T T I I C C T T A A B B L L E E SYMPTOM POSSIBLE CAUSE RECOMMENDATION...
Page 533 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T 1 1 9941686 R01 - 2025 Indian Scout Service Manual 10.29 ©...
Page 534 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T 2 2 NOTE These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive...
Page 535 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T 3 3 SYMPTOM POSSIBLE CAUSE Starter clutch malfunction.
Page 536 ELECTRICAL S S T T A A R R T T E E R R S S O O L L E E N N O O I I D D G G R R O O U U N N D D C C I I R R C C U U I I T T T T E E S S T T WARNING Ensure that the motorcycle is secure and that the transmission is in neutral for the following test.
Page 537 ELECTRICAL G G E E A A R R S S E E L L E E C C T T O O R R S S E E N N S S O O R R T T E E S S T T •...
Page 538 ELECTRICAL C C L L U U T T C C H H S S W W I I T T C C H H C C I I R R C C U U I I T T T T E E S S T T S S T T A A R R T T E E R R S S O O L L E E N N O O I I D D P P O O S S I I T T I I V V E E C C I I R R C C U U I I T T T T E E S S T T The symptom of a faulty clutch switch circuit is: WARNING...
Page 539 ELECTRICAL S S T T A A R R T T E E R R C C U U R R R R E E N N T T D D R R A A W W T T E E S S T T •...
Page 540 ELECTRICAL 5. Set the multi meter to Volts DC scale and connect red lead of meter to positive post of battery. 6. Connect black lead of meter to negative post of battery. 7. Turn the ignition switch ON to power up the electrical system and observe ammeter.
Page 541 ELECTRICAL S S T T A A R R T T E E R R M M O O T T O O R R S S E E R R V V I I C C E E 4. Slightly lift the radiator upward to disengage it from the bottom grommets S S A A F F E E T T Y Y I I N N F F O O R R M M A A T T I I O O N N WARNING...
Page 542 ELECTRICAL INSTALLATION 1. Install Starter and secure with fasteners. IMPORTANT Hand thread top fastener into starter first, followed by the bottom fastener. 2. Torque the starter mounting fasteners to specification. TORQUE Starter Motor Fasteners: 88 in-lbs (10 N·m) 3. Connect positive terminal to the starter motor. Torque the starter motor positive terminal nut to specification.
Page 543 ELECTRICAL C C L L U U T T C C H H S S W W I I T T C C H H R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 544 ELECTRICAL 5. Gently pull the clutch switch out of the lever perch 2. Install the clutch pivot fastener nut. until the locating pin is free. TORQUE CAUTION Clutch Lever Pivot Nut: 49 in-lbs (5.5 N·m) The clutch switch has a locating pin on the bottom side which slide into the clutch lever perch.
Page 545 ELECTRICAL 4. Connect the electrical connector to the clutch switch. 5. Adjust clutch cable freeplay. See Clutch Lever Free Play page 5.4 S S T T A A R R T T E E R R C C L L U U T T C C H H R R E E M M O O V V A A L L •...
Page 546 ELECTRICAL C C H H A A R R G G I I N N G G S S Y Y S S T T E E M M S S E E R R V V I I C C E E T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G , , C C H H A A R R G G I I N N G G S S Y Y S S T T E E M M NOTICE The battery must be fully charged and in good condition to obtain accurate readings.
Page 547 ELECTRICAL C C U U R R R R E E N N T T D D R R A A I I N N I I N N S S P P E E C C T T I I O O N N 3.
Page 548 ELECTRICAL 7. Locate the faulty component or wiring by disconnecting accessories, wiring connections, and fuses one-at-a-time while observing current drain. When current drain falls within specifications, focus efforts on the last circuit or component that was disconnected. 9941686 R01 - 2025 Indian Scout Service Manual 10.44 ©...
Page 549 ELECTRICAL R R E E G G U U L L A A T T E E D D V V O O L L T T A A G G E E / / A A M M P P E E R R A A G G E E O O U U T T P P U U T T 4.
Page 550 ELECTRICAL S S T T A A T T O O R R A A C C V V O O L L T T A A G G E E O O U U T T P P U U T T T T E E S S T T 10.
Page 551 ELECTRICAL S S T T A A T T O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T 3.
Page 552 ELECTRICAL S S T T A A T T O O R R W W I I N N D D I I N N G G S S T T O O G G R R O O U U N N D D I I N N S S P P E E C C T T I I O O N N 4.
Page 553 ELECTRICAL S S T T A A T T O O R R R R E E M M O O V V A A L L 6. Push the rubber harness seal to inside of stator cover . Remove stator assembly 1.
Page 554 ELECTRICAL S S T T A A T T O O R R I I N N S S T T A A L L L L A A T T I I O O N N 5. Insert wire terminals into stator connector housing. Note: Verify there is an audible “click”...
Page 555 ELECTRICAL R R E E C C T T I I F F I I E E R R / / R R E E G G U U L L A A T T O O R R C C O O N N N N E E C C T T O O R R I I N N S S P P E E C C T T I I O O N N 1.
Page 556 ELECTRICAL D D I I O O D D E E L L E E A A K K A A G G E E T T E E S S T T R R E E G G U U L L A A T T O O R R / / R R E E C C T T I I F F I I E E R R R R E E P P L L A A C C E E M M E E N N T T REMOVAL IMPORTANT Engine must be OFF.
Page 557 ELECTRICAL K K E E Y Y F F O O B B INSTALLATION K K E E Y Y F F O O B B O O V V E E R R V V I I E E W W 1.
Page 558 10 seconds, then not available and you cannot remember your PIN, the system exits the procedure. The new PIN was please see your INDIAN MOTORCYCLE dealer. NOT saved. Continue to use your former valid PIN. Return to step 1 to try again.
Page 559 ELECTRICAL Driving Key Fob Operation: • After starting the engine, the Wireless Control Module (WCM) will verify that the key fob is within range again when wheel speed is >5 mph. The security light will flash once during this check. •...
Page 560 ELECTRICAL K K E E Y Y F F O O B B A A U U T T H H E E N N T T I I C C A A T T I I O O N N K K E E Y Y F F O O B B T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G Four things must occur for the WCM to authenticate 1.
Page 561 1; Pin 11 is Antenna connection 2. c. Does antenna test within specification? SPECIFICATION YES — Replace WCM Antenna Capacitance: 3.4 nF (± 2 %) NO — Contact Indian Motorcycle Technical Service. 9941686 R01 - 2025 Indian Scout Service Manual 10.57 © Copyright Polaris Industries Inc.
Page 562 ELECTRICAL K K E E Y Y F F O O B B B B A A T T T T E E R R Y Y R R E E P P L L A A C C E E M M E E N N T T 1.
Page 563 ELECTRICAL 5. Install the battery cover back on to the key fob. 6. If applicable, verify the key fob lock and unlock functions work correctly. 9941686 R01 - 2025 Indian Scout Service Manual 10.59 © Copyright Polaris Industries Inc.
Page 564: General Precautions
ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M GENERAL PRECAUTIONS G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N •...
Page 565 ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M S S E E R R V V I I C C E E S S P P E E C C I I A A L L T T O O O O L L S S I I G G N N I I T T I I O O N N C C O O I I L L R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N SPECIAL TOOL...
Page 566 ELECTRICAL I I G G N N I I T T I I O O N N S S W W I I T T C C H H / / P P O O W W E E R R B B U U T T T T O O N N 5.
Page 567 ELECTRICAL IGNITION SWITCH REPLACEMENT 4. Install ignition cover fasteners and torque to specification. REMOVAL 1. Park motorcycle on a flat surface, fully extend side stand, and make sure vehicle is stable. 2. Remove ignition switch side cover fasteners TORQUE Ignition Cover Fasteners: 88 in-lbs (10 N·m) 3.
Page 568 ELECTRICAL 5. Remove ignition switch fasteners and remove 1. Install ignition cover to engine mount bracket from ignition cover. and install retention clips 6. Press in on retaining tabs to disengage the 2. Install switch housing into ignition cover until switch housing from ignition cover and remove.
Page 569 ELECTRICAL 4. Install ignition electrical harness 5. Install ignition cover to frame and install retention clips 6. Install ignition cover fasteners and torque to specification. TORQUE Ignition Cover Fasteners: 88 in-lbs (10 N·m) 9941686 R01 - 2025 Indian Scout Service Manual 10.65 ©...
Page 570 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G T T E E S S T T L L E E A A D D A A D D A A P P T T E E R R K K I I T T I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G B B A A S S I I C C S S 1.
Page 571 ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M T T E E S S T T F F L L O O W W C C H H A A R R T T 9941686 R01 - 2025 Indian Scout Service Manual 10.67 ©...
Page 572 ELECTRICAL B B A A T T T T E E R R Y Y V V O O L L T T A A G G E E I I N N S S P P E E C C T T I I O O N N T T E E S S T T 1 1 S S P P A A R R K K I I N N S S P P E E C C T T I I O O N N T T E E S S T T 2 2 1.
Page 573 ELECTRICAL I I G G N N I I T T I I O O N N C C O O I I L L P P O O W W E E R R / / G G R R O O U U N N D D S S I I G G N N A A L L T T E E S S T T •...
Page 574 ELECTRICAL I I G G N N I I T T I I O O N N C C O O I I L L R R E E S S I I S S T T A A N N C C E E T T E E S S T T 4 4 Ignition Coil Primary Winding 1.
Page 575 ELECTRICAL C C H H A A S S S S I I S S E E L L E E C C T T R R I I C C A A L L G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S Keep the following notes in mind when diagnosing an electrical problem:...
Page 576: Input Signals
ELECTRICAL C C O O N N T T R R O O L L L L E E R R O O V V E E R R V V I I E E W W O O V V E E R R V V I I E E W W Listed below are all the electronic controllers found on the Scout chassis.
Page 577: Replaceable Components
ELECTRICAL REPLACEABLE COMPONENTS • Throttle Body • Fuel Pump • Rear Coil – Fuel Level Sensor • Front Coil • Gear Selector Switch • Engine Relay Control • Side-Stand Switch • Headlight Relay Control • TMAP Sensor • Starter Relay •...
Page 578 ELECTRICAL REPLACEABLE COMPONENTS • Horn Assembly • Headlight Assembly • Grips • Fog Lights WCM (WIRELESS CONTROL MODULE) INPUT SIGNALS OUTPUT SIGNALS • Switched Power • VCM (Wake-Up) • Low Frequency Antenna • Power Button LED • Power Button • CANbus A •...
Page 579 ELECTRICAL REPLACEABLE COMPONENTS • GPS Antenna • Cellular Antenna • Cellular Diversity Antenna ABS Module (Antilock Brake System) INPUT SIGNALS OUTPUT SIGNALS • Antilock Brake • ABS Pump Power • Front Wheel Speed Sensor • CANbus C • Rear Wheel Speed Sensor •...
Page 580: Output Signals
ELECTRICAL Digital Round Terminator Resistor 2 Must be replaced as an assembly INPUT SIGNALS OUTPUT SIGNALS • Oil Pressure Switch • GPS Antenna Signal • CANbus D • USB Connection • CANbus D Speedometer (CPI) Terminator Resistor 2 Must be replaced as an assembly INPUT SIGNALS OUTPUT SIGNALS •...
Page 581 ELECTRICAL A A S S S S E E M M B B L L Y Y V V I I E E W W S S H H E E A A D D L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S ( ( S S U U P P E E R R S S C C O O U U T T / / S S C C O O U U T T C C L L A A S S S S I I C C ) ) TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 582 ELECTRICAL H H E E A A D D L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S ( ( S S C C O O U U T T B B O O B B B B E E R R ) ) TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 583 ELECTRICAL H H E E A A D D L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T S S C C O O U U T T / / 1 1 0 0 1 1 S S C C O O U U T T ) ) TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 584 ELECTRICAL T T A A I I L L L L I I G G H H T T / / L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S ( ( S S C C O O U U T T C C L L A A S S S S I I C C ) ) TORQUE (IF APPLICABLE) ITEM DESCRIPTION...
Page 585 ELECTRICAL L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S ( ( A A L L L L E E X X C C E E P P T T S S C C O O U U T T C C L L A A S S S S I I C C ) ) BOBBER / SPORT / 101 SCOUT MODELS SUPER SCOUT 9941686 R01 - 2025 Indian Scout Service Manual...
Page 586 ELECTRICAL TORQUE (IF APPLICABLE) ITEM DESCRIPTION 88 in-lbs (10 N·m) License Plate Bracket Fastener License Plate Lamp Pad, Cam (wave side facing up) License Plate Light Nuts 18 in-lbs (2 N·m) Washer License Plate Mount Wire Retainer Clip Spring License Plate Bracket 88 in-lbs (10 N·m) License Plate Mount Fasteners Turn Signal Fastener...
Page 587 ELECTRICAL F F U U S S E E B B O O X X TORQUE (IF APPLICABLE) ITEM DESCRIPTION Fuse Box Cover Tabs Fuse Box Cover ABS Fuse 9941686 R01 - 2025 Indian Scout Service Manual 10.83 © Copyright Polaris Industries Inc.
Page 588 ELECTRICAL F F U U S S E E B B O O X X F F U U S S E E A A P P P P L L I I C C A A T T I I O O N N C C H H A A R R T T CIRCUIT DESCRIPTION WIRE COLOR FROM...
Page 589 ELECTRICAL CIRCUIT DESCRIPTION WIRE COLOR FROM STARTER HSD Fuse Box (16) ECM1 (41) PK/BK COOLING FAN CIRCUIT BREAKER Fuse Box (17) FUSEBOX (1) OUTPUT UNFUSED BATTERY START SOLENOID Fuse Box (18) (M6 RNG) UNFUSED BATTERY START SOLENOID Fuse Box (19) (M6 RNG) VCM POWER Fuse Box (20)
Page 590 ELECTRICAL G G C C M M R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N G G A A T T E E W W A A Y Y C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( G G C C M M ) ) REMOVAL G G A A T T E E W W A A Y Y C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( G G C C M M ) ) O O V V E E R R V V I I E E W W...
Page 591 ELECTRICAL 1. Connect the chassis harness to the GCM connector and install GCM IMPORTANT Listen for audible “click” when pressing into place. Pull gently on connector once seated to ensure a proper connection has been made. 2. Install battery plate 3.
Page 592 ELECTRICAL G G C C M M P P I I N N O O U U T T FUNCTION LOW CAN C (ABS, ECM) LOW CAN D (Diag, Infotainment) 12V WAKE / SLEEP V IN (BATTERY) LOW CAN A (ECM, VCM, WCM, Swithcubes) LOW CAN B (TCU) HIGH CAN B (TCU) HIGH CAN A (ECM, VCM, WCM, Swithcubes)
Page 593 ELECTRICAL V V E E H H I I C C L L E E C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( V V C C M M ) ) V V E E H H I I C C L L E E C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( V V C C M M ) ) , , R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N V V E E H H I I C C L L E E C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( V V C C M M ) ) O O V V E E R R V V I I E E W W...
Page 594 ELECTRICAL 4. Disconnect the diagnostic connector from the left- 7. Remove VCM by removing its fasteners from the hand battery box connector. battery tray. 5. Disconnect the starter solenoid electrical INSTALLATION connector and terminal nuts IMPORTANT If this component is being replaced, the new component requires Digital Wrench II to program it.
Page 595 ELECTRICAL 4. Connect the starter solenoid electrical connector 6. Connect the diagnostic connector to the left-hand battery tray connector. and terminal nuts . Torque nut to specification. IMPORTANT IMPORTANT Listen for audible “click” when pressing into place. Listen for audible “click” when pressing into place. Pull gently on connector once seated to ensure a Pull gently on connector once seated to ensure a proper connection has been made.
Page 596 ELECTRICAL V V C C M M P P I I N N O O U U T T FUNCTION VCM Power CAN A High LH Heated Grips Output Aux Light Switch Indicator Light Low Beam Aux Light Switch Output Horn Power Heat Grip Switch Decrease Switched Power Control...
Page 597 ELECTRICAL W W I I R R E E L L E E S S S S C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( W W C C M M ) ) W W C C M M R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N REMOVAL W W I I R R E E L L E E S S S S C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( W W C C M M ) ) O O V V E E R R V V I I E E W W...
Page 598 ELECTRICAL 3. Disconnect the negative (-) battery terminal 6. Release the retaining tab fastener and cable. NOTICE 7. Lift the WCM up and back to remove. Install the fastener into the battery after removal to capture the nut in the battery post. 4.
Page 599 ELECTRICAL 2. Push down on the back of the WCM until it locks 5. Connect the negative (-) battery cable and terminal properly in the rear retaining tab of the battery fastener . Torque to specification. cover. TORQUE Battery Terminal Fasteners: 3.
Page 600 ELECTRICAL W W C C M M P P I I N N O O U U T T FUNCTION VCM Control Power CAN HI Signal CAN A Low Signal Digital Input Power Button VCM Wake Power Switched Power Control Power Button Feed LF Antenna Connection 1 LF Antenna Connection 2...
Page 601 ELECTRICAL T T E E L L E E M M A A T T I I C C C C O O N N T T R R O O L L U U N N I I T T ( ( T T C C U U ) ) T T E E L L E E M M A A T T I I C C C C O O N N T T R R O O L L U U N N I I T T ( ( T T C C U U ) ) O O V V E E R R V V I I E E W W The Telematic Control Unit (TCU) provides all of the real time data functionality for the displays, it provides...
Page 602 ELECTRICAL T T C C U U R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 4.
Page 603 ELECTRICAL 7. Remove TCU by disengage retention tab 2. Connect TCU electrical connection , USB Data remove from the battery tray. GPS, , Cellular , and Diversity IMPORTANT Listen for audible “click” when pressing into place. Pull gently on connector once seated to ensure a proper connection has been made.
Page 604 ELECTRICAL 5. Install battery plate 8. Install the battery. See Battery Installation page 10.16. 9. Install the seat. See Seat Installation page 7.19. 6. Connect the diagnostic connector to the left-hand battery tray connector. IMPORTANT Listen for audible “click” when pressing into place. Pull gently on connector once seated to ensure a proper connection has been made.
Page 605 ELECTRICAL T T C C U U P P I I N N O O U U T T FUNCTION VCM Accessory Power Out Instrumentation Fuse Output 256K CAN High Ground 256K CAN Low 9941686 R01 - 2025 Indian Scout Service Manual 10.101 ©...
Page 606 ELECTRICAL H H E E A A D D L L I I G G H H T T S S E E R R V V I I C C E E SCOUT BOBBER H H E E A A D D L L I I G G H H T T R R E E P P L L A A C C E E M M E E N N T T 1.
Page 607 ELECTRICAL INSTALLATION 5. Install headlight bezel fasteners and torque to specification. SCOUT BOBBER 1. Install spring steel clips noting placement and orientation. TORQUE Headlight Retaining Ring Fastener: 35 in-lbs (4 N·m) 2. Connect the electrical connection to the headlight. 3. Install the headlight assembly into the bucket.
Page 608 ELECTRICAL CLASSIC / SPORT / SUPER / 101 SCOUT 6. Install fastener and torque to specification. 1. Install spring steel clips noting placement and orientation. TORQUE Headlight Retaining Ring Fastener: 2. Connect the electrical connection to the headlight. 35 in-lbs (4 N·m) 3.
Page 609 ELECTRICAL H H O O R R N N S S E E R R V V I I C C E E INSTALLATION H H O O R R N N R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 610 ELECTRICAL T T A A I I L L L L A A M M P P S S E E R R V V I I C C E E L L E E D D T T U U R R N N / / T T A A I I L L / / B B R R A A K K E E L L I I G G H H T T O O P P E E R R A A T T I I O O N N The multiple LED turn / tail / brake lamp functions much like a conventional incandescent tail / brake lamp.
Page 611 ELECTRICAL T T A A I I L L / / B B R R A A K K E E / / L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T R R E E - - 5.
Page 612 ELECTRICAL 9. To remove the license plate lamp, remove nuts 2. Install the license plate light and route the harness lead through the rear lighting bracket. 10. Remove the license plate light from the license plate bracket. NOTICE Make sure to route the lamp lead through the IMPORTANT opening in the plastic mounting bracket indicated by Note the wire routing within the bracket.
Page 613 ELECTRICAL L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T R R E E P P L L A A C C E E M M E E N N T T ( ( A A L L L L SUPER SCOUT MODELS E E X X C C E E P P T T S S C C O O U U T T C C L L A A S S S S I I C C ) ) 1.
Page 614 ELECTRICAL INSTALLATION 5. Remove license plate fasteners. 1. Install the license plate light. 2. Install nuts onto the license plate light. 3. Verify the license plate light wire is properly routed as shown. Connect electrical connection. 6. Remove the license plate light nuts from the license plate bracket.
Page 615 ELECTRICAL SUPER SCOUT MODELS 6. To secure the wires, install the wire retainer by first inserting the lower tab into the license bracket, 1. Install the license plate light. then the clips onto the bracket tube. 2. Install nuts onto the license plate light. 3.
Page 616 ELECTRICAL T T U U R R N N S S I I G G N N A A L L / / H H A A Z Z A A R R D D S S Y Y S S T T E E M M S S E E R R V V I I C C E E F F R R O O N N T T T T U U R R N N S S I I G G N N A A L L R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N T T U U R R N N S S I I G G N N A A L L O O P P E E R R A A T T I I O O N N...
Page 617 ELECTRICAL R R E E A A R R T T U U R R N N S S I I G G N N A A L L R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 618 ELECTRICAL INSTALLATION 4. Disconnect the turn signal electrical connector SCOUT CLASSIC 5. Remove fastener and remove the turn signal. 1. Install fastener and washer. Torque fastener to specification. TORQUE Turn Signal Fastener (rear): 18 ft-lbs (25 N·m) 2. Route and secure turn signal harness in offset bracket tabs, then connect the tail light connector.
Page 619 ELECTRICAL 3. To secure the wires, install the wire retainer by first 3. To secure the wires, install the wire retainer by first inserting the lower tab into the bracket tube, then inserting the lower tab into the license bracket, the clips onto the license bracket.
Page 620 ELECTRICAL S S W W I I T T C C H H C C U U B B E E 3. Remove handlebar retention ties. S S W W I I T T C C H H C C U U B B E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N REMOVAL 1.
Page 621 ELECTRICAL c. Disconnect the switch cube electrical e. Carefully insert a 2mm allen wrench into the connectors. switchcube relief to release the retention clip d. Using compressed air, blow air under the inner part of the hand grip, remove the ETC and hand f.
Page 622 ELECTRICAL INSTALLATION b. Carefully insert a 2mm allen wrench into the switch cube opening and press down on the 1. Install right-hand switch cube: retaining clip as shown. a. Slide the switch cube inwards onto the handlebar. b. Install the retaining clip into the alignment hold in the handlebar as shown.
Page 623 ELECTRICAL d. Install the ETC and hand grip to the handebar. g. Install the bottom electronic throttle control (ETC) fastener. Torque fastener to specification. NOTICE TORQUE Isopropyl Alcohol can be used to aid in grip installation. Electronic Throttle Control (ETC) Fastener: 27 in-lbs (3 N·m) e.
Page 624 ELECTRICAL b. Install the retaining clip into the alignment hole e. Connect the switch cube electrical connectors. in the handlebar as shown. f. Install handlebar retention ties. c. Slide the switch cube toward the retaining clip IMPORTANT until it locks into position. Make sure the brake and clutch lines are NOT retained by the ties.
Page 625 ELECTRICAL S S W W I I T T C C H H C C U U B B E E P P I I N N O O U U T T LEFT SWITCH CUBE FUNCTION CAN Control Power CAN Control Ground CAN A HIGH CAN LOW...
Page 626 ELECTRICAL E E L L E E C C T T R R O O N N I I C C T T H H R R O O T T T T L L E E C C O O N N T T R R O O L L ( ( E E T T C C ) ) 3.
Page 627 ELECTRICAL INSTALLATION 3. Install hand grip to the ETC. 1. Install the ETC and align the ETC parting line with the lower button feature on the switch cube as shown. NOTICE Isopropyl Alcohol can be used to aid in grip installation.
Page 628 ELECTRICAL E E L L E E C C T T R R O O N N I I C C T T H H R R O O T T T T L L E E C C O O N N T T R R O O L L ( ( E E T T C C ) ) P P I I N N O O U U T T FUNCTION VCC 1...
Page 629 ELECTRICAL I I N N S S T T R R U U M M E E N N T T A A T T I I O O N N 3. Press tab down to disengage the electrical connector from the instrument cluster. I I N N S S T T R R U U M M E E N N T T C C L L U U S S T T E E R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N SPORT / 101 SCOUT...
Page 630 ELECTRICAL 6. Separate gage mount , housing , gasket , and INSTALLATION cluster 1. Align gasket tab to cluster and housing as shown. NOTICE Soapy water is recommended to separate the gasket from the housing. 2. Install gasket into housing , then press gasket/ housing over instrument cluster .
Page 631 ELECTRICAL 3. Connect TCU-USB, , Antenna GPS , and chassis 5. Install riser cap and fasteners. Torque front two harness connectors to the cluster. fasteners , then rear 4. Install instrument cluster fasteners. Torque TORQUE fasteners to specification. Handle Bar Riser Fasteners: 18 ft-lbs (25 N·m) TORQUE Instrument Cluster Mount Fasteners:...
Page 632 ELECTRICAL CLASSIC / SUPER / BOBBER SCOUT 4. Separate gage mount , housing , gasket , and cluster REMOVAL NOTICE 1. Remove four instrument cluster mount fasteners. Soapy water is recommended to separate the gasket from the housing. INSTALLATION 1. Align gasket tab to cluster and housing as shown. 2.
Page 633 ELECTRICAL U U S S B B C C H H A A R R G G E E P P O O R R T T O O V V E E R R V V I I E E W W 3.
Page 634 ELECTRICAL U U S S B B C C H H A A R R G G E E P P O O R R T T R R E E P P L L A A C C E E M M E E N N T T 4.
Page 635 ELECTRICAL U U S S B B C C H H A A R R G G E E P P O O R R T T T T E E S S T T I I N N G G 2.
Page 636 ELECTRICAL R R I I D D E E C C O O M M M M A A N N D D D D I I A A G G N N O O S S T T I I C C S S / / T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G Problem: Black Screen / Will Not Power On STEP...
Page 637 ELECTRICAL STARTUP LIGHTS Some lights may be illuminated or slowly flashing on the display before operation. NOTICE This is normal operation of the motorcycle. Digital and Analog Instrument Cluster • Anti-Lock Brake System (ABS) light on and slowly flashing until you reach 5 mph. ABS Not Activated •...
Page 638 ELECTRICAL C C H H A A S S S S I I S S H H A A R R N N E E S S S S CHASSIS HARNESS REMOVAL C C H H A A S S S S I I S S H H A A R R N N E E S S S S R R E E M M O O V V A A L L 1.
Page 639 ELECTRICAL 4. Remove ground terminal fasteners. 7. Remove starter terminal nut. CAUTION Hold the lower terminal nut with an open ended wrench while tightening or loosening the upper nut to avoid damage. 8. Remove headlight bezel fastener and headlight bezel assembly. 5.
Page 640 ELECTRICAL 11. Disconnect front wheel speed sensor and front 19. Disconnect gateway control module connector ignition coil 20. Disconnect the vehicle control module connector 12. Disconnect harness retention features 21. Disconnect the starter solenoid electrical connector 22. Disconnect the starter motor cable 23.
Page 641 ELECTRICAL 28. Disconnect the rear brake pressure switch 2& 29. Disconnect the ABS connector 30. Disconnect the sidestand switch 31. Disconnect the crank position switch and Engine Sensor Pigtail retention. 32. Disconnect the rear wheel speed sensor 33. Disconnect gear selector switch 34.
Page 642 ELECTRICAL C C H H A A S S S S I I S S H H A A R R N N E E S S S S I I N N S S T T A A L L L L A A T T I I O O N N 10.
Page 643 ELECTRICAL 19. Connect the coolant temp sensor 27. Install ground terminal fasteners. Torque to specification. 20. Connect the TMAP sensor electrical connector TORQUE 21. Connect the oil pressure switch electrical Chassis Harness Ground Fasteners: connector 53 in-lbs (6 N·m) 22. Connect the Cam phasor sensor electrical connector 28.
Page 644 ELECTRICAL 30. Install headlight bezel assembly and headlight 32. Connect the horn , front O2 sensor , and bezel fastener. Torque fastener to specification. cooling fan connectors. Install cable ties. TORQUE 33. Install starter terminal nut. Torque to specification. Headlight Retaining Ring Fastener: TORQUE 35 in-lbs (4 N·m) Starter Nut:...
Page 645 ELECTRICAL FINAL ASSEMBLY 35. Connect the electrical connectors from the regulator / rectifier. 1. Install swingarm. See Swingarm Installation page 8.101 2. Install the head pipe. See Head Pipe Installation page 3.93. 3. Install the air box. See Air Box Installation page 3.12.
Page 646 ELECTRICAL C C H H A A S S S S I I S S H H A A R R N N E E S S S S P P I I N N O O U U T T WIRE COLOR FROM PORT...
Page 647 ELECTRICAL Front Splice Splice 0019 Splice 0031 Ground ETC Motor (+) PK / RD ECM 2 ETC Motor ETC Motor (–) ECM 2 ETC Motor Acc Switch Splice 0043 GY / WH Fusebox Output Acc Switch Front 12V Splice 0043 GY / WH Output Switched...
Page 648 ELECTRICAL VCM Accessory Headlight Splice 0071 PK / GN Power Out VCM Accessory Splice 0071 PK / GN Power Out VCM Accessory Splice 0071A Splice 0071E PK / GN Power Out Handlebar-LH LH Can Control Splice 0071E PK / GN Control Power Handlebar-RH...
Page 649 ELECTRICAL Twist Grip YE / BK ECM 2 PPS 2 Return MAP Sensor BN / GN ECM 2 TMAP Return BN / WH ECM 2 ETC Motor TPS Return LH AUX Light Fog Lights DG / RD Feed Twist Grip PPS 2 Output YE / GN ECM 2...
Page 650 ELECTRICAL Engine Breaker Splice 0127 RD / DB Fusebox Output Knock Sensor ECM 1 Knock Sensor Return Front Heated O2 GY / YE ECM 1 Front O2 Sensor Splice 0132A ECM 2 250K CAN HIGH Gateway Splice 0132A CANA HIGH Splice 0132A Splice 0132B 250K CAN HIGH...
Page 651 ELECTRICAL ACC Constant Splice 0153 Charge Port GY / RD Fuse Output ACC Constant Diag Splice 0153 GY / RD Fuse Output PPS 1 +5V Twist Grip WH / RD ECM 2 Reference BN / PK ECM 1 TMAP TMAP Power Splice 0019 Horn Horn Ground...
Page 652 ELECTRICAL Rear Coil Signal ECM 2 Coil Rear AUX Engine Splice 0194 Relay Power DB / PK Fusebox Output AUX Engine Splice 0194 Relay Power DB / PK Front O2 Output AUX Engine Splice 0194 DB / PK Rear O2 Relay Output Purge Valve Splice 0194...
Page 653 ELECTRICAL Ignition Coil Splice 0225 Fusebox Feed Splice 0225 Coil Front Front Coil Power Splice 0225 Coil Rear Front Coil Power Fog Lights Cavity Plug Rear Splice Splice 0031 Splice 0236 Ground Splice 0236 Ground Gateway Splice 0236 Ground BK / DG ECM 1 ECM Ground Gear Select...
Page 654 ELECTRICAL Left Heated Heated Grips Grips Output CAT Heated O2 GY / DG ECM 1 CAT O2 Sensor Heater Control CAT Heated O2 BG / BK ECM 1 CAT O2 Sensor Output CAT Heated O2 GY / BK ECM 1 CAT O2 Sensor Return Fan Relay...
Page 655 ELECTRICAL T T A A I I L L L L I I G G H H T T H H A A R R N N E E S S S S 7. Remove wire routing trays via retention clips. T T A A I I L L L L I I G G H H T T H H A A R R N N E E S S S S R R E E P P L L A A C C E E M M E E N N T T REMOVAL 1.
Page 656 ELECTRICAL INSTALLATION 4. Connect the tail light harness to the chassis harness. IMPORTANT Align white tape marks on the harness to the ends of the plastic wire trays. 1. Route wire routing through retention clips. 5. Install rear fender. See Rear Fender Installation page 7.23.
Page 657 ELECTRICAL S S W W I I T T C C H H T T E E S S T T I I N N G G C C L L U U T T C C H H S S W W I I T T C C H H T T E E S S T T B B R R A A K K E E L L I I G G H H T T S S W W I I T T C C H H T T E E S S T T 1.
Page 658 ELECTRICAL W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R / / A A B B S S S S Y Y S S T T E E M M C C H H E E C C K K S S 9941686 R01 - 2025 Indian Scout Service Manual 10.154 ©...
Page 659 ELECTRICAL WHEEL SPEED SENSOR TESTING WARNING This procedure requires raising and supporting the motorcycle so that the front wheel is off the ground. Precautions should be taken to ensure the motorcycle is properly stabilized at all times. Failure to properly support motorcycle may result in personal injury or damage to the motorcycle.
Page 660 ELECTRICAL E E L L E E C C T T R R I I C C A A L L D D I I A A G G N N O O S S T T I I C C S S E E L L E E C C T T R R I I C C A A L L S S E E R R V V I I C C E E N N O O T T E E S S S S T T A A T T I I C C A A N N D D D D Y Y N N A A M M I I C C T T E E S S T T I I N N G G Keep the following notes in mind when diagnosing an...
Page 661 ELECTRICAL C C O O N N N N E E C C T T O O R R P P R R O O B B I I N N G G G G U U I I D D E E L L I I N N E E S S You can use test probe kit PV–43526, test leads, and electrical tape to create a bridge with exposed testing F F R R O O N N T T P P R R O O B B I I N N G G...
Page 662 ELECTRICAL T T E E S S T T I I N N G G C C O O N N T T I I N N U U I I T T Y Y / / R R E E S S I I S S T T A A N N C C E E Testing using the Ohmmeter function of your DMM is one of the first things you will do when troubleshooting an electrical issue.
Page 663 ELECTRICAL T T E E S S T T I I N N G G F F O O R R A A S S H H O O R R T T T T O O G G R R O O U U N N D D T T E E S S T T I I N N G G P P R R O O C C E E D D U U R R E E Shorts to ground happen when the current flowing in a 1.
Page 664 ELECTRICAL T T E E S S T T I I N N G G F F O O R R A A S S H H O O R R T T T T O O V V O O L L T T A A G G E E There are three possible short to voltage causes: 1.
Page 665 ELECTRICAL T T E E S S T T I I N N G G F F O O R R I I N N T T E E R R M M I I T T T T E E N N T T C C O O N N D D I I T T I I O O N N S S T T E E S S T T I I N N G G C C U U R R R R E E N N T T F F L L O O W W ( ( A A M M P P E E R R A A G G E E ) ) Intermittent conditions are very difficult to diagnose, Performing a current flow test requires the meter leads...
Page 666: Testing Procedure
ELECTRICAL T T E E S S T T I I N N G G P P A A R R A A S S I I T T I I C C D D R R A A W W T T E E S S T T I I N N G G V V O O L L T T A A G G E E D D R R O O P P Parasitic draw is when there is excessive current flow NOTICE...
Page 669 INDEX ABS Module, Replacement .........9.27 Balance Shaft ABS System Assembly View .............6.14 Checks ............10.154 Installation ............6.17 Special Tools ............9.3 Removal...............6.16 Air Box Service Specifications ..........6.3 Assembly View .............4.14 Special Tools ............6.2 Installation ............3.12 Battery Removal...............3.12 Current Drain Test ..........10.43 Air Filter Inspection ............
Page 670 INDEX Brake Pads, Rear Rebuilding ............9.46 Replacement ............9.41 Removal...............9.46 Brake Pedal Caliper, Rear Inspection ............. 9.5 Assembly View .............9.17 Lubrication............9.6 Rebuilding ............9.52 Brake System Removal...............9.52 ABS Brake Fluid Change .........9.32 Cam Chain ABS General Information ........9.20 Installation ............3.55 ABS Module............9.18 Removal...............3.55 ABS Module Replacement ........9.27 Cam Chain Guide, Lower...
Page 671 INDEX Free Play Adjustment ..........5.4 Disassembly ............6.20 Lubrication............5.4 Resealing .............6.40 Clutch Pinion Shaft Separation............6.20 Assembly View .............5.10 Torque Sequence ........... 6.6 Clutch Rack Crankcase Emission Control ........1.10 Installation ............5.21 Crankcase Ventilation Removal...............5.21 Inspection ............. 3.8 Crankcase, Left Side Clutch Switch Circuit Test............
Page 672 INDEX Diagnostic Connector ..........1.19 Installation ............4.41 Digital Wrench II Removal...............4.41 User Manual ..........1.19, 4.60 Emission Control Systems ..........1.10 Drill Sizes Emission Sources .............1.10 Metric ..............1.26 Engine SAE ..............1.26 Assembly View ..........3.47, 3.49 Compression Test........... 3.9 Drive Belt Adjustment............8.76 Compression Test (Wet) .........3.10 Alignment ............8.76 Installation ............3.21...
Page 673 INDEX Disassembly (inverted) ..........8.50 Fuel Tank Installation ............8.63 Assembly View .............4.13 Removal...............8.41 Installation ............4.29 Fork Inspection, Front ..........8.62 Mounting .............4.13 Frame Removal...............4.21 Assembly View ............7.9 Vent Inspection (49 State) ........4.8 Installation ............7.30 Vent Inspection (CA)..........4.8 Fuse Box Removal...............7.29 Service Notes ............
Page 674 INDEX Installation ............10.62 Master Cylinder, Rear Removal............. 10.62 Assembly View .............9.14 Ignition System Rebuilding ............9.50 Service Notes ............. 10.60 Removal...............9.50 Service Specifications .......... 10.61 Master Torque Table ..........1.20 Special Tools ............10.61 Mirror Test 1: Battery Voltage Inspection......10.68 Installation ............8.32 Test 2: Spark............
Page 675 INDEX Piston Pin End Gap Measurement...........3.84 Inspection ............3.85 Installation ............3.85 Piston Ring Profile & Orientation ..........3.81 Inspection ............3.84 Routing Installation ............3.85 Details ..............1.30 Profile & Orientation ..........3.81 Routing Documents..........1.30 Power Button Routing Documents............ B.1 Installation ............10.62 Removal............. 10.62 Powertrain Characteristics .......... 1.4 Pressure Oil Pump Installation ............3.36 Saddle Bag...
Page 676 INDEX Primary Drive ............5.2 Locating...............1.12 Rear Suspension............8.72 Lubrication, Engine ..........3.25 Rear Wheel ............8.72 Maintenance............2.8 Ordering Information ..........1.12 Starting System .............10.8 Tires..............8.107 Piston ..............3.78 Wheels .............. 8.107 Primary Drive ............5.2 Rear Wheel and Suspension ........8.71 Shift Arm Installation ............5.19 Starting System .............10.7 Removal...............5.19...
Page 677 INDEX Service Notes ............8.4 Service Notes ............. 8.106 Service Specifications ..........8.5 Size Specifications ..........2.15 Special Tools ............8.4 Specifications ............1.3 Suspension, Front Fork TMAP Sensor Disassembly (conventional) ........8.43 Overview .............4.36 Disassembly (inverted) ..........8.50 Replacement ............4.36 Suspension, Rear Tools, Special ............1.14 Torque Specifications Service Notes ............8.71...
Page 678 INDEX Removal...............3.60 Service Specifications .......... 8.107 Valve Seat Wireless Control Module (WCM) Inspection ............3.70 Overview ............10.93 Reconditioning .............3.70 Pinout..............10.96 Valve Spring Replacement ............10.93 Free Length Inspection...........3.67 Wiring Diagrams Chassis..............A.1 Valve Stem Inspection ............8.114 Installation ............8.114 Valve Timing ............3.58 Valve Train Special Tools ............3.45...

Indian Motorcycle Scout 2025 Service Manual

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