2015 Indian Motorcycle

Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most
recent version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer®
technicians in a properly equipped shop and should be kept available for reference. All references to left and
right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with the service procedures before starting any repair. Certain procedures require the use of special tools. Use
only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures
outlined in this Service Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more
useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit
feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature
Question'.
Consumers, please provide your feedback in writing to: Indian Motorcycle Company ATTN: Service Publications
Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed July 2014 (PN 9925346 R01)

© Copyright 2014 All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

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

CAUTION

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

CAUTION

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

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
 GENERAL / SPECIFICATIONS 1

MAINTENANCE 2

FRAME / BODY 3

LUBRICATION / COOLING 4

FUEL DELIVERY / EFI / EXHAUST 5

ENGINE REMOVAL / INSTALLATION 6

CYLINDER HEAD / VALVES 7

CYLINDER / PISTON 8

CLUTCH / PRIMARY / SHIFT 9

TRANSMISSION / CRANKSHAFT 10

FRONT WHEEL / SUSPENSION 11

REAR WHEEL / SUSPENSION 12

TIRES 13

BRAKES 14

STARTING / CHARGING 15

IGNITION SYSTEM 16

CHASSIS ELECTRICAL 17
Trademarks
INDIAN MOTORCYCLE ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
LOCTITE, is a registered trademark of the Henkel Corporation
DUNLOP, is a registered trademark of the Dunlop Tire Corporation.
STA-BIL, is a registered trademark of Gold Eagle
NYOGEL, trademark of Gold Eagle
FLUKE, registered trademark of the Fluke Corporation
XM, a registered trademark of XM® Satellite Radio, Inc.
Torx, Registered Trademark of Textron
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.
 GENERAL / SPECIFICATIONS

CHAPTER 1 1
GENERAL / SPECIFICATIONS
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MANUFACTURER LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TIRE INFORMATION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2015 SCOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
GROSS VEHICLE WEIGHT RATING (GVWR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
PUBLICATIONS & TECHNICAL LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
EMISSION SOURCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11
EVAPORATIVE EMISSION CONTROL (CALIFORNIA MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
USING SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
SPECIAL TOOLS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19

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GENERAL / SPECIFICATIONS
VEHICLE INFORMATION

Model Number Designation

Example: N15MSA00AA
GRP MY TYPE MODEL LINE DISP NET MARKET COLOR
BRAKE HP CONFIG
1st 2nd/ 4th digit* 5th digit* 6th digit* 7th digit* 8th digit* 9th digit 10th digit
digit 3rd
digit

N 15 M = Mid-size S = Scout A = Standard 0 = 1133 cc (69 0 = 92hp A = 49 State A = Thunder Black

ci) V-Twin B = 50 State H = Thunder Black
C = Canadian Smoke
E = EU (WVTA) R = Indian Red
J = Japan (SVA) S = Black Hills
Silver

* = digits that would transfer to 17 digit VIN and are used in digits 4–8 respectively.
First 3 digits, 9th digit, and 10th digit are used in model number only. They are not used with the 17 digit VIN.

Engine Number Location

The engine number (1) is stamped into the bottom of
the LH engine case.. The stamping identifies the
engine model and serial number.

Vehicle Identification Number (VIN)

Designation
Example: 56KTCAAA0E3000024
Vehicle Descriptors Vehicle Identifiers

World Mfg. ID Chec-

Chas- Type Disp k Mfg
HP Series MY* Individual Serial No.
sis Digit

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

5 6 K C C A A A 0 E 3 0 0 0 0 0 0

* Model Year: E = 2014; F = 2015; G = 2016; H = 2017

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 GENERAL / SPECIFICATIONS
VIN Location
The vehicle identification number (1) is stamped on 1
the right side of the steering head.

Manufacturer Label
The manufacturer label (1) located on the left side of
the steering head contains the following information:
Vehicle Identification Number (VIN)
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating (GAWR)
Tire Type and Load Information.

Tire Information Label

See Manufacturer label for tire information. See
Manufacturer Label, page 1.3.

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GENERAL / SPECIFICATIONS
GENERAL SPECIFICATIONS
2015 SCOUT
Model Numbers
N15MSA00AA
N15MSA00AB
N15MSA00AH
N15MSA00AR
N15MSA00BA
N15MSA00BB
N15MSA00BH
N15MSA00BR
N15MSA00CA
N15MSA00CB
N15MSA00CH
N15MSA00CR
N15MSA00EA
N15MSA00EB
N15MSA00EH
N15MSA00ER

Chassis
CATEGORY SPECIFICATION
Dry Weight 516 lbs (235 kg)
Wet Weight 560 lbs (255 kg)
Gross Vehicle Weight Rating 988 lbs (449 kg)
Gross Axle Weight Rating, Front 337 lbs (153 kg)
Gross Axle Weight Rating, Rear 651 lbs (296 kg)
Maximum Load 428 lbs (194 kg)
Overall Length 91.0 in (2311 mm)
Overall Width 34.6 in (880 mm)
Overall Height 47.5 in (1207 mm)
Seat Height 25.3 in (643 mm)
Ground Clearance 5.3 in (135 mm)
Total Storage Volume N/A
Passenger Capacity 1

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 GENERAL / SPECIFICATIONS

CATEGORY SPECIFICATION
Wheelbase 61.5 in (1562 mm) 1
Rake / Trail 29° / 4.7 in (119.9 mm)

Engine
Engine Number 1204691
Engine Type V-Twin
Engine Configuration Liquid Cooled V-Twin 60°
Engine Wet Weight 205 lbs (93 kg)
Engine Displacement 69 cid (1133 cc)
Engine Cooling System Liquid
Compression Ratio 10.7:1
Compression Pressure 210 - 230 psi (1448 - 1586 kPa)
Valve Train DOHC, 4 Valves Per Cylinder, Graded Buckets
Bore x Stroke 3.898 in x 2.898 in (99 mm x 73.6 mm)
Idle Speed / Fast Idle Speed 1100 RPM ± 50 RPM (fully warm)
Oil Capacity 4.5 qts (4.3 L) Dry engine
Oil Type SAE Synthetic 15W60
Lubrication System Semi-Dry Sump
Spark Plug Type / Gap NGK MR7F / 0.030 in (0.8 mm)
Exhaust System Two O2 Sensors (one each bank) / Single three-way catalyst
in each muffler

Fuel System
Fuel System Type Electronic Fuel Injection (ME17)
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 58 psi (400 kPa)
Throttle Body Bore Size 2.362 in (60 mm)
Fuel Capacity 3.5 gal (13.2 L)
Fuel Reserve Capacity 0.5 gal (1.9 L)
Fuel Type 91 Octane (recommended)

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GENERAL / SPECIFICATIONS
Electrical
Stator Rated Output 460 W @ 3000 RPM
Battery 12V / 12 AH / 210 CCA, Maintenance Free AGM
Headlights Osram HB2 12V 60/55W Long Life
Tail / Brake / License LED (non-serviceable)
Turn Signals RY10W
Starting System Electric Start
Ignition System Bosch ME-17 (ECM Controlled)
Instrument Type Multifunction Instrument Cluster

Drivetrain
Transmission Type 6 Speed / Sliding Mesh
Clutch Type Wet, Multi-Plate, Coil Spring
Primary Drive Type Wet, Gear Drive
Primary Reduction Ratio 1.674:1
Final Drive Type / Ratio Belt / 2.357:1
Belt Type / Belt Width 22 mm Carbon Fiber Reinforced Belt
Gear Shift Pattern 1 Down, 5 Up
Transmission Gear Ratios:
1st 2.769:1
2nd 1.882:1
3rd 1.500:1
4th 1.273:1
5th 1.125:1
6th 1.036:1

Suspension
Front Suspension Type Conventional Telescopic Fork
Front Travel 4.7 in (120 mm)
Front Tube Diameter 41 mm
Rear Shock Type Monotube Dual Shocks
Rear Swingarm Type Steel Weldment
Rear Travel 3.0 in (76 mm)

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 GENERAL / SPECIFICATIONS
Wheels / Brakes
Front Tire Type / Size Kenda Kruz K673F - 130/90-16 72H 1
Front Wheel Type / Size Cast / 16 in X 3.5 in
Front Tire Air Pressure 36 PSI (248 kPa)
Front Brake, Type Single Solid Disc / 2 Piston Calipers
Rear Tire Kenda Kruz K673 - 150/80-16 71H
Rear Wheel Cast / 16 in X 3.5 in
Rear Tire Air Pressure 40 PSI (276 kPa)
Rear Brake, Type Single Solid Disc / 1 Piston Caliper
Brake Fluid Type DOT 4

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

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GENERAL / SPECIFICATIONS
VEHICLE LOADING PUBLICATIONS & TECHNICAL
LITERATURE
Gross Vehicle Weight Rating (GVWR)
Publication Part Numbers
Some Indian Motorcycle publications, such as Owner’s
WARNING Manuals and Parts Books may be available on-line at
the Indian Motorcycle website; http://www.
Exceeding the gross vehicle weight rating of your indianmotorcycle.com/
motorcycle can reduce stability and handling and Service Manuals and Owner’s Manuals can be
could cause loss of control. NEVER exceed the gross purchased through any authorized Indian motorcycle
vehicle weight rating of your motorcycle. dealer. The part numbers are listed in the following
table.
The maximum load capacity of your motorcycle is the
maximum weight you may add to your motorcycle SERVICE OWNER’S
without exceeding the GVWR. This capacity is MODEL MANUAL PART MANUAL PART
determined by calculating the difference between NUMBERS NUMBERS
your motorcycle’s GVWR and wet weight. 2015 Indian 9925346 9924830
Refer to the specification section of this manual or the Scout
Manufacturing Information / VIN label on the Motorcycle
motorcycle frame for model-specific information. (U.S.)
Refer to Information label section in this manual for 2015 Indian 9925346 9924831
location on the motorcycle. Scout
When determining the weight you will be adding to Motorcycle
your motorcycle, to ensure you do not exceed the (CAN)
maximum load capacity, include the following:
2015 Indian 9925346 9924343
• operator body weight Scout
Motorcycle
• passenger body weight (INT’L)
• weight of all riders’ apparel and items in or on
apparel
• weight of any accessories and their contents
• weight of any additional cargo on the
motorcycle

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REFINISHING
Paint Colors By Model 1
Scout

MODEL NUMBER PAINT COLOR PAINT CODE

N15MSA00AA Thunder Black P-266
N15MSA00AH Thunder Black Smoke P-463
N15MSA00AR Indian Red P-639
N15MSA00BA Thunder Black P-266
N15MSA00BH Thunder Black Smoke P-463
N15MSA00BR Indian Red P-639
N15MSA00BS Black Hills Silver P-581
N15MSA00CA Thunder Black P-266
N15MSA00CH Thunder Black Smoke P-463
N15MSA00CR Indian Red P-639
N15MSA00CS Black Hills Silver P-581
N15MSA00EA Thunder Black P-266
N15MSA00EH Thunder Black Smoke P-463
N15MSA00ER Indian Red P-639
N15MSA00ES Black Hills Silver P-581

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EMISSIONS INFORMATION 6. Replacing any moving part of the motorcycle or
parts of the exhaust / intake system with parts
Emission Control Systems other than those specified by the manufacturer.
The U. S. Environmental Protection Agency and
California Air Resources Board (CARB) require
manufacturers to certify that their motorcycles comply
with applicable exhaust emissions standards during
their useful life, and that motorcycles built after
January 1, 1983 comply with applicable noise emission
standards for one year or 6,000 km (3,730 mi) after the
time of sale to the ultimate purchaser, when operated
and maintained according to the instructions
provided.

Emission Sources
An internal combustion engine produces carbon
monoxide and hydrocarbons during operation.
Hydrocarbons must be controlled because under
some conditions hydrocarbons react with sunlight to
produce photochemical smog. Carbon monoxide must
be controlled because it is toxic.

Exhaust Emission Control

Indian Motorcycles have an electronic engine
management system which controls fuel delivery and
ignition timing to control hydrocarbon and carbon
monoxide emissions. If components are replaced that
affect idle speed, no adjustments should be made to
the system. The Electronic Fuel Injection (EFI) and
Electronic Throttle Control (ETC) systems control idle
speed.

Noise Emission Control

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

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Crankcase Emission Control
The crankcase emission control system is comprised 1
of a closed system that routes crankcase emissions
through the air cleaner into the combustion chamber.

Evaporative Emission Control (California

Models)
California models are equipped with an Evaporative
Emissions Canister (1). Activated charcoal inside the
canister temporarily stores fuel system vapors until
the engine is started and the motorcycle is driven. The
Electronic Control Module (ECM) automatically opens
a Purge Control Valve under certain conditions, and
engine intake vacuum draws vapors out of the
canister.

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GENERAL / SPECIFICATIONS
SPECIAL TOOLS How To Use This Book
The Special Tools Index located in this chapter
Using Special Tools provides a comprehensive list and pictorial
Special tools have been designed exclusively for representation of the special tools used throughout
servicing the specialized components found on Indian this service manual. The Special Tools section at the
Motorcycles. By using these tools, service technicians beginning of each chapter provides a short list of the
can maximize efficiency and minimize the likelihood tools required to perform procedures specific to that
of causing damage to the motorcycle during service. chapter.

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Tool Ordering Information
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, 1
while other tools may be substituted with a similar tool, if available. Indian Motorcycle recommends use of the
Special Tools referenced in the chapters of this service manual when servicing any Indian Motorcycle product.
Dealers may order special tools through Indian Motorcycle’s official tool supplier, Bosch Automotive Service
Solutions, by phone at 1-800-345–2233 or on-line via your dealer website at https://polaris.service-solutions.com/
.

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Special Tools Index

ABS Tool Battery Tester Bearing Removal Kit

PV-50104 PU-50296 PU-51324

Belt Tension Meter Crankcase Separator Tool Crankshaft Locking Pin

PV-43532 PF-51234-A PF-51235-A

Fuel Tank Fitting Plug 12mm Fork Spring Compressor Fuel Pressure Adapter
PV-50567 PV-49463 PV-48656

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Fuel Pressure Gauge Oil Pressure Gauge Output Shaft Seal Tool 1
PU-43506A PV-43531 PF-51243

Relay Bypass Tool Smartlink Module Kit Swingarm Bushing Tool

PU-49466 PU-47471 PF-51237

USB to Serial Adapter Engine Transmission Lock Tool Flywheel Puller

PU-50621 PF-51612 PA-49316

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Fork Socket Adapter / Cartridge Engine Case Assembly Cup Mainshaft / Crankcase Installer
Tool PF-51663 PV-45030
PF-51664-2

Cup Adapter Engine Stand Adapter Fork Oil Seal Driver

PF-51665 PF-51609 PF-51610

Water Pump Seal Installation Tool Fork Seal Installation Tool

PF-51608 PF-51611

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REFERENCE Metric Tap Drill Sizes
SAE Tap Drill Sizes DECIMAL NEAREST
1
DRILL
TAP SIZE EQUIVA- FRAC-
SIZE
THREAD SIZE / DRILL THREAD SIZE / DRILL LENT TION
SIZE SIZE 3x.50 #39 0.0995 3/32
#0-80 3/64 1/2-13 27/64 3x.60 3/32 0.0937 3/32
#1-64 #53 1/2-20 29/64 4x.70 #30 0.1285 1/8
#1-72 #53 9/16-12 31/64 4x.75 1/8 0.125 1/8
#2-56 #51 9/16-18 33/64 5x.80 #19 0.166 11/64
#2-64 #50 5/8-11 17/32 5x.90 #20 0.161 5/32
#3-48 5/64 5/8-18 37/64 6x1.00 #9 0.196 13/64
#3-56 #45 3/4-10 21/32 7x1.00 16/64 0.234 15/64
#4-40 #43 3/4-16 11/16 J
8x1.00 0.277 9/32
#4-48 #42 7/8-9 49/64
8x1.25 17/64 0.265 17/64
#5-40 #38 7/8-14 13/16
9x1.00 5/16 0.3125 5/16
#5-44 #37 1-8 7/8
9x1.25 5/16 0.3125 5/16
#6-32 #36 1-12 59/64
10x1.25 11/32 0.3437 11/32
#6-40 #33 1 1/8-7 63/64
10x1.50 R 0.339 11/32
#8-32 #29 1 1/8-12 1 3/64
11x1.50 3/8 0.375 3/8
#8-36 #29 1 1/4-7 1 7/64
12x1.50 13/32 0.406 13/32
#10-24 #24 1 1/4-12 1 11/64
12x1.75 13/32 0.406 13/32
#10-32 #21 1 1/2-6 1 11/32
#12-24 #17 1 1/2-12 1 27/64
#12-28 #15 1 3/4-5 1 9/16
1/4-20 7 1 3/4-12 1 43/64
1/4-28 3 2-4 1/2 1 25/32
5/16-18 F 2-12 1 59/64
5/16-24 I 2 1/4-4 1/2 2 1/32
3/8-16 O 2 1/2-4 2 1/4
3/8-24 Q 2 3/4-4 2 1/2
7/16-14 U 3-4 2 3/4
7/16-20 25/64

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GENERAL / SPECIFICATIONS
Decimal Equivalents 39/64 in = .6094 in
1/64 in = .0156 in 5/8 in = .625 in [16mm=. 6299 in]
1/32 in = .0312 in [1 mm = .0394 in] 41/64 in = .6406 in
3/64 in = .0469 in 21/32 in = .6563 in [17 mm = .6693 in]
1/16 in = .0625 in 43/64 in = .6719 in
5/64 in = .0781 in [2 mm = .0787 in] 11/16 in = .6875 in
3/32 in = .0938 in 45/64 in = .7031 in [18 mm = .7087 in]
7/64 in = .1094 in [3 mm = .1181 in] 23/32 in = .7188 in
1/8 in = .1250 in 47/64 in = .7344 in [19 mm = .7480 in]
9/64 in = .1406 in 3/4 in = .75 in
5/32 in = .1563 in [4 mm = .1575 in] 49/64 in = .7656 in
11/64 in = .1719 in 25/32 in = .7813 in [20 mm = .7874 in]
3/16 in = .1875 in [5 mm = .1969 in] 51/64 in = .7969 in
13/64 in = .2031 in 13/16 in = .8125 in [21 mm =. 8268 in]
7/32 in = .2188 in 53/64 in = .8281 in
15/64 in = .2344 in [6 mm = .2362 in] 27/32 in = .8438 in
1/4 in = .25 in 55/64 in = .8594 in [22 mm = .8661 in]
17/64 in = .2656 in [7 mm = .2756 in] 7/8 in = .875 in
9/32 in = .2813 in 57/64 in = .8906 in [23 mm = .9055 in]
19/64 in = .2969 in 29/32 in = .9063 in
5/16 in = .3125 in [8mm= .3150 in] 59/64 in = .9219 in
21/64 in = .3281 in 15/16 in = .9375 in [24 mm = .9449 in]
11/32 in = .3438 in [9 mm = .3543 in] 61/64 in = .9531 in
23/64 in = .3594 in 31/32 in = .9688 in [25 mm = .9843 in]
3/8 in = .375 in 63/64 in = .9844 in
25/64 in = .3906 in [10 mm = .3937 in] 1 in = 1.0 in
13/32 in = .4063 in
27/64 in = .4219 in [11 mm =.4331 in]
7/16 in = .4375 in
29/64 in = .4531 in
15/32 in = .4688 in [12 mm = .4724 in]
31/64 in = .4844 in
1/2 in = .5 in [13mm = .5118 in]
33/64 in = .5156 in
17/32 in = .5313 in
35/64 in = .5469 in [14 mm = .5512 in]
9/16 in = .5625 in
37/64 in = .5781 in [15 mm = .5906 in]
19/32 in = .5938 in

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 GENERAL / SPECIFICATIONS
Fahrenheit To Celsius UNIT OF MULTIPLIED
COVERTS TO
oC to oF: 9 (oC + 40) ¸ 5 - 40 = oF MEASURE BY 1
oF to oC: 5 (oF + 40) ¸ 9 - 40=oC mm x.03937 = in
DEGREES F DEGREES C in x 2.54 = cm

32 0 mile x 1.6 = km
41 5 km x.6214 = mile
50 10 Ounces (oz) x 28.35 = grams (g)
59 15 Fluid Ounce x 29.57 = CCs
68 20 grams (g) x.035 = Ounces (oz)
77 25 = Fluid Ounces
cc’s x.03381 (oz)
86 30
95 35 lbs x.454 = kg
104 40 kg x 2.2046 = lbs
113 45 = Cubic
Cubic Inches x 16.387
122 50 Centimeters

131 55 Cubic
x.061 = Cubic Inches
Centimeters
140 60
Imperial pints x.568 = liters (l)
149 65
liters (l) x 1.76 = Imperial pints
158 70
Imperial quarts x 1.137 = liters (l)
167 75
176 80 = Imperial
liters (l) x.88 quarts
185 85
Imperial quarts x 1.201 = US quarts
194 90
= Imperial
203 95 US quarts x.833 quarts
212 100
US quarts x.946 = liters
liters x 1.057 = US quarts
Measurement Conversion Chart
US gallon x 3.785 = liter
UNIT OF MULTIPLIED
COVERTS TO liter x .264 = US gallon
MEASURE BY
ft-lbs x 12 = in-lbs Pounds force
= Kilo pascals
per square inch x 6.895
in-lbs x.0833 = ft-lbs (kPa)
(psi)
ft-lbs x 1.356 = Nm
= Pounds force
Kilo pascals
in-lbs x.0115 = kg-m x .145 per square inch
(kPa)
(psi)
Nm x.7376 = ft-lbs
Kilo pascals = Kilograms
kg-m x 7.233 = ft-lbs x .01
(kPa) force per cm2
kg-m x 86.796 = in-lbs Kilograms force = Kilo pascals
per cm2 x 98.1 (kPa)
kg-m x 10 = Nm
in x 25.4 = mm p (3.14159) x R2 x H (height) = Cylinder
Volume

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GENERAL / SPECIFICATIONS

NOTES

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 MAINTENANCE

CHAPTER 2
MAINTENANCE
MAINTENANCE QUICK REFERENCE GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE INTERVAL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
AIR FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
ENGINE OIL & FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
COOLING SYSTEM PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
IDLE SPEED / FAST IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
TIRE PRESSURE / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
CLUTCH CABLE INSPECTION / LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
CLUTCH LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
CLUTCH LEVER FREE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
FRONT BRAKE LEVER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
FRONT BRAKE LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
BRAKE PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
SHIFT PEDAL INSPECTION / LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
FRONT BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
CRANKCASE VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
FUEL TANK VENT INSPECTION (49 STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
FUEL SUPPLY HOSE (FUEL RAIL) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
SPARK PLUG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
SPARK PLUG INSPECTION / GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
SPARK PLUG INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
ENGINE COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
ENGINE COMPRESSION TEST (WET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

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BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
BATTERY, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
DRIVE BELT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
DRIVE BELT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
HEADLIGHT AIM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
HEADLIGHT AIM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
SIDESTAND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
SIDESTAND REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
STEERING HEAD / FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
SWINGARM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
REAR SHOCK PRELOAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
REAR SHOCK PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

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 MAINTENANCE
MAINTENANCE QUICK REFERENCE GUIDE
Specifications
General Specifications
ITEM STANDARD SERVICE LIMIT 2
Battery Type / CCA 12 Volt / 12 AH / 210 CCA —

Brake Pad Thickness, Front .16 in (4.0 mm) .04 in (1.0 mm)
Brake Disc Thickness, Front .20 in (5.0 mm) .18 in (4.5 mm)
Brake Pad Thickness, Rear .25 in (6.5 mm) .04 in (1.0 mm)
Brake Disc Thickness, Rear .20 in (5.0 mm) .18 in (4.5 mm)
Clutch Lever Freeplay .019 - .059” (0.5–1.5 mm) —

Compression Pressure 210 - 230 psi (1448 -1586 kPa) Below 190 psi (1310 kPa)
(Cylinder)
Drive Belt Deflection (with 10 .472“ (12 mm) or 45 - 50 Hz with Sonic Tension —
lbs force) Meter
Fuel Pressure (KOEO) 58 psi (400 kPa) 51 psi (350 kPa)
Idle Speed / Fast Idle Speed 1100 RPM ±50 RPM
Oil Pressure, Lubrication @ 40 PSI (275 kPa) ± 20 % 32 PSI (220 kPa)
3000 rpm Engine at operating temperature.
Ride Height (Rear Spring Pre- See adjustment procedure outlined in this —
Load) chapter
Spark Plug Type / Gap NGK MR7F GAP - .030 in (0.8 mm) —

Tire Pressure Front: 36 PSI (248 kPa) —

Rear: 40 PSI (276 kPa)
Tire Tread Depth (Minimum) — .063 in (1.6 mm)
Valve Lash (Int. / Ex.) 0.006 in (0.152 mm) / 0.008 in (0.203 mm) —

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Torque Specifications
DESCRIPTION TORQUE SPECIFICATIONS
Air Filter Screws - M5 x 0.8 x 16 (QTY.6) 24 in-lbs (2.7 Nm)
Axle Nut, Rear 65 ft-lbs (88 Nm)
Battery Terminal Screw 45 in-lbs (5.08 Nm)
Battery Bracket Screw 84 in-lbs (9.49 Nm)
Battery Cable to Starter Motor 63 in-lbs (7.1 Nm)
Brake Bleeder Screws (Caliper) 48 in-lbs (5.4 Nm)
Brake Lever Pivot Bolt 84 in-lbs (9.49 Nm)
Camshaft Carrier Bolls 84 in-lbs (9.49 Nm)
Clutch Cable Guide Jam Nut 48 in-lbs (5.4 Nm)
Clutch Lever Bolt 84 in-lbs (9.49 Nm)
Clutch Perch Clamp Bolt 145 in-lbs (16.38 Nm)
Drive Sprocket Nut 133 ft-lbs (180 Nm)
Drive Sprocket Nut Retainer Plate 88 in-lbs (10.0 Nm)
Fuel Tank Mounting Screws 18 ft-lbs (24.5 Nm)
Master Cylinder Cover Screws (Front) 14 in-lbs (1.6 Nm)D
Master Cylinder Cover Screws (Rear) 14 in-lbs (1.6 Nm)
Oil Drain Plugs (2) 15 ft-lbs (20.0 Nm)
Oil Filter Approximately 3/4 turn after sealing ring has contacted the
filter adapter.
Shift Rod Jam Nuts 96 in-lbs (10.8 Nm)
Sidestand Pivot Bolt 35 ft-lbs (47.4 Nm)
Spark Plugs 106.2 in-lbs (12 Nm)

Fluid Specifications
DESCRIPTION FLUID TYPE CAPACITY
Brake Hydraulic Fluid DOT 4 —

Engine / Transmission Oil 15W60 Full Synthetic 4.5 Qts (5.2 L) Dry Engine
Fork Oil Indian Motorcycle Fork Oil 11.3 oz (335 cc) per leg
Fuel 91 Octane (Recommended) 3.5 gal (13.2 L) / Reserve 0.5 gal (1.9 L)
Coolant / Antifreeze Polaris Extended Life 50/50 2.77 Qts (2.63 Ltrs)

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Periodic Maintenance Interval Table
ENGINE MILES (KILOMETERS)

10000 (16000)

15000 (24000)

20000 (32000)

25000 (40000)

30000 (48000)

35000 (56000)

40000 (64000)

45000 (72000)

50000 (80000)
2500 (4000)

5000 (8000)
500 (800)
2

Air Filter I I I R I R I R I R I R
Crankcase Ventilation System I I I I I I I I I I I I

Cooling System / Radiator I I I I I I I I I I I I

Drive Belt I I I I I I I R I I I I
Engine Compression I I I I I I

Engine Mount Fasteners I

Engine Oil* R R R R R R

Engine Oil Filter* R R R R R R

Evaporative Emission Control

System (CA. Only) I I I I I I I I I I I I

Exhaust System I I I I I I I I I I I I

Fuel Filter R R
Fuel System I I I I I I I I I I I I

Oil Lines / Oil System

Inspection I I I I I I I I I I I I

Spark Plugs I I R I

Engine Coolant I I I I I I I I I I I R

Valve Lash Clearance I I

Operation Codes:
I - Inspect (tighten, clean, adjust, correct or replace if necessary)
R - Replace/Rebuild
L - Lubricate with proper lubricant as directed
P - Perform
* - Replace at specified interval or annually. If driven in extreme conditions.
** - Replace at specified interval or every 2 years

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CHASSIS MILES (KILOMETERS)

10000 (16000)

15000 (24000)

20000 (32000)

25000 (40000)

30000 (48000)

35000 (56000)

40000 (64000)

45000 (72000)

50000 (80000)
2500 (4000)

5000 (8000)
500 (800)
Battery I I I I I I I I I I I I

Brake Fluid** I I I R I R I R I R I R
Brake Pads I I I I I I I I I I I I
Clutch Lever L I L I L I L I L I L
Control Cable Ends I I L I L I L I L I L
Fasteners I I I I I I I I I I I I
Front Brake Lever L I L L L L L L L L L L
Front Fork Oil** I I I R I I R I I R I
Front Forks and Front Axle I I I I I I I I I I I I
Gear Shift Pedal I I I I I I I I I I I I
Head Light I I I I I I I

Rear Brake Pedal I I I I I I I I I I I I

Rear Shock Absorber I I I I I I I I I I I R
Rear Wheel Alignment I I I I I I I I I I I I

Road Test P P P P P P P P P P P P
Sidestand / Sidestand Safety
L I L I I I I I I I I I
Switch
Steering Bearings I I I I I I I I I I I I

Shock Bushings and Fasteners I I I I I I I I I I I I

Swing Arm, Rear Axle, Swing

Arm Pivot, and Pivot Bearings I I I I I I I I I I I I

Tires / Wheels I I I I I I I I I I I I

Operation Codes:
I - Inspect (tighten, clean, adjust, correct or replace if necessary)
R - Replace/Rebuild
L - Lubricate with proper lubricant as directed
P - Perform
* - Replace at specified interval or annually. If driven in extreme conditions.
** - Replace at specified interval or every 2 years

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GENERAL INFORMATION Observe the following precautions during the break-in
period:
Service Notes • Upon initial start-up, do not allow the engine to
Periodic Maintenance Overview idle for long periods.
Inspection, adjustment and lubrication of important • Avoid fast starts with wide open throttle. Drive
components are explained in the periodic slowly until the engine warms up. 2
maintenance chart.
• Avoid running the engine at extremely low RPM
Inspect, clean, lubricate, adjust and replace parts as in higher gears (lugging the engine).
necessary. When inspection reveals the need for
replacement parts, use genuine Indian Motorcycle
parts available from your Indian Motorcycle dealer. Break-In Guidelines
IMPORTANT: Service and adjustments are ODOMETER BREAK-IN
critical. If you’re not familiar with safe service and PROCEDURE
adjustment procedures, have a qualified dealer
perform these operations. 0–90 Miles (0–145 km) Do not operate for
extended periods above
1/3 throttle or at any one
Special Tools throttle position. Vary
engine speed frequently.
TOOL DESCRIPTION PART NUMBER 91–300 Miles (146–483 Do not operate for
Brake Lever Reserve PV-50104 km) extended periods above
Tool 1/2 throttle or at any one
throttle position. Vary
Battery Tester PU-50296 engine speed frequently.
Belt Tension Meter PV-43532 301–500 Miles (484–805 Do not operate for
Oil Filter Wrench PU-50105 km) extended periods above
3/4 throttle.
Shock Spanner Wrench PV-46993
500 Miles (805 km) Perform the break-in
maintenance procedure
Bosch Automotive Service Solutions: 1-800-345-
outlined in the Periodic
2233 or https://polaris.service-solutions.com/
Maintenance Interval
Table located in this
Break-In Procedure chapter.
Engine break-in for Indian Motorcycles occurs in the
first 500 miles (800 km) of operation. Indian
Motorcycles are manufactured using the best possible
materials and manufacturing techniques, but the final
machining process is the break-in. During this break-
in period, critical engine parts wear and polish to
correct operating clearances. Read, understand and
follow all break-in procedures to ensure the long-term
performance and durability of the engine.

CAUTION

Failure to properly follow the engine break-in

procedures outlined in this manual can result in
serious damage to the engine. Follow all break-in
procedures carefully. Avoid full throttle operation and
other condition that may place an excessive load on
the engine during the break-in period.

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MAINTENANCE PROCEDURES CAUTION
Air Filter Replacement A loose fitting cover or improperly installed filter
element may allow debris to enter the engine which
NOTE: If the motorcycle is operated in wet or may cause premature engine wear.
dusty conditions, more frequent servicing is
required.
The air filter element cannot be cleaned. Replace Engine Oil Level Check
the filter when necessary.
Engine MUST BE AT FULL OPERATING TEMPERATURE
when checking oil level.
1. With the motorcycle in an upright (vertical)
WARNING position, run the engine for 30 seconds.
2. Stop engine.
Allow engine and exhaust to cool completely before
3. Place the machine on a level area and hold it in an
disconnecting fuel line or removing tank. Protect fuel
upright (centered) position.
tank finish when removing, storing, and installing
tank. 4. Remove the engine oil dipstick (Item 1) and clean
off the engine oil.
Be prepared to place the fuel tank in a secure location
with a drain pan positioned to catch any fuel that may
leak or drip from disconnected hoses or fittings.
1. Remove the seat. See Seat Removal / Installation,
page 3.7.
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21.
3. Remove the six air filter fasteners (Item 1).

5. Reinsert the dipstick and thread in until fully

seated.
6. Remove the dipstick and view oil level.

4. Inspect filter element (Item 2) and replace if dirty,

wet, or oil fouled.
5. Reverse steps to install filter.
6. Torque air filter fasteners (Item 1) to specification.

Air Filter Element Screws: 24 in-lbs (2.7 Nm)

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7. Oil level should be between the ADD and FULL 7. Clean the engine oil filter mount sealing surface
lines on dipstick. If oil level is low, add Indian and surrounding area.
Motorcycle 15W60 Full Synthetic engine oil and
repeat steps 3 - 6 until the reading is within the 8. Place a small amount of oil on the new oil filter seal
safe operation range. and spin filter on until the filter seal contacts the
sealing surface. Tighten oil filter to specification.
Do not overfill! Approximate volume from ADD to FULL
is 1/2 US qt (.47 L). 2
CAUTION
Oil Filter: 6 ft lbs (8 Nm) or approximately 3/4 to 1
Oil level will NOT be accurate if checked on a cold full turn after seal contacts the filter mount
engine. DO NOT ADD oil to bring to FULL mark on a sealing surface.
cold engine, as this can result in overfilling.
9. Use new sealing washers and reinstall the drain
plugs. Torque to specification.
Engine Oil & Filter Change
Engine MUST BE WARMED before performing the fol-
lowing procedure.

Engine Oil Drain Plug: 15 ft-lbs (20 Nm)

WARNING
10. Use a funnel to add 3 US quarts (2.8 Liters) of
Indian Motorcycle 15W60 Full Synthetic engine oil
CAUTION HOT COMPONENTS Wear insulated through the engine oil dipstick hole.
gloves and use caution handling these parts.
NOTE: 3 US quarts will bring the engine oil
1. Run engine until warm, then turn engine off. level at or near the “FULL” mark on the
dipstick. For a new or rebuilt (dry) engine add
2. Securely support the motorcycle in a vertical an additional .5 US quart (.47 Liters).
“centered” position.
3. Place an oil drain pan under the engine oil drain 11. Securely support the motorcycle in a vertical
plugs (Items 1 and 2). “centered” position, idle engine for approximately
30 seconds.
12. Remove oil dipstick and wipe clean, then reinsert
and fully tighten dipstick. Remove dipstick and
read the engine oil level. Add engine oil as
required to bring oil level to the dipstick full mark.
DO NOT OVERFILL!
IMPORTANT: Total engine oil fill volume with
oil filter change will be approximately 3.0 - 4.0
US quarts (2.8 - 3.8 Liters). Total engine oil fill
volume with a new or rebuilt (dry) engine will
be approximately 4.5 quarts (4.25 Liters).

13. Refer to the Checking Engine Oil, page 2.8

section in this chapter for setting proper oil level.
NOTE: If the low oil pressure indicator
remains illuminated longer than usual after an
4. Remove the drain plugs and sealing washers. oil change, do not increase RPM above idle
until indicator lamp goes out or engine may be
5. Allow oil to drain completely. Dispose of oil
damaged.
properly.
6. Remove oil filter (Item 3) and allow oil to drain. 14. Check for leaks around drain plug and oil filter.
Dispose of oil filter properly.
NOTE: Recycle used oil and oil filter in
accordance with local regulations.

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Cooling System Overview Coolant Level Inspection
1. The pressure cap (Item 1) is located under the fuel
NOTE: Use Indian Motorcycle 50/50 Extended Life tank.
coolant / anti-freeze only. Do not mix coolant
types.

The engine coolant level is controlled or maintained

by the recovery system. The recovery system
components are the recovery bottle, filler neck,
pressure cap and connecting hoses.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the
system past the pressure cap and into the recovery
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back from the
tank past the pressure cap and into the cooling
system.
NOTE: Some coolant level drop on new vehicles is
normal as the system is purging itself of trapped
air. Observe coolant levels often during the break- 2. The coolant reservoir (Item 2) is located under the
in period. driver seat. The coolant level must be maintained
at the “COLD FULL” level indicated on the
Overheating of engine could occur if air is not fully reservoir.
purged from the cooling system. 3. Position the motorcycle upright on a level surface.
Indian Motorcycle 50/50 Coolant is premixed and 4. View the coolant level in the reservoir.
ready to use. Do not dilute with water.

Coolant Strength / Type

Test the strength of the coolant using an antifreeze
hydrometer.
• A 50/50 mixture of extended life antifreeze and
distilled water will provide the optimum cooling,
corrosion protection, and antifreeze protection.
• Do not use tap water, straight antifreeze, or
straight water in the system. Tap water contains
minerals and impurities which build up in the
system.
• Straight water or antifreeze may cause the 5. If the coolant level is below the “COLD FULL” line,
system to freeze, corrode, or overheat. coolant will need to be added to the system.
6. Remove the driver seat. See Seat Removal /
Installation, page 3.7.
7. Remove the filler cap (Item 3). Using a funnel, add
coolant to the filler cap opening until the coolant
Recommended Anti-Freeze/Coolant: level in the reservoir is to the “COLD FULL” line.
Indian Motorcycle 50/50 Pre-Mixed Extended Life 8. Reinstall the filler cap.
Antifreeze
(PN 8560214) (Quart)

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9. Reinstall the driver seat. See Seat Removal /
Installation, page 3.7.

Cooling System Pressure Test

NOTE: Coolant may be present at the water pump
weep hole due to normal water pump function. 2
Verify integrity of the water pump seal with a
cooling system pressure test.

1. Remove the seat. See Seat Removal / Installation,

page 3.7.
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21.

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.

3. Remove the pressure cap from the thermostat cover

and pressure test the cooling system using a
commercially available tester.
4. The system must retain 11-14 psi (75-95 kPa) for
five minutes or longer. If pressure loss is evident
within five minutes, check the radiator, all cooling
system hoses, hose clamps and water pump for
leakage.

Cooling System Pressure Cap Test

1. Remove the seat. See Seat Removal / Installation,
page 3.7.
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21.

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.

3. Remove the cooling system pressure cap and test

using a cooling system pressure tester.
(Commercially available).
4. The cooling system pressure cap relief pressure is
16 lbs. Replace cap if it does not meet this
specification.

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Cooling System Hoses

COOLING SYSTEM HOSES

1 Hose, Radiator Inlet 5 Hose, Front Head Outlet
2 Hose, Radiator Outlet 6 Hose, Cooler Return
3 Hose, Bypass 7 Hose, Cooler Supply
4 Hose, Rear Head Outlet

1. Inspect all vehicle coolant hoses for cracks,

deterioration, abrasion or leaks. Replace if
necessary.
2. Check tightness and condition of all hose spring
clamps. Replace if necessary.

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Radiator Inspection / Cleaning

CAUTION

Washing the vehicle with a high-pressure washer

could damage the radiator fins and impair the
2
radiators effectiveness. Use of a high-pressure
washer is not recommended.

Item Number Description

1 Radiator Cover
2 Upper Radiator Mount
3 Radiator
4 Cooling Fan Assembly

1. Check radiator air passages for restrictions or

damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with low pressure
compressed air or low pressure water.

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Coolant Drain / Fill NOTE: Pressure test before and after servicing
the cooling system.

Cooling System Drain

WARNING
1. Remove the radiator cover fasteners (Item 1).
Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.

2. Slide radiator cover down to disengage posts from

the upper radiator mounts (Item 2).

3. Remove the coolant return hose (Item 3) from the

oil cooler assembly to drain the coolant.

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9. Remove the vacuum bleeder and install the
pressure cap.
10. Remove the pinch pliers from the coolant line
between the reservoir and thermostat housing.
11. Add Indian Motorcycle Extended Life 50/50 Engine
Coolant to the reservoir fill opening (Item 2) until
the coolant reservoir (Item 3) is half full.
2
12. Install the fuel tank assembly. (See Fuel Tank
Installation).
13. Run the engine until the cooling fan cycles ON and
OFF.
14. Recheck the coolant level in the reservoir and add
to the “COLD FULL” level.

Cooling System Fill/Bleeding 15. Repeat the fill/bleed procedure until the coolant
level in the reservoir remains at the “COLD FULL”
NOTE: Pressure test before and after servicing level.
the cooling system.
16. Install the seat. See Seat Removal / Installation,
page 3.7..
1. Reconnect the coolant return hose to the oil cooler
assembly. Idle Speed / Fast Idle Speed
2. Install the radiator cover.
NOTE: Idle speed is continuously monitored and
3. Remove the seat. See Seat Removal / Installation, adjusted by the ECM.
page 3.7.
4. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21. Tire Pressure / Specifications
5. Remove cooling system pressure cap (Item 1).
6. Use pinch pliers (commercially available) to pinch
off the coolant line (Item 4) between the coolant WARNING
reservoir and thermostat housing.
Indian motorcycles are produced using the
designated tires listed below as original equipment.
This includes field testing to ensure stability and
superior handling. The use of tires other than original
equipment may cause instability. See Chapter 13 for
a review of all tire related Warnings.

1. Inspect tires for weather checking, cuts, imbedded

foreign objects, etc.
2. Inspect front and rear wheels for damage.
3. Measure tread depth at center of tread.

7. Install a cooling system vacuum bleeder

(commercially available) on the pressure cap
opening to create a vacuum in the cooling system.
8. Using the vacuum bleeder draw in Indian
Motorcycle Extended Life 50/50 Engine Coolant to
fill the cooling system.

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4. Measure in 3-4 places equally spaced around the
tire and record the smallest measurement.

WARNING

It is dangerous to ride with a worn tire. When a

tire reaches the minimum tread depth listed
below, replace the tire immediately.

Minimum Tread Depth

Front Tire Minimum
.063 in (1.6 mm)
Tread Depth
Rear Tire Minimum
.063 in (1.6 mm)
Tread Depth

Tire Pressure Table (Cold)

NOTE: Also refer to Manufacturing
Information label.

SCOUT
FRONT: Kenda Kruz 36 PSI (248 kPa)
K673F - 130/90-16 72H
REAR: Kenda Kruz K673 40 PSI (276 kPa)
- 150/80-16 71H

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Clutch Cable Inspection / Lubrication 3. Remove the jam nut (Item 3) that retains the clutch
cable in the lower cable guide. Using an
NOTE: Control cable casings are lined with a low adjustable wrench, rotate the clutch shaft arm
friction sleeve and are factory lubricated for (Item 4) to release the cable housing from the
reliable operation. Periodic lubrication of cables is mounting boss.
not required and could be detrimental to cable
performance. Only cable ends must be
periodically inspected and lubricated in
2
accordance with the Periodic Maintenance
Schedule. See Periodic Maintenance Interval
Table, page 2.5.

CAUTION

Inspect inner cable for fraying. Do not kink, bend or

twist inner cable or cable casing during removal or
installation.

1. Inspect the clutch cable (Item 1) for proper

routing, smooth movement, and damage to the
external casing. 4. Apply a thin coating of all purpose grease to both
cable ends.
5. Reverse steps 3 - 4 to reinstall clutch cable.
6. Tighten the lower cable guide jam nut to
specification

Cable Guide Jam Nut: 48 in-lbs (5.4 Nm)

7. Adjust cable free play.

Clutch Lever Lubrication

1. Disconnect clutch cable at primary cover. See
Clutch Cable Inspection / Lubrication, page 2.17.
2. Inspect the lower cable end for damage or frayed
wires. 2. Pull cable housing out of lever perch and remove
barrel from clutch lever. Do not kink cable.

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3. Remove the nut (Item 1) and push pivot bolt (Item Clutch Lever Free Play
2) upward to remove. 1. With handlebars pointing straight ahead, measure
the clutch lever free play at point shown (Item 1)
between lever and perch.

4. Inspect both ends of inner cable for frayed

strands. Clean parts and apply moly paste to pivot
bolt and both cable ends.
5. Assemble lever.
6. Install cable to lever. Rotate cable back through
slot in perch, and push outer casing back into
perch recess. Clutch Lever Free Play: .019–.059” (0.5–1.5 mm)
7. Install the pivot bolt and torque the nut to
2. Compare measurement to specification. If
specification.
adjustment is required, proceed to Step 3.
3. Locate the clutch cable adjuster boot (Item 2) and
pull it back to expose the jam nut and barrel
adjuster.

Clutch Pivot Bolt: 84.0 in-lbs (17.2 Nm)

8. Lubricate and attach lower end of cable to clutch

arm on primary cover.
9. Adjust clutch lever free play. See Clutch Lever
Free Play, page 2.18.

4. Hold cable and loosen the adjuster jam nut.

5. Turn cable adjuster in or out until clutch free play
is correct.

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6. Tighten adjuster jam nut to specification. Front Brake Lever Lubrication
1. Remove the nut (Item 1) and pivot bolt (Item 2).

Clutch Cable Adjuster Jam Nut: 48 in-lbs (5.4 Nm) 2

7. Slide adjuster boot back over adjuster assembly.

Front Brake Lever Inspection

1. Pull and release the front brake lever. It should
move freely and smoothly and return to its rest
position quickly when released. Lubricate brake
lever if binding, or if it does not return quickly and
completely when released. See Front Brake Lever
Lubrication, page 2.19.
2. Measure brake lever free play (1). You should feel
a firm resistance in the lever within the specified 2. Clean pivot bolt, lever and lever perch.
length of lever travel. If brake lever travels too far
before beginning to apply the brake, inspect for 3. Remove brake lever and apply grease to pivot bolt
brake fluid leaks and bleed air from the system. (Item 2), lever bushing, and pushrod contact
See Brake Bleeding / Fluid Change, page . surface of lever (Item 3) as shown.

4. Assemble brake lever.

5. Torque brake lever pivot bolt nut to specification.

Brake Lever Free Play: .75 - 1.0” (19.1–25.4 mm)

3. Safely elevate the front wheel. Verify wheel rotates

freely without drag or binding when lever is Brake Lever Bolt: 84 in-lbs (17.2 Nm)
released.

Brake Pedal Inspection

1. Press and release the brake pedal. It should move
freely and smoothly and return to the rest position
quickly when released.

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2. Press brake pedal and check for firm resistance. If Brake Pedal Lubrication
pedal feels spongy or travels too far without
resistance, inspect system for leaks and bleed
brakes. See Brake Bleeding / Fluid Change,
page .

1. Brake Pedal 8. Bolt, Shoulder Pivot

2. Bearing, Brake Pedal Pivot 9. Washer, Wave
3. Footpeg Mount 10. Washer
4. Footpeg 11. Pin, Pivot Footpeg
5. Pad, Brake Pedal 12. Ring, Retaining Spiral
6. Spring, Brake Return 13. Bushing, Pivot Brake Pushrod
7. Screw 14. Screw, Brake Pushrod

Lubricate brake pedal at intervals listed on periodic

maintenance table. See Periodic Maintenance Interval
Table, page 2.5.
1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.

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2. Working on the RH side of the motorcycle, remove 4. Remove brake pedal return spring (Item 5).
brake line p clamp bolt (Item 1) and footpeg Remove brake pushrod pivot bushing (Item 6).
mount bolts (Item 2). Move footpeg mount/master Remove the brake pedal bushing (Item 7) and
cylinder assembly so the brake pedal pivot washer (Item 8).
shoulder bolt can be accessed.

5. Clean off old lubricant and dirt from all parts.

NOTE: It is not necessary to disconnect the 6. Apply all-purpose grease to pushrod and pedal
brake line from the master cylinder to perform bushings as shown.
this procedure.

IMPORTANT: Keep the floorboard / master

cylinder assembly in an upright position at all
times to ensure air does not enter the brake
system.

3. Remove the brake pedal pivot shoulder bolt (Item

3) and flat washer. Remove the pushrod bolt (Item
4) from the brake pedal.

7. Install pedal bushing (Item 7). Assemble pedal,

washer (Item 8), brake pedal pivot shoulder bolt
(Item 3) and flat washer to the footpeg mount.
8. Install pushrod pivot bushing and bolt.
9. Assemble footpeg support to frame. Torque
mounting bolts (Item 2) and p-clamp bolt (Item 1)
to specification. See Footpeg (Driver), Removal /
Installation, page .
10. Depress brake pedal to verify proper operation
and pedal feel. Bleed brakes if necessary. See
Brake Bleeding / Fluid Change, page .

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Shift Pedal Inspection / Lubrication 3. IMPORTANT: The shift linkage rod (3) must be
1. Check all shift pedal and linkage fasteners to be threaded into each pivot end a minimum of seven
sure they are tight. Torque fasteners to complete turns.
specification. See Shift Pedal Adjustment, page
2.22.
2. Lubricate shift pedal pivot bushing and all pivots
(Item 1) with all-purpose lubricant.

4. Tighten jam nuts (1) to specification.

Shift Pedal Adjustment Shift Rod Jam Nuts: 8 ft-lbs (10.8 Nm)
1. Loosen jam nuts (1).
2. Rotate linkage rod (2) until pedal angle is correct.
CAUTION
Do not remove and reposition the shift arm on the
shift shaft to adjust gear shift pedal height. Dots on
shift shaft and shift arm must be aligned for gears to
shift correctly.

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Brake Fluid Level Inspection 7. Reinstall reservoir diaphragm and cover and
torque screws to specification.
IMPORTANT: The brake fluid level in the
reservoir will go down as brake pads wear. If you
notice a constant or sudden lowering of the brake
fluid level, inspect brake pads for wear and brake
system for leaks.
Front Master Cylinder Cover Screws: 14 in-lbs (1.6
2
Front Brake Fluid Inspection Nm)
1. Turn handlebars or adjust the motorcycle until top
of reservoir is level. Rear Brake Fluid Inspection
8. Fluid level is checked at the rear brake master
cylinder reservoir.
9. View fluid level through reservoir sight glass (Item
5). The fluid should be clear and at or above the
middle of the site glass (Item 5).

2. View front brake fluid level through sight glass.

The fluid should be clear and at the middle of the
site glass (Item 1).
3. Wipe area around reservoir cover with a clean
cloth.
4. Wipe brake fluid container with a clean cloth.
5. Remove screws (Item 2), reservoir cover (Item 3) 10. Wipe area around reservoir cover with a clean
and diaphragm (Item 4). If diaphragm is extended, cloth.
return it to the neutral position.
11. Wipe brake fluid container with a clean cloth.
12. Remove screws (Item 6), reservoir cover (Item 7),
and diaphragm (Item 8). If diaphragm is extended,
return it to the neutral position.

6. Carefully add enough DOT 4 brake fluid to bring

level to the upper edge of the sight glass.

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13. Carefully add enough DOT 4 brake fluid to bring Rear Brake Pad Inspection
level to the upper edge of the sight glass.
14. Install diaphragm and cover. Tighten cover screws NOTE: Wear indicator grooves are provided on
each rear brake pad to allow for a visual inspection
to specification.
without pad removal. Inspect pads by viewing
from the rear of the motorcycle, directly behind
the LH tailpipe.
Replace pads if worn to bottom of grooves. See
Rear Brake Pad Replacement, page 14.21.
Rear Master Cylinder Cover Screws: 14 in-lbs (1.6
Nm) 1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.
2. Viewing the rear brake pads from behind the
Front Brake Pad Inspection motorcycle and below the lip of the rear fender,
locate the wear indicator grooves (Image 1).
NOTE: Wear indicator grooves are provided on
each front brake pad to allow for a visual
inspection without pad removal. Inspect pads by
viewing from rear of caliper.
Replace pads if worn to bottom of grooves. See
Front Brake Pad Replacement, page 14.21

1. Viewing the front brake pads from the front of the

caliper, locate the wear indicator grooves (1).
2. Wear indicator grooves should be visible on both
inboard and outboard brake pads.

3. Wear indicator grooves should be visible on both

inboard and outboard brake pads.

Crankcase Ventilation System

1. Inspect condition of ventilation hoses (Item 1)
along the entire length and at both ends.

CAUTION
Front brake pads should always be replaced as a
complete set. If it is determined that an individual
brake pad has worn past the wear indicator groove,
the front caliper should receive a new pad set. Failure
to replace both front brake pads together may cause
reduced braking performance or brake failure,
resulting in a vehicle crash.

2. Be sure hoses are not restricted, kinked, or

cracked.
3. Replace worn or damaged hoses.

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Fuel Tank Vent Inspection (49 State) Evaporative Emission Control System
1. Inspect fuel tank vent hose (1) in accordance with (California Models)
periodic maintenance schedule and any time fuel
tank has been removed and installed. Be sure the NOTE: The fuel tank vent line is routed to a vapor
hose is clear and not pinched or kinked, and that canister where the fuel vapor is stored until
all connections are tight. specific operating parameters are met and the
ECM opens the purge valve. Fuel vapor is then 2
routed out of the vapor canister, through the purge
valve and into the throttle body for combustion.
Inspect all EVAP lines for abrasion or wear. Check
that all connections for both vent and canister
purge systems are securely attached.

NUMBER PART DESCRIPTION

1 Fuel Tank Vent Hose
2 Evaporative Emissions Vapor Canister
3 Purge Hose (Canister to Purge Valve)

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NUMBER PART DESCRIPTION

4 Canister Purge Valve
5 Purge Hose (Purge Valve to Throttle Body)
6 Fuel Cap Recess Drain Hose

Fuel Supply Hose (Fuel Rail) Inspection NOTE: The engine should be at room temperature
1. The fuel supply hose (fuel rail) can be found to perform this procedure.
behind the engine cover on the RH side of the
motorcycle.
2. Inspect fuel supply line (1) and fuel rail (2) for
deterioration, damage, leakage, or kinked areas.
Inspect fuel supply line-to-fuel rail connection (3)
for signs of leakage.

1. Place the motorcycle on the sidestand and allow

engine to cool.
2. Remove the seat. See Seat Removal / Installation,
page 3.7.
3. Remove the fuel tank. See Fuel Tank Removal,
3. Replace any components that fail inspection with page 5.21.
genuine Indian Motorcycle replacement parts.
4. Remove air box. See Air Box Removal, page 5.18.
5. Disconnect the ignition coil electrical connector.
WARNING 6. Remove the ignition coil fastener (Item 1).

The fuel lines exiting fuel pump are subjected to high 7. Remove the ignition coil assembly (Item 2).
pressure. Replace with genuine Indian Motorcycle 8. Using a 6” extension and a 5/8” spark plug socket,
replacement parts to reduce the possibility of fuel remove spark plug (Item 3).
line failure. Be sure fuel lines are routed properly and
do not come in contact with sharp or hot objects, or NOTE: Check gap on replacement spark plug.
anything that may cause wear or damage.

Spark Plug Inspection / Gap

Spark Plug Removal

WARNING
WARNING
A hot engine can cause serious burns. Allow engine
to cool or wear protective gloves when removing the
HOT COMPONENTS Wear insulated gloves and/
spark plugs.
or allow engine and exhaust to cool before
handling these parts.
1. Remove spark plug (s). See Spark Plug Removal,
page 2.26.

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2. Inspect electrodes for wear and carbon buildup. 3. Torque spark plugs to specification.
Look for a sharp outer edge with no rounding or
erosion of the electrodes.
3. Clean with electrical contact cleaner or a glass
bead spark plug cleaner only.
Spark Plug: 106.2 in-lbs (12 Nm) 2
CAUTION
A wire brush or coated abrasive (sandpaper) should
not be used to clean electrodes. CAUTION
Do not over tighten spark plugs. Damage to the
4. Measure electrode gap with a wire gauge (1).
cylinder head or spark plug may result.
Adjust gap if necessary by carefully bending the
grounding electrode until the specified gap is
achieved. 4. Install ignition coil. See Ignition Coil Removal /
Installation, page 16.6.
5. Install air box assembly. See Air Box Installation,
page 5.18
6. Install fuel tank assembly. See Fuel Tank
Installation, page 5.26
7. Install seat assembly. See Seat Removal /
Installation, page 3.7

Engine Compression Test

1. Warm engine to operating temperature.
2. Shift transmission into neutral and stop engine.
3. Remove the seat. See Seat Removal / Installation,
page 3.7.
4. Remove the fuel tank. See Fuel Tank Removal,
page 5.21
Spark Plug Type: NGK MR7F
5. Remove the air box assembly. See Air Box
Removal, page 5.18.
Spark Plug Gap: .030 in (0.8 mm) 6. Remove ignition coils. See Ignition Coil Removal /
Installation, page 16.6.
7. Remove the fuse box cover (1).
Spark Plug Installation
1. Inspect spark plug gap with a wire gauge. If gap
adjustment is necessary, bend ground electrode
carefully using a spark plug gap tool.

Spark Plug Type: NGK MR7F

Spark Plug Gap: .030 in (0.8 mm)

2. Apply anti-seize compound sparingly to spark

plug threads, avoiding the bottom 2 - 3 threads.

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8. Remove the Fuel Pump Relay (2) to disable fuel Engine Compression Test (Wet)
pump. If a cylinder leakage tester is not available, perform a
wet cylinder compression test.
1. Pour 3-5 cc of clean engine oil into each cylinder
through spark plug hole. Repeat cylinder
compression test. See Engine Compression Test,
page 2.27.
2. If compression increases substantially, inspect
cylinder, piston, and rings.
3. If compression does not increase, inspect valves
and valve seats.

Battery
This motorcycle is equipped with a maintenance free
battery which is located under the seat. DO NOT
remove cell caps or add distilled water to the battery.
If the battery discharges, refer to Chapter 15 for
9. Remove spark plug from cylinder to be tested. See diagnostic information.
Spark Plug Removal, page 2.26.
10. Install compression tester in the spark plug hole
following manufacturers instructions. WARNING
11. Crank engine until needle on compression gauge
stops rising (about 5 seconds). Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
12. Repeat procedure for other cylinder. eyes or clothing. Antidote:
Specification - Scout External: Flush with water.
STD: 210 - 230 psi (1448 - 1586 kPa) Internal: Drink large quantities of water or milk.
SERVICE LIMIT: Below 190 psi (1310 kPa) Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
High engine compression may indicate: Eyes: Flush with water for 15 minutes and get prompt
medical attention.
• Carbon deposits in combustion chamber
Batteries produce explosive gases. Keep sparks,
• Engine modification flame, cigarettes, etc. away. Ventilate when charging
• Faulty Gauge or using in an enclosed space. Always shield eyes
when working near batteries. KEEP CHILDREN
AWAY FROM BATTERY.
Low engine compression may indicate:
• Slow starter motor cranking speed
• Carbon or foreign material on valve seat CAUTION
• Worn or damaged piston and/or piston rings
• Leaking exhaust or intake valves Whenever removing the battery, disconnect the
negative (black) cable first. When reinstalling the
• Leaking head gasket battery, connect the negative (black) cable last.
• Valve timing incorrect Do not remove the battery cables while the engine is
running. Doing so may damage the Electronic
• Non-OEM camshafts or faulty gauge
Control Module (ECM).
If cylinder compression is below specification, Take great care NOT to reverse the battery leads
perform a cylinder leakage test to determine when installing the battery.
where the leak is occurring. Follow the instructions
provided with the leakdown tester.

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Battery Inspection Battery Charging
Battery terminals and connections should be kept free CHARGING NEW BATTERY
of corrosion. If cleaning is necessary, remove the
corrosion with a stiff wire brush. Wash with a solution 1. Charge the battery at 1.8 amps for 5 to 10 hours. use
of one tablespoon baking soda to one cup water. Rinse a straight rate charger (not load sensing or battery
well with tap water and dry off with clean rags. Coat tender type) for the initial charge of a new battery.
terminals with dielectric grease. 2
1. Visually inspect the exterior of the battery. CAUTION
Replace battery if housing is damaged, case is
deformed, or if electrolyte is leaking.
Do not attempt to quick charge the battery at any
2. To remove corrosion, remove battery from time.
motorcycle and wash terminals with water and
baking soda solution. Clean terminals, bolts, and 2. Remove battery from charger and let it sit for 30
cable ends with a brass wire brush and apply a minutes or longer.
thin film of dielectric grease.
3. Measure voltage with a digital multimeter. If lower
3. Measure battery voltage. than 12.5 Vdc, battery must be recharged again in
accordance with step 1 and 2 above.
4. After charging battery and letting it sit for 30
minutes or more, check battery voltage again. If
battery voltage is still below 12.5 Vdc, replace the
battery.
CHARGING BATTERY IN SERVICE
1. Measure battery voltage with a digital multimeter.
The reading should be above 12.5 Vdc. If battery
voltage is lower than 12.

CAUTION

Do not remove caps on battery while recharging. Do

not attempt to inspect or add fluid to a maintenance
free battery.

2. Charge battery at 1.8 amps for 5 to 10 hours.

Battery Charging Specification:

1.8 A for 5-10 hours

3. Remove battery from charger and let it sit for 30

minutes or longer.
4. Measure battery voltage with a digital multimeter.
If battery voltage is lower than 12.5 Vdc, battery
Specification: 12.5V DC minimum must be recharged again in accordance with step 1
and 2 above.
4. If battery voltage is below 12.5V DC, charge it
thoroughly. See Battery Charging, page 2.29.
5. Replace battery if it will not accept a charge.

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5. After charging battery and letting it sit for 30 4. Disconnect positive battery terminal.
minutes or more, check the battery voltage again.
5. Remove battery hold down bracket fastener (Item
If battery voltage is still below 12.5 Vdc, replace
2).
battery.
NOTE: When motorcycle is not used for one (1)
month or more, remove battery and store it in a
cool, dry area. Inspect voltage monthly and
charge according to above instructions if
necessary.

Battery Storage
When the motorcycle is not used for periods of one
month or longer the battery should be fully charged
prior to operation. Store battery in a cool, dry place.
Battery should be charged monthly using a 12 volt
battery charger with a maximum charge rate of 1.8
amp-hr.

6. Lift the battery out of the battery box.

WARNING

Battery charging can create explosive gasses;

keep sparks, flames, cigarettes or anything that
could ignite the gasses away. Provide adequate
ventilation when charging in an enclosed space.
Batteries contain acid that is caustic. Wear
protective clothing and a face shield or protective
eyewear when working with the battery. KEEP
OUT OF REACH OF CHILDREN.

Battery, Removal
1. Remove the seat. See Seat Removal / Installation,
page 3.7.
2. Release fuse panel (Item 1) and move off to the
side.
Battery Installation
1. Install battery into battery box.
2. Install battery hold down bracket and torque
fastener to specification.

Battery Bracket Fastener: 84 in-lbs (9.4 Nm)

3. Disconnect negative battery terminal.

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3. Connect the positive battery terminal and torque
fastener to specification.

Battery Terminal Fastener: 45 in-lbs (5.08 Nm)

2
4. Connect the negative battery terminal and torque
fastener to specification.
5. Install fuse panel.
6. Install the seat. See Seat Removal / Installation,
page 3.7..

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Drive Belt Inspection 3. If the drive belt or sprocket is being replaced due
to damage, replace belt and both sprockets as a
NOTE: Inspect drive belt in accordance with set if drive system has more than 5000 miles (8000
Periodic Maintenance Interval Chart and replace Km) of use.
at specified intervals regardless of belt condition.
See Periodic Maintenance Interval Table, page Drive Belt Specifications
2.5.
Drive Belt Deflection Data

DRIVE BELT CONDITION SERVICE

IMPORTANT:
WEAR RECOMMEN-
EXAMPLES DATION
MODEL DEFLECTION FREQUENCY
External Tooth Replace Belt
AT 10 LBS
Cracks
FORCE
Scout .472“ (12 mm) 40–50 Hz
Internal Tooth OK to run, but
Cracks monitor Drive Belt Frequency Tension Data
condition
NOTE: 45-50 Hz with Sonic Tension Meter
Fuzzy Edge OK to run, but
Cord monitor
condition Drive Belt Tension
Special Tool: Belt Tension Gauge PV-43532
Hook Wear Replace Belt

WARNING
Missing Teeth Replace Belt Care should be taken to be sure the motorcycle will
not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls.

Bevel Wear OK to run, but 1. Secure motorcycle in an upright position with the
(Outer Edge monitor front wheel clamped in a wheel vise.
Only) condition
2. Shift transmission into NEUTRAL.
Chipping (Not OK to run, but 3. ELEVATE rear wheel off the ground when
Serious) monitor checking deflection or adjusting the belt.
condition IMPORTANT! Do not adjust the belt when wet,
or immediately after riding. Belt must be dry
Stone Damage Belt should be and the drive system must be at ambient
replaced if temperature (60-80° F). This is extremely
damage is on important for accuracy.
the edge of the Find Tight Spot In Belt
belt

1. Periodically inspect drive belt for cuts, excessive

wear, foreign substance (oil, grit), missing teeth,
or any other damage.
2. If any damage is found, belt should be replaced.
NOTE: Adjust drive belt tension at intervals in
accordance with the Periodic Maintenance
Interval Chart. See Periodic Maintenance
Interval Table, page 2.5.

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4. Use the tire valve stem as a reference and perform 7. Push up on gauge until O-ring just touches tool
the following Steps: body. See Drive Belt Specifications, page 2.32 for
drive belt deflection specifications.
• Check / record belt deflection at 4 different
points, 90 degrees apart. Rotate wheel in a 8. If belt deflects more than the specified distance
CLOCKWISE rotation as viewed from belt side of with 10 lbs. of force, tighten the belt. If deflection
motorcycle. is less than specified loosen the belt. See Drive
Belt Adjustment, page 2.33. 2
• Place a mark on rear wheel at the tightest point
(least deflection) to use as a reference. NOTE: New drive systems (new vehicle or
when belt and sprockets are replaced) should
• Continue to rotate the wheel in normal drive
be set to the tight side of the specification and
direction (CLOCKWISE) 1-2 revolutions until
inspected after the first 500 miles (800 km).
your reference mark (the tightest point) is lined
up with the tension setting window in the lower
belt guard (1).
Drive Belt Adjustment
Rear Wheel Alignment / Belt Adjustment

WARNING

A rear axle not in alignment can cause drive line

noise and damage the drive belt, causing
possible belt failure and loss of control of the
motorcycle.

NOTE: Marks (1) and (2) are used as a reference

for initial wheel alignment. Marks should be in
same position on both left and right sides of wheel.

1. Place the motorcycle in an upright position with

• Adjust belt deflection with wheel in this position. the front wheel clamped in a wheel vise.
5. Place tape measure or ruler next to drive belt or 2. Raise the rear of the motorcycle so the rear tire can
use the graduations on lower belt guard for be freely rotated.
reference.
3. Loosen axle nut (3).
6. Slide O-ring on belt tension gauge to the 10 lb.
mark.
• Place belt tension gauge squarely against belt at
center and keep it at a 90° angle to the belt
surface.
•

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4. Turn adjuster nuts (4) to achieve: 7. Rotate the wheel in FORWARD direction. Loosen
left rear axle adjuster until belt just moves off the
• Recommended belt tension right flange and begins to track to left (inboard)
• Wheel alignment (marks equal both sides) sprocket flange during forward wheel rotation. Tap
left end of axle (if necessary) to be sure left side of
wheel moves forward when adjuster is loosened.

5. When belt tension is correct, check and adjust

final wheel alignment as follows. 8. Rear wheel alignment is satisfactory when the
drive belt tracks slightly closer to the inboard
NOTE: To minimize change in belt tension, sprocket flange. Sprocket teeth should be
use LEFT SIDE adjuster only to make final visible from both sides of the drive belt.
adjustments to belt alignment. Be sure to keep
axle seated forward against axle adjusters 9. Tighten rear axle nut to specification.
during this procedure. 10. Pump rear brake pedal several times to reset
brake pad distance.
6. Rotate the wheel BACKWARD. Tighten LEFT rear
axle adjuster until belt begins to track to right 11. Verify wheel rotates smoothly and freely without
(outboard) sprocket flange during backward drag when brake pedal is released.
wheel rotation.

Rear Axle Nut: 65 ft-lbs (88 Nm)

Sprocket Inspection
NOTE: Drive belt and sprocket service life are
maximized and drive line noise minimized by
proper cleaning. Cleaning interval is
approximately every tire change, or more often if
operated in dirty, dusty, or high debris
environments.

Inspection
Rear Wheel Alignment (Final) 1. Clean the drive belt and front and rear sprockets
with a mild mixture of dish soap and warm water.
Rinse and dry thoroughly.

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2. Inspect front and rear sprocket teeth for wear or 3. Release the fuse box cover clips (Item 2) and
damage from foreign material. remove cover.

3. Closely inspect drive belt condition. 4. If any fuse is blown, turn off main switch. Install
new fuse of specified amperage. Turn on switches
and see if system operates correctly. Repeat fuse
Fuse Replacement failure indicates an electrical problem.
Fuses and relays are located in the fuse box under the
seat.
CAUTION
1. Remove the seat. See Seat Removal / Installation,
page 3.7. Do not use fuses of a higher amperage rating than
2. Release the retainer and slide the fuse box what is specified.
rearward. If the correctly rated fuse continues to blow,
something is wrong and needs to be corrected.
Substituting a higher amperage fuse can lead to
extensive electrical system and vehicle damage.

Headlight Aim Inspection

Adjust headlight aim when there is a change in load
(rider, cargo, accessories, etc.) or after suspension
adjustment.
ALL MODELS: With the headlight switched to HIGH
beam, the center of highest intensity (appears as a
diamond shape) should be 7.5 in (19 cm) below the
height of the headlight bulb when centered straight
ahead at 25 feet (7.62 m).
Follow all steps below to ensure accurate aim
inspection.
1. Check and adjust the tire pressure. See Tire
Pressure / Specifications, page 2.15.
2. Verify suspension ride height is set correctly. See
Ride Height Measurement
, page .
3. Move the motorcycle to a clear area with a level
floor and dim lighting, and place it so the top front
edge of the headlight housing is 25 ft. (7.6 m) from
the wall.

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4. Have the rider (and passenger if normally present) 2. Inspect sidestand spring for damage or loss of
straddle the motorcycle in an upright position and tension. Be sure stand returns to fully retracted
sit in the seat (s). Center the handlebars in a position.
straight ahead position.
5. Turn ignition switch ON.
6. Set headlight to HIGH beam.
7. Compare the position of headlight beam on the
wall to the illustration below and adjust if
necessary.

3. Inspect side stand for smooth movement.

4. Inspect sidestand pivot bolt nut for proper torque.

Headlight Aim Adjustment

1. To adjust the headlight vertically, loosen the
headlight housing mount fastener (Item 1) and
pivot the headlight housing up or down as
required. To adjust the headlight horizontally, Sidestand Pivot Bolt: 35 ft-lbs (47.4 Nm)
loosen the headlight mounting bolt (Item 2) and
pivot the headlight side-to-side as required. 5. Replace sidestand if it is bent. Do not attempt to
straighten sidestand.

Sidestand Removal / Installation

WARNING

The sidestand spring is under tension. Wear eye and

face protection when removing and installing the
spring and sidestand. Be sure the vehicle is properly
secured before you begin.

1. Sidestand will be moved between the UP

(retracted) and DOWN (extended) position during
removal and installation. Be sure vehicle is
properly secured.
Sidestand Inspection
1. Support the motorcycle in an upright position with
the front wheel clamped in a wheel vise.

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2. Remove sidestand pivot bolt (Item 1) using a 6mm Steering Head / Front Wheel Inspection
hex wrench while holding the nut (Item 2) with a
15 mm wrench.

WARNING

Care should be taken to be sure the motorcycle will

not tip or fall while elevated. Severe personal injury
2
or death may occur if the motorcycle tips or falls.

NOTE: Be sure control cables, hoses and wiring

are not interfering with handle bar rotation.

1. Secure motorcycle with front wheel off the floor.

2. Turn handlebars from full left to full right and
inspect for smooth, free movement. Point front
wheel straight ahead, grasp fork tubes and pull/
push fork tubes back and forth. If steering binds,
feels rough or uneven, or if movement is detected
3. Grasp sidestand firmly and move it to the UP at steering stem, adjust or replace steering head
position. bearings as necessary.
4. Pull sidestand rearward against spring tension
until mounting flange on sidestand is clear of the
mounting boss on the frame.
5. Relax tension and remove spring.
6. Installation: Attach spring to sidestand.
7. Lightly grease sidestand mounting boss on frame
and the shouldered portion of the pivot bolt.
8. Place loose end of spring through hole in frame
rail.
9. With sidestand in the retracted position (up), pull
stand rearward against spring tension until the
mounting flange on the sidestand drops onto the
mounting boss on the frame.
10. Swing sidestand to the extended position to align
bolt hole and install bolt and nut. 3. Rotate front wheel and inspect for smooth rotation
of front wheel bearings. If roughness or unusual
11. Torque to specification and wipe off any excess sounds are present, replace front wheel bearings.
grease. See Chapter 11.
4. Turn handle bars full right or left and hold against
the fork stop. Attempt to move front wheel side-to-
side. If movement is observed, inspect front axle,
wheel, and bearings. See Chapter 11.
Sidestand Pivot Bolt: 35 ft-lbs (47.4 Nm)

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

returns to the fully retracted position.

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Swingarm Inspection 5. Rotate rear wheel and inspect for smooth rotation
of rear wheel bearings. If roughness or unusual
sounds are detected, inspect rear wheel bearings,
belt tension and alignment, and brake pads.
WARNING
6. Inspect rear shock for leakage and all rear
suspension components for damage or loose
Care should be taken to be sure the motorcycle will fasteners.
not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls. 7. Inspect suspension pivots and shock mounts for
radial movement in all pivot joints. If a joint has
1. Sit astride the motorcycle. Compress the rear radial movement, remove rear shock absorber and
suspension several times and check for smooth inspect suspension pivot linkage. See Chapter 12.
and quiet operation (2). 8. Verify axle nut is tight.
2. Secure motorcycle with rear wheel elevated. 9. Replace any worn or damaged parts.
3. Inspect for worn swing arm bearings by grasping
the rear wheel and attempting to move wheel side- Rear Shock Preload Inspection
to-side (Item 1). Inspect for worn bearings and Periodically inspect rear shock preload. For the most
linkages by moving the wheel side-to-side (Item comfortable ride and proper ground clearance, adjust
2). preload if ride height is out of specification.
1. Verify that tire pressure is at specification. See
Tire Pressure / Specifications, page 2.15.
2. Load the motorcycle with all intended cargo.
3. Determine shock preload (Item 1) by measuring
from the upper shock mount bolt center to lower
shock mount bolt.

4. If movement is detected, determine if movement is

at axle area (Item 3) or swingarm pivot area (Item
4). Refer to wheel bearing and swingarm bearing
replacement.

4. Adjust preload as needed to achieve suspension

sag indicated in the table below. See (Rear Shock
Preload Adjustment) for adjustment procedure.

SHOCK PRELOAD LENGTH

Scout 282 mm (from shock
mount bolts center-to-
center)

Rear Shock Preload Adjustment

1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.

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2. Using shock spanner wrench (PV-46993) loosen Valve Clearance Inspection
the lock nut by turning it counter-clockwise (as
1. Remove the seat. See Seat Removal / Installation,
viewed from the top of the shock).
page 3.7.
3. Spray a light lubricant on the adjuster nut where it
2. Remove the fuel tank. See Fuel Tank Removal,
contacts the spring.
page 5.21.
4. Adjust shock preload by rotating the adjuster nut
clockwise (as viewed from the top of the shock) to 3. Remove air box. See Air Box Removal, page 5.18. 2
INCREASE preload (firm) or counter-clockwise to 4. Remove thermostat housing cover. See Thermostat
DECREASE preload (softer). Housing Cover Removal / Installation, page 3.10.
5. Remove valve covers. See.
6. Remove spark plugs. See Spark Plug Removal,
page 2.26
7. Remove flywheel access cover.
8. Rotate the engine CCW (from flywheel side) until
the cam lobes (1) are facing away from valves
being inspected.

5. Recheck the preload measurement after adjusting.

6. Tighten the lock nut securely against the adjuster
nut.

9. Measure the valve clearance at location (2) with a

feeler gauge.

10. If the valve clearance is out of specification,

proceed to “Valve Clearance Adjustment”. See
Valve Clearance Adjustment, page .
11. Repeat steps 8 - 10 on each of the eight valves.

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12. If previously removed, apply anti-seize compound
to the spark plug threads and reinstall the spark
plugs. Torque spark plugs to specification. See
Spark Plug Installation, page 2.27.
13. Inspect the valve cover seal and replace if
necessary.
14. Install NEW isolators on the valve cover bolts.
Install the valve cover and the three T40 bolts.
Torque cover bolts to specification. See Valve
Cover Installation, page 7.23
15. Install the ignition coil. See Ignition Coil Removal /
Installation, page 16.6.
16. Install the air box. See Air Box, page 5.10.
17. Install the fuel tank. See Fuel Tank Installation,
page 5.26. 4. Reference the valve clearance measurement
recorded for that valve, along with the 3-digit
18. Install the seat. See Seat Removal / Installation, tappet number.
page 3.7.
5. Refer to the appropriate tappet selection matrix to
select the proper tappet. See Intake Valve Lash -
Valve Clearance Adjustment Tappet Selection Matrix, page 7.35or Exhaust Valve
Procedure to adjust valve clearance as part of sched- Lash - Tappet Selection Matrix, page 7.36.
uled maintenance.
6. Install the proper tappet.
NOTE: Consult the Periodic Maintenance Interval
NOTE: Lubricate the outer portion of the valve
Table for maintenance intervals.
tappet upon installation.
1. If any of the valve clearance measurements are out
7. Repeat steps 2 - 6 until all necessary valves have
of specification, remove the camshaft carriers and
been adjusted.
camshafts and proceed with this procedure.
8. Reinstall the camshafts and camshaft carriers and
Intake Camshaft - PN 3022484 tighten the bolts evenly to specification.
Exhaust Camshaft - PN 1204693

Camshaft Carrier Bolts: 84 in - lbs (10 Nm)

Intake Valve Clearance (cold): 9. Measure and confirm that valve clearance is now
0.006 in (0.152 mm) within specification for each valve.
Exhaust Valve Clearance (cold): 10. If valve clearance is not within specification, repeat
0.008 in (0.203 mm) this procedure.

2. Remove the valve tappet from a valve that was out

of specification.
NOTE: Keep mated parts together and in order
with respect to their location in the cylinder
head for assembly purposes. Mark each
component or place them in an organized rack
as you remove them.

3. Record the 3 digit number on the bottom of the

tappet. (Item 1).

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CHAPTER 3
FRAME / BODY
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
FENDERS / SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
FOOTPEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
BODY / FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
FOOTPEG (DRIVER) REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
FOOT PEGS (PASSENGER), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
SEAT REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
FRONT FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
FRONT FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
REAR FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
REAR FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
INSTRUMENT PANEL REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
IGNITION SIDE COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
THERMOSTAT HOUSING COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
FRAME REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

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GENERAL INFORMATION is too tight. Do not over tighten body components in
order to avoid damage.
Service Notes
This section covers the removal and installation of Special Tools
frame and body components, assemblies and systems.
Pay close attention to assembly procedures and torque TOOL DESCRIPTION PART NUMBER
specifications. PV-49955 Body Panel Tool Kit
Cables, hoses and tie straps that have been removed
during disassembly must be replaced per factory Bosch Automotive Service Solutions: 1-800-345-
standards during assembly. Caution should be used 2233 or https://polaris.service-solutions.com/
when tightening body panels. Any deformation on the
panel around the screw is an indication that the screw Torque Specifications

Torque Specifications
DESCRIPTION TORQUE SPECIFICATIONS
Ignition Side Cover Screws, (Qty. 3) 96 in-lbs (10 Nm)
Instrument Panel Screw, (Qty.4) 22 ft-lbs (29.8 Nm)
Screw - M8 x 1.25 x 16 (QTY.2), Backbone 19 ft-lbs (25.7 Nm)
Bracket to Front Frame
Screw, Frame Backbone to Front Frame- M10 x 35 ft-lbs (47.4 Nm)
1.5 x 145 (QTY.2), Backbone to Front Frame
Screw, Footpeg Driver - M10 x 1.50 x 35 35 ft-lbs (47.5 Nm)
(QTY.2)
Screw, Front Fender - M8 x 1.25 x 50 (QTY.4) 18 ft-lbs (24.4 Nm)
Screw - M12 x 1.75 x 95 (QTY.2), Front Frame to 51 ft-lbs (69.1 Nm)
Engine
Screw - M10 x 1.50 x 30 (QTY.4), Mid Cast 35 ft-lbs (47.4 Nm)
Frame to Backbone
Screw - M12 x 1.75 x 250 (QTY.2), Mid Frame to 51 ft-lbs (69.1 Nm)
Engine
Screw, Footpeg Passenger - M6 x 1.0 x 10 19 ft-lbs (25.7 Nm)
(QTY.1)
Screw, Rear Fender - M8 x 1.25 x 20 (QTY.4 18 ft-lbs (24.4 Nm)
Screw - M10 x 1.50 x 25 (QTY.4), Rear 35 ft-lbs (47.4 Nm)
Subframe to Midframe
Screw, Seat Mount - M8 x 1.25 x 16 (QTY.1) 18 ft-lbs (24.4 Nm)
Seat Lanyard, Bolt 36 in-lbs (4 Nm)
Shift Rod, Bolt 7 ft-lbs (9.5 Nm)
Swingarm Pivot Tube 5 ft-lbs (6.7 Nm)
Thermostat Housing Cover, Screws (Qty.3) 96 in-lbs (10.0 Nm)

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ASSEMBLY VIEWS
Frame

NUM- PART DESCRIPTION TORQUE (IF TORQUE SEQUENCE

BER APPLICABLE)
1 Backbone, Frame Weld - -
2 Backbone, Frame Weld - -
3 Pivot, Swingarm 5 ft-lbs (6.7 Nm) 3
4 Frame, Subframe Rear - -
5 Spacer - 280D x 131D x 12.5 - -

6 Frame, Mid LH - -
7 Frame, Mid RH - -
8 Frame, Front - -
9 Foam, Air Box Frame - -
10 Bolt, Swingarm Pivot - M16 x 1.50 - -
x 340
11 Screw - M10 x 1.50 x 25 (QTY.4), 35 ft-lbs (47.4 Nm) 4
Rear Subframe to Midframe
12 Screw - M8 x 1.25 x 16 (QTY.2), 19 ft-lbs (25.7 Nm) 13 (Right)
Backbone Bracket to Front Frame 14 (Left)
13 Screw - M12 x 1.75 x 250 (QTY.2), 51 ft-lbs (69.1 Nm) 1 (Lower)
Mid Frame to Engine 2 (Upper)

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NUM- PART DESCRIPTION TORQUE (IF TORQUE SEQUENCE

BER APPLICABLE)
14 Screw, Frame Backbone to Front 35 ft-lbs (47.4 Nm)
Frame- M10 x 1.5 x 145 (QTY.2), -
Backbone to Front Frame
15 Screw - M12 x 1.75 x 95 (QTY.2), 51 ft-lbs (69.1 Nm) 5 (Left)
Front Frame to Engine 6 (Right)
16 Screw - M10 x 1.50 x 30 (QTY.4), 35 ft-lbs (47.4 Nm) 7 (Left Rear)
Mid Cast Frame to Backbone 8 (Left Front)
9 (Right Rear)
10 (Right Front)
17 Nut - M10 x 1.50 (QTY.2), 11 (Right Rear)
-
Backbone to Front Frame 12 (Right Front)
18 Nut - M12 x 1.75 (QTY.3) - -

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Fenders / Seat

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Front Fender - M8 x 1.25 x 50 (QTY.4) 18 ft-lbs (24.4 Nm)
2 Screw, Seat - M8 x 1.25 x 16 (QTY.1) 18 ft-lbs (24.4 Nm)
3 Screw, Rear Fender - M8 x 1.25 x 20 (QTY.4) 18 ft-lbs (24.4 Nm)

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Footpegs

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Footpeg Passenger - M8 x 1.25 x 20 (QTY.2) 19 ft-lbs (25.7 Nm)
2 Screw, Footpeg Driver - M10 x 1.50 x 35 (QTY.2) 35 ft-lbs (47.5 Nm)
3 Screw, M6 x 1.0 x 10 (QTY.1) 84 in-lbs (9.5 Nm)
4 Shoulder Screw (QTY.2) 50 ft-lbs (68 Nm)

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BODY / FRAME SERVICE Seat Removal / Installation
1. Lift up on the seat front to disengage the front of
Footpeg (Driver) Removal / Installation the seat from the frame post.
Foot Pegs (Passenger), Removal /
Installation
NOTE: Remove Exhaust to access left foot peg.

1. Remove bolts (1) securing foot peg bracket to

frame.
2. Remove foot peg / bracket as an assembly. 3

2. Lift the seat and pull rearward to disengage the

seat from the mount (2) holding the back of the
seat to the frame.

3. INSTALLATION is performed by reversing the

removal procedure.

Seat Mount Screw: 18 ft-lbs (24.4 Nm)

3. INSTALLATION is performed by reversing the

removal procedure. Front Fender Removal
4. Torque passenger foot peg bracket bolts (1) to Motorcycle should be parked on a level surface rest-
specification. ing on the side stand.

Passenger Foot Peg Bolts: 19 ft-lbs (26 Nm)

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CAUTION CAUTION

Use care not to scratch or damage painted surfaces Use care not to scratch or damage painted surfaces
during fender removal and / or installation. during fender removal and / or installation.

1. Remove two fender mount bolts from each side of 1. Gently squeeze the sides of the front fender and
the motorcycle. “roll” the fender into position so the bolt holes line
up.

2. Stand in front of the motorcycle facing the front

fender and squeeze the sides together while 2. Install the two bolts on each side of the fender and
“rolling” the fender out from the fork legs. torque to specification.

Once fender has been removed from the motor-

cycle, make sure the fender is stored safely until it
is reinstalled.

Front Fender Installation Front Fender Bolts: 18 ft-lbs (24.4 Nm)

Motorcycle should be parked on a level surface rest-
ing on the side stand. 3. Turn the handlebar all the way to the left and right
to verify proper operation and freedom of
movement.

Rear Fender Removal

1. Remove seat. See Seat Removal / Installation,
page 3.7

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2. Remove two bolts (1) and fender washers (2) from 3. Plug the rear harness connector (3) into the
both sides of the fender. chassis harness.
4. Torque fender screws to specification.

Fender Screw : 10 ft-lbs (13.5 Nm)

5. Install seat. See Seat Removal / Installation, page

3.7
3
Instrument Panel Removal / Installation
1. Remove four handle bar screws securing the
instrument panel to the handle bars.

3. Locate the rear harness connector (3) and

disconnect.

2. Lift instrument panel and disconnect the single

multi-plug (1).
4. Lift the fender off of the motorcycle.

CAUTION
Be careful not to damage painted surfaces.

Rear Fender Installation

CAUTION

Use care not to scratch or damage painted surfaces

during fender removal and / or installation.
3. INSTALLATION is performed by reversing the
1. Route the rear harness along the rear fender and removal procedure.
secure with cable ties.
2. Place the rear fender assembly onto the
motorcycle so the bolt holes line up and install
screws and (1) fender washers (2) so they are
finger tight. Instrument Panel Screw : 22 ft-lbs (29.8 Nm)

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Ignition Side Cover Removal / Installation Frame Removal / Installation
1. Remove ignition side cover fasteners (1).

WARNING

Care should be taken to be sure the motorcycle will

not tip or fall while elevated. Severe personal injury
or death could occur if the motorcycle tips or falls.

REMOVAL
1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Remove the seat assembly. See Seat Removal /
Installation, page 3.7
3. Disconnect the negative cable from the battery.
4. Remove the fuel tank. See Fuel Tank Removal,
2. Remove ignition side cover (2). page 5.21.
5. Remove the battery box. See Battery Box Removal,
3. Installation is reverse of removal and torque
fasteners to specification. page 15.11.
6. Remove the driver footpegs. See Footpeg (Driver),
NOTE: Torque Specification: Removal / Installation, page .
Ignition Side Cover Screws
96 in-lbs (10 Nm) 7. Remove the passenger footpegs (if equipped). See
Footpeg (Passenger), Removal / Installation, page
3.7.
Thermostat Housing Cover Removal / 8. Remove the head pipe assembly. See Head Pipe
Installation Removal, page .
1. Remove the thermostat housing cover fasteners (1). 9. Support the engine with a platform jack.

10. Remove the rear fender. See Rear Fender Removal,

page 3.8.
11. Remove the rear swingarm. See Swingarm
2. Remove the thermostat housing cover (2). Removal, page 12.18.
3. Installation is reverse of removal and torque 12. Remove any electrical harness clips to the frame.
fasteners to specification.
NOTE: Torque Specification:
Thermostat Housing Cover Screws
96 in-lbs (10 Nm)

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13. Remove the rear subframe fasteners (1) and 18. Remove the lower fasteners (4) holding the front
subframe assembly. frame to the vehicle and remove front frame.

14. Remove the RH and LH mid cast frame fasteners INSTALLATION

(2).
NOTE: Frame fasteners must be torqued in
sequence. See Torque Specifications, page 3.2.

1. Thread the swingarm pivot (5) completely into the

RH mid frame (6).

15. Remove front triple clamps and forks. See Triple

Clamp Removal, page 11.26.
16. Remove radiator assembly. See Radiator Removal /
Installation, page 4.21.
17. Remove the fasteners (3) holding the RH and LH
backbone to the vehicle.

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2. Assemble RH mid frame (6), LH midframe (7), 5. Install RH frame backbone (11) and LH frame
spacers (8) on the engine with mounting bolts (9) backbone (12) on the midcast frames.
to hand tightness.

6. Position the spacer (14) between the front frame

3. Assemble the rear subframe (10) to the midcast assembly (13) and engine case.
frames.

7. Install the front frame assembly (13) to the frame

4. Install the airbox if previously removed. See Air backbones and engine case.
Box Removal, page 5.18.

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8. Torque fasteners to specification. See Frame, page 21. Install seat assembly. See Seat Removal /
3.3. Installation, page 3.7.

Front Frame Lower Fasteners: 51 ± 6 ft-lbs (69 ± 8

Nm)
Backbone Fasteners: 35 ± 4 ft-lbs (47 ± 5Nm)
Main Frame Fasteners: 51 ± 6 ft-lbs (69 ± 8 Nm)
Rear Subframe Fasteners: 35 ± 4 ft-lbs (47 ± 5Nm) 3
9. Torque swingarm pivot (5) outward to 5 ft-lbs ( 6.7
Nm) to seat against LH midcast frame.

10. Install swingarm assembly. See Swingarm

Installation, page 12.20.
11. Install the radiator assembly. See Radiator
Removal / Installation, page 4.21.
12. Install the triple clamps. See Triple Clamp
Installation / Steering Head Bearing Adjustment,
page 11.27.
13. Install the forks. See Front Fork Installation, page
11.25.
14. Install the head pipe assembly. See Head Pipe
Installation, page 5.16.
15. Install mufflers. See Muffler Installation, page 5.14.
16. Install the driver foot controls. See Footpeg
(Driver), Removal / Installation, page .
17. Install passenger foot pegs if equipped. See
Footpeg (Passenger) Removal / Installation, page
3.7.
18. Install battery box. See Battery Box Installation,
page .
19. Install the fuel tank. See Fuel Tank Installation,
page 5.26.
20. Connect battery cables.

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NOTES

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CHAPTER 4
LUBRICATION / COOLING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4
COOLANT FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11
OIL PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
SCAVENGE OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
PRESSURE OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
SCAVENGE OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
PRESSURE LUBRICATION OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
OIL COOLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
OIL COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
OIL COOLER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
COOLING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
COOLING SYSTEM PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
COOLANT FILL / BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
RADIATOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25

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GENERAL INFORMATION Troubleshooting
Service Notes LOW OIL PRESSURE HIGH OIL PRESSURE
The Scout uses a semi-dry sump lubrication system. Incorrect oil being used Incorrect oil being used
The engine oil is housed in a separate chamber within or low oil level
the engine cases (1) as shown in the image below. Engine temp above test Additives added to oil to
temperature range increase viscosity
Damaged O-rings or Engine temp below test
leaks at pipes or fittings temperature range
Damaged or worn oil Restricted oil passages
pump or oil pump drive
Pressure relief valve Incorrect oil filter
stuck open
Damaged engine Pressure relief valve stuck
bearings/excessive closed
engine wear.
Restricted oil filter, oil
filter screen or
passages

Special Tools

TOOL DESCRIPTION PART NUMBER

The engine has two separate oil pumps, a scavenge Oil Pressure Gauge PV-43531
pump (2) and pressure (lubrication) pump (3). The
scavenge pump has two sets of internal gerotors. One
set scavenges oil from the right side of the engine Bosch Automotive Service Solutions: 1-800-345-
crankcase and the second set from the left side. The 2233 or https://polaris.service-solutions.com/
scavenge pump supplies oil to fill the oil tank area (1)
of the engine. The oiling system pressure relief valve
is located inside the pressure oil pump.

To access the scavenge oil pump, the stator cover must

be removed. To access the pressure pump, remove the
right engine cover. Before disassembly, review the
troubleshooting charts located in this chapter.
If the engine is making irregular noises that appear to
be coming from rotating parts, check the lubrication
side oil pressure. Check the oil pressure before
engine disassembly, and recheck the oil pressure after
a repair.

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Torque Specifications

PART DESCRIPTION TORQUE SPECIFICATION

Oil Drain Plugs - Scavenge and Oil Tank 15 ft-lbs (20.0 Nm)
Oil Filter (Apply oil to filter seal) 6 ft-lbs (8 Nm) or approximately 3/4 to 1 full turn
after seal contacts the filter mount sealing surface
Oil Cooler Spigot 22 ft-lbs (30.0 Nm)
Lubrication Oil Pickup Screen to Crankcase 88 in-lbs (10.0 Nm)
Oil Pressure Sensor 88 in-lbs (10.0 Nm) Apply sealer to threads
Scavenge Oil Pump to Crankcase 88 in-lbs (10.0 Nm)
Lubrication Oil Pump to Crankcase 88 in-lbs (10.0 Nm) 4
Lubrication Oil Tube to Oil Pump 88 in-lbs (10.0 Nm)
Oil Scavenge Inlet Screens 88 in-lbs (10.0 Nm)
Oil Scavenge Tube to Oil Pump 88 in-lbs (10.0 Nm)

Service Specifications

ITEM STANDARD SERVICE LIMIT

Engine Oil Fill Capacity (for DRY 4.5 U.S. qts (4.3 Liters) Not Applicable
rebuilt engine)
Engine Oil Capacity (for Change with 3.0 - 3.5 U.S. qts (2.8 - 3.3 Liters) Not Applicable
Filter) Follow the oil change procedure
outlined in Chapter 2.
Engine Oil Capacity (for Change 2.9 - 3.2 U.S. qts (2.7 - 3.0 Liters) Not Applicable
without Filter) Follow the oil change
procedure outlined in Chapter 2.
Recommended Engine Oil if Indian Indian Motorcycle Synthetic Not Applicable
Motorcycle 15W60 is not available, 15W60
use motorcycle oil with same
specifications.
Oil Pressure @ 3000 rpm (supply side) 40 psi (275 kPa)Readings should MINIMUM PRESSURE: 32 psi (220
Measurements must be taken with be within 20% of the kPa)
engine at operating temperature specification.
and specified Indian Motorcycle
Engine Oil

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OIL PUMP CLEARANCES (SCAVENGE)

Pump Gerotor OD to Oil Pump Body .003"-.007" (0.100 mm - 0.200 .011" (.300 mm)
mm)
Oil Pump End Clearance .0019"-.003" (.050 mm - 0.100 .007" (.200 mm)
mm)
Gerotor Tip Clearance .0031"-.007" (.080 mm -.200 mm) .0098" (.250 mm)
OIL PUMP CLEARANCES (FEED)
Pump Gerotor OD to Oil Pump Body .003"-.007" (0.100 mm - 0.200 .011" (.300 mm)
mm)
Oil Pump End Clearance .0019"-.003" (.050 mm - 0.100 .007" (.200 mm)
mm)
Gerotor Tip Clearance .0031"-.0059" (.080 mm - .150 .007" (.200 mm
mm)

COOLING SYSTEM SPECIFICATIONS

ITEM DESCRIPTION SPECIFICATION / CAPACITY
Capacity Engine Coolant / Extended Life Anti-Freeze 50/50 System 2.77 Qts (2.63 Ltrs) /
Antifreeze Premixed (Yellow) Recovery Bottle .16 Qt (.15 Ltrs)
Thermostat Opening Temperature 180 Degrees F (82 Degrees C)
Cooling System Pressure Cap Relief Pressure 16 PSI
COOLING FAN OPERATION
CONDITION APPROXIMATE RESISTANCE TEMPERATURE
OHMS Ω
Engine Protection Misfire 120Ω 240.8 Degrees F (116 Degrees C)
Coolant Hot Lamp (On Solid) 140Ω 233.6 Degrees F (112 Degrees C)
Cooling Fan On 200Ω 204.8 Degrees F (96 Degrees C)
Cooling Fan Off 210Ω 203.0 Degrees F (95 Degrees C)
Room Temperature 2500Ω 68 Degrees F (20 Degrees C)

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ASSEMBLY VIEWS
Cooling System

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Filler, Funnel Coolant --
2 Tank, Coolant Surge --

3 Hose, Coolant Radiator Inlet --

4 Hose, Coolant Oil Cooler Inlet --
5 Fan, Cooling Assy --

6 Hose, Coolant Radiator Outlet --

7 Radiator, Assy --

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Coolant Flow Diagram
Cooling System Flow Thermostat Closed (Bypass)

Cooling System Flow Thermostat Open

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Lubrication System
Pressure Lubrication System Assembly View

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Oil Pump Mounting- M6 x 1.0 x 15 (QTY.3) 7 ft-lbs (10 Nm)
2 Screw, Oil Pump Gear 7 ft-lbs (10 Nm)
3 Washer, Oil Pump Gear –

4 Gear, Oil Pump –

5 Oil Pump Assembly (Pressure) –

6 Screw - M6 x 1.0 x 12 7 ft-lbs (10 Nm)

7 Tube, Oil Pressure Inlet –
8 Seal, Oil Pressure Inlet Tube (QTY 2) –

9 Screw, Dipstick Adapter 7 ft-lbs (10 Nm)

10 Dipstick , Engine Oil Level 7 ft-lbs (10 Nm)
11 Adapter, Engine Oil Dipstick –

12 Seal, Engine Oil Adapter –

13 Seal, Oil Pump Pickup –

14 Screen, Oil Pump Pickup –

15 Screw, Oil Pump Pickup Screen 7 ft-lbs (10 Nm)

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

16 Filter, Engine Oil 6 ft-lbs (8 Nm) or Approximately
3/4 turn after sealing ring has
contacted the filter adapter.
17 Spigot, Oil Cooler 22 ft-lbs (30 Nm)
18 Cooler, Engine Oil –

19 Switch, Engine Oil Pressure 7 ft-lbs (10 Nm)

20 Cooling Jet, Piston Rear –

21 Screw, Piston Cooling Jet 5ft-lbs (7 Nm)

22 Cooling Jet, Piston Front –

23 Screw, Piston Cooling Jet 5ft-lbs (7 Nm)

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Scavenge Lubrication System Assembly View

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Oil Pump Mounting- M6 x 1.0 x 15 (QTY.3) 88 in-lbs (10.0 Nm)
2 Pump, Engine Oil Scavenge –

3 Tube, Scavenge Oil Return –

4 Screw, Scavenge Oil Return Tube 88 in-lbs (10.0 Nm)

5 Screw, Scavenge Pump Mount 88 in-lbs (10.0 Nm)
6 Oil Drain Plug 15 ft-lbs (20.0 Nm)
7 Washer, Oil Drain Plug Sealing –

8 Screen, Inlet Scavenge Engine Oil –

9 Screw, Inlet Scavenge Screen 88 in-lbs (10.0 Nm)

10 Screw, Inlet Scavenge Screen 88 in-lbs (10.0 Nm)
11 Screen, Inlet Scavenge Engine Oil –

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Oil Flow Diagram

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OIL PRESSURE INSPECTION
Oil Pressure

CAUTION

Use caution when working around hot engine oil.

NOTE: Oil pressure switch activates at 3 psi ± 1

psi.

1. Start the engine and run until operating

temperature is reached.
2. Turn the engine OFF. 4
3. Remove oil pressure sensor (1).

4. Install oil pressure gauge.

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

Oil Pressure Switch: 88 in-lbs (10 Nm)

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OIL PUMP SERVICE 7. Remove the stator cover fasteners (5) and stator
cover assembly (6).
Scavenge Oil Pump Removal
1. Drain cooling system. Coolant Drain / Fill, page
2.14
2. Remove the left side ignition cover fasteners (1)
and cover (2).

8. Remove the scavenge inlet tube fastener (7) and

scavenge oil pump fasteners (8).

3. Disconnect the radiator outlet hose (3) from the

fitting on the stator cover.

9. Remove scavenge oil pump assembly (9).

10. Remove and discard the O-ring on both sides (10).

4. Disconnect coolant bypass return hose (4) from

the stator cover.
5. Remove the crankshaft position sensor CPS. See
Crankshaft Position Sensor Test/Replace.
6. Disconnect the stator electrical connector.

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Pressure Oil Pump Removal
1. Remove exhaust head pipe. See Head Pipe
Removal, page 5.15.
2. Disconnect clutch cable from engine clutch lever.
See Clutch Cable, Removal / Installation, page
11.12.
3. Remove primary cover fasteners (1) and cover
assembly (2).

6. Remove pressure pump (12) and inlet tube (11)

4
assembly from engine.

4. Remove primary drive cover fasteners (3), seal (5)

and cover assembly (4).

7. Separate inlet tube (11) from pressure pump (12)

and discard inlet tube seals (10).
8. Separate gear shield (14) from oil pump gear (13).

5. Remove pressure pump pickup tube fastener (6),

gear fastener (7), washer (8) and three mounting
bolts (9).

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Scavenge Oil Pump Installation Pressure Lubrication Oil Pump
1. Install a new o-ring (1) on the inlet tube. Installation
1. Assemble gear shield (14) and gear (13) onto
lubrication pump (12).

2. Install the oil pump (2) into the crankcase and

loosely install bolt (4) securing the snorkel tube to
the LH crankcase. 2. Lubricate new inlet tube seals (10) with engine oil
3. Align bolt holes and install oil pump bolts (3) and and install the seals on the inlet tube (11).
torque to specification. 3. Assemble the inlet tube to the pump and torque
screw to specification.

Oil Pump Bolts: 88.5 in-lbs (10.0 Nm)

Inlet Tube to Pump Screw
4. Torque inlet tube bolt to specification. 7.37 ft-lbs (10 Nm)

4. Install the lubrication pressure pump assembly into

the right crankcase and torque fasteners (9), (6) to
specification.
Snorkel Tube Bolts: 88.5 in-lbs (10.0 Nm)

5. Assemble engine stator cover. See Stator Cover

Installation, page 9.19.
6. Verify engine oil pressure after assembly. See Oil Oil Pump to Crankcase Screws
Pressure, page 4.11. 7.37 ft-lbs (10 Nm)

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5. Install the oil pump gear screw (7) and washer (8)
4
onto pump shaft. Torque fastener to specification.

Oil Pump Gear Screw

7.37 ft-lbs (10 Nm)

6. Install the primary drive cover assembly. See

Primary Drive Cover Installation, page 9.7.

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OIL COOLER SERVICE Oil Cooler Inspection
1. Inspect cooler, lines and all connection for leaks.
Oil Cooler Removal
2. Inspect coolant lines for proper routing. Replace if
1. Drain the cooling system. See Cooling System there is any sign of abrasion or damage.
Drain/Fill.
3. Inspect cooler surface for kinks or debris.
2. Remove the horn assembly. See Horn Removal/
Installation 4. Inspect cooler mounting fastener for proper
torque.
3. Disconnect the supply coolant line at the oil
cooler. 5. Replace any damaged components.

Oil Cooler Installation

Inspect the oil cooler sealing surfaces/seals for dam-
age and replace if necessary.
1. Fit the oil cooler assembly (1) on the engine so the
locating tang (2) is positioned in the recess.

4. Place an oil pan beneath the oil filter adapter to

catch any oil that drains out of the cooler assembly
upon removal.
5. Remove oil filter assembly.
6. Hold the oil cooler assembly (2) from turning to
prevent distorting the locating tang (3) and
remove the oil cooler mounting spigot (4). 2. Prevent the oil cooler assembly from spinning
when installing the oil cooler adapter spigot (3)
and torque spigot to specification.

Oil Cooler Adapter Spigot: 22 Ft-lbs (30 Nm)

3. Install new oil filter.

4. Connect the supply and return coolant lines to the
oil cooler.
5. Install the horn assembly. See Horn Removal/
Installation.
6. Install the radiator cover.
7. Fill and bleed the cooling system. See Coolant
NOTE: It may be necessary to hold the oil Drain/Fill.
cooler assembly from turning to assist with
removal oil cooler mounting spigot. 8. Check engine oil level. See Engine Oil Level
Check.
7. Remove the oil cooler assembly from the vehicle.

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9. Run the engine to cycle oil through the oil cooler
and check oil level. Top off if necessary.
10. Check for engine oil or coolant leaks.

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COOLING SYSTEM SERVICE
WARNING
Coolant Strength / Type
Never remove pressure cap when engine is warm or
Test the strength of the coolant using an antifreeze
hot. The cooling system is under pressure and
hydrometer.
serious burns may result.
• A 50/50 mixture of extended life antifreeze and Allow the engine and cooling system to cool before
distilled water will provide the optimum cooling, servicing.
corrosion protection, and antifreeze protection.
3. Remove the pressure cap from the thermostat cover
• Do not use tap water, straight antifreeze, or
and pressure test the cooling system using a
straight water in the system. Tap water contains
commercially available tester.
minerals and impurities which build up in the
system. 4. The system must retain 11-14 psi (75-95 kPa) for
five minutes or longer. If pressure loss is evident
• Straight water or antifreeze may cause the
within five minutes, check the radiator, all cooling
system to freeze, corrode, or overheat.
system hoses, hose clamps and water pump for
leakage.

Recommended Anti-Freeze/Coolant:
Indian Motorcycle 50/50 Pre-Mixed Extended Life
Antifreeze
(PN 8560214) (Quart)

Cooling System Pressure Test

NOTE: Coolant may be present at the water pump
weep hole due to normal water pump function.
Verify integrity of the water pump seal with a
cooling system pressure test.

1. Remove the seat. See Seat Removal / Installation,

page 3.7.
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21.

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Cooling System Pressure Cap Test NOTE: Pressure test before and after servicing
the cooling system.
1. Remove the seat. See Seat Removal / Installation,
page 3.7.
Cooling System Drain
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21. 1. Remove the radiator cover fasteners (Item 1).

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.
4
3. Remove the cooling system pressure cap and test
using a cooling system pressure tester.
(Commercially available).
4. The cooling system pressure cap relief pressure is
16 lbs. Replace cap if it does not meet this
specification.
2. Slide radiator cover down to disengage posts from
the upper radiator mounts (Item 2).
Coolant Drain / Fill

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.

3. Remove the coolant return hose (Item 3) from the

oil cooler assembly to drain the coolant.

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9. Remove the vacuum bleeder and install the
pressure cap.
10. Remove the pinch pliers from the coolant line
between the reservoir and thermostat housing.
11. Add Indian Motorcycle Extended Life 50/50 Engine
Coolant to the reservoir fill opening (Item 2) until
the coolant reservoir (Item 3) is half full.
12. Install the fuel tank assembly. (See Fuel Tank
Installation).
13. Run the engine until the cooling fan cycles ON and
OFF.
14. Recheck the coolant level in the reservoir and add
to the “COLD FULL” level.

Cooling System Fill/Bleeding 15. Repeat the fill/bleed procedure until the coolant
level in the reservoir remains at the “COLD FULL”
NOTE: Pressure test before and after servicing level.
the cooling system.
16. Install the seat. See Seat Removal / Installation,
page 3.7..
1. Reconnect the coolant return hose to the oil cooler
assembly.
2. Install the radiator cover.
3. Remove the seat. See Seat Removal / Installation,
page 3.7.
4. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.21.
5. Remove cooling system pressure cap (Item 1).
6. Use pinch pliers (commercially available) to pinch
off the coolant line (Item 4) between the coolant
reservoir and thermostat housing.

7. Install a cooling system vacuum bleeder

(commercially available) on the pressure cap
opening to create a vacuum in the cooling system.
8. Using the vacuum bleeder draw in Indian
Motorcycle Extended Life 50/50 Engine Coolant to
fill the cooling system.

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Coolant Fill / Bleeding Radiator Removal / Installation
1. Remove seat assembly. See “Seat Removal”.
2. Remove fuel tank assembly. See “See Fuel Tank
Removal”. WARNING
3. Remove the pressure cap (Item 1). Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.

1. Place the motorcycle on the sidestand and rotate

the handlebars to the full left lock position.
2. Drain the cooling system. (See Coolant Drain/Fill).
3. Remove radiator cover fasteners.
4

4. Add coolant to top of filler neck (Item 2).

5. Install commercially available vacuum bleeder to
remove air from the cooling system.
6. Remove vacuum bleeder.
7. Add coolant to top of the filler neck.
8. Install the pressure cap.
9. Add coolant to the filler funnel (Item 3) until the
coolant is visible in the surge tank (Item 4).
4. Protect the painted surface of the front fender and
remove radiator cover.

10. Install the fuel tank. See “Fuel Tank Installation”.

11. Run engine until the cooling fan cycles on and off. 5. Remove the radiator mount fasteners (Item 3).
12. Check coolant level in the surge tank and add as
required.
13. Install seat. See “Seat Removal/Installation”.

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4. Disconnect the radiator outlet hose (Item 3) at the
left engine cover.

6. Disconnect the cooling fan electrical connector.

7. Remove the radiator inlet and outlet hoses.
8. Remove the coolant return hose at the radiator. 5. Disconnect the bypass hose (Item 4) at the left
engine cover.
9. Remove the radiator and store in a location to
prevent damage. 6. Disconnect the stator harness connector.
10. Reverse removal procedure for installation. 7. Remove the stator cover fasteners (Item 5) and
stator cover (Item 6).
11. Fill cooling system. See Coolant Fill / Bleeding,
page 4.21

Water Pump
NOTE: Coolant may be present at the water pump
weep hole due to normal water pump function.
Verify integrity of the water pump seal with a
cooling system pressure test.

1. Drain cooling system. See Coolant Drain / Fill,

page 4.19.
2. Remove Crankshaft Position Sensor from the stator
cover. See Crankshaft Position Sensor, Test /
Replace, page 5.45.
3. Remove three (3) Ignition Cover fasteners (Item 1)
and remove the Ignition Cover (Item 2). 8. Remove water pump impeller (Item 7).

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 LUBRICATION / COOLING
3. Remove fuel tank assembly. See Fuel Tank
Removal, page 5.21.
4. Remove right thermostat housing cover.

9. Remove the water pump seal assembly (8).

4

5. Drain the cooling system. See Coolant Drain / Fill,

page 4.19.
6. Disconnect the radiator inlet hose (2) and overflow
reservoir hose (3) from the thermostat housing.

10. Clean the water pump seal bore and inspect for
scoring on the seal bore surfaces.
11. Utilize water pump seal installation tool PF-51608 to
seat the replacement water pump seal.
12. Reverse the removal procedure to reassemble.

Thermostat
7. Remove thermostat housing fasteners (4) and
thermostat housing (5).

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and
serious burns may result.
Allow the engine and cooling system to cool before
servicing.

1. Place motorcycle on the sidestand.

2. Remove seat. See Seat Removal / Installation, page
3.7.

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LUBRICATION / COOLING
Coolant Temperature Sensor
1. Drain cooling system. See Coolant Drain / Fill.
2. Remove ignition switch side cover. See Ignition
Side Cover Removal.
3. Remove ignition switch bracket fasteners (1).

8. Remove the thermostat assembly (6).

4. Disconnect the ignition switch electrical connector

(2) and remove the ignition switch bracket
assembly (3).
5. Disconnect the coolant bypass hose (4) from the
stator housing.

9. Reverse removal procedure for installation.

10. Fill and bleed the cooling system. See Coolant
Drain / Fill, page 4.19.

6. Disconnect the coolant outlet hose (5) from the rear

cylinder head.

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 LUBRICATION / COOLING
Troubleshooting
Overheating
• Low coolant level
• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked
in radiator, lines, pump, or water jacket,
accident damage)
• Engine running lean (fuel system restriction)

7. Disconnect the coolant temperature sensor

• Fuel pump output weak 4
• Water pump failure/ Loose impeller
electrical connector and remove the sensor (6)
from the rear cylinder head. • Engine Coolant Temperature Sensor failure
• Electrical malfunction
• Cooling fan inoperative or turning too slowly
• Low oil level
• Faulty hot lamp circuit
• Thermostat stuck closed or not opening
completely

Temperature Too Low

• Thermostat stuck open

Leak at Water Pump Weep Hole

• Faulty water pump mechanical seal

8. Reverse removal procedure for installation. • Worn pump shaft or pump shaft bearing

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NOTES

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 FUEL DELIVERY / EFI / EXHAUST

CHAPTER 5
FUEL DELIVERY / EFI / EXHAUST
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
EFI SYSTEM PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL LINE ROUTING (49 STATE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL LINE ROUTING (CA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 5
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
SENSORS - POWERTRAIN MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
EXHAUST SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
MUFFLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
MUFFLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
HEAD PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
HEAD PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
AIR BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
AIR BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
FUEL DELIVERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
INTAKE MANIFOLD, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
FUEL PUMP PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
FUEL SYSTEM DEPRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
FUEL TANK VENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
FUEL LEVEL SENSOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
FUEL PUMP SUPPLY VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
FUEL PUMP CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
EFI SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
FUEL INJECTION SYSTEM - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.33
SENSOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.41

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ECM PINOUT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.41
ECM CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.41
ECM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.42
TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) REPLACEMENT . . . . . . . . . . . . . . . .5.42
COOLANT TEMPERATURE SENSOR, TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.43
FUEL INJECTOR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.43
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.44
CRANKSHAFT POSITION SENSOR, TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.45
THROTTLE BODY (ETC) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.45
LOAD / TIP OVER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.46
DIGITAL WRENCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
DIAGNOSTIC SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
ECM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
GUIDED DIAGNOSTIC AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
DIGITAL WRENCH DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47
DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.48
DIGITAL WRENCH VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.48
DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.48
DIGITAL WRENCH FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.50
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.53
FUEL SYSTEM TROUBLESHOOTING, PART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.53
FUEL SYSTEM TROUBLESHOOTING, PART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.54
FUEL SYSTEM TROUBLESHOOTING, PART 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.55
FUEL SYSTEM TROUBLESHOOTING, PART 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.56

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 FUEL DELIVERY / EFI / EXHAUST
GENERAL INFORMATION
WARNING
Service Notes
If you get gasoline in your eyes or if you swallow
Many hazards are present when working on or around
gasoline, see your doctor immediately. Never try to
the fuel injection system. Read and pay close attention
syphon gasoline using mouth suction.
to the following warnings and cautions when working
on any component in this section.

WARNING WARNING

Gasoline is extremely flammable and is explosive Never start the engine or let it run in an enclosed
under certain conditions. Work in a well ventilated area. Engine exhaust fumes are poisonous and can
area. Open flames, sparks and cigarettes must be cause loss of consciousness and death in a short time.
kept away from gasoline.

WARNING
WARNING 5
The battery should always be disconnected before
working on the fuel system.
Careless handing of the control cables can result in
twisting or bending of the cables. This can cause the
cables to stick or bind, resulting in loss of vehicle When replacing fuel lines, always use genuine Indian
control. Motorcycle replacement parts. This will ensure top
performance, function and durability.
Fuel lines remain under pressure at all times. Use
caution when disconnecting lines for service.
WARNING
Disconnect the fuel pump electrical connector to
The engine exhaust from this product contains disable fuel pump and crank engine to release
chemicals known to cause cancer, birth defects or pressure. Always depressurize the fuel system prior to
other reproductive harm. service.
Cover the fuel hose connections with a clean,
absorbent towel to minimize spillage while
disconnecting.
WARNING Don’t overlook the basics while troubleshooting
the fuel system:
The engine and exhaust system become very hot • Except where noted, views of connectors are
during operation and remains hot for a period of time from WIRE side of the connector.
after the engine is shut off. Wear insulated protection
for hands and arms or wait until the engine and • A battery in a low state of charge can cause
exhaust system have cooled before performing problems. Be sure battery is in good condition
service work. and fully charged.
• Air leaks in intake tract / air box - check for air
leaks and repair to avoid misdiagnosing the EFI
system.
WARNING
• Contaminated or improper fuel.
Always stop the engine and refuel outdoors or in a • Restricted fuel flow / filters (low fuel pressure).
well ventilated area. • Fuel tank vent line pinched or obstructed.
• Faulty spark plug(s).
• Corroded, disconnected, or incorrectly
connected wiring.

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FUEL DELIVERY / EFI / EXHAUST
• Poor ground connections - be sure all grounds DESCRIPTION TORQUE
are clean and tight. SPECIFICATION
• Exhaust system restriction or improper exhaust. Rear Head Pipe Hanger 18 ft-lbs (24.4 Nm)
• Engine mechanical condition. Side Stand Switch 43 in-lbs (4.9 Nm)
TMAP 62 in-lbs (7.0 Nm)
Special Tools
Wheel Speed Sensor 96 in-lbs (10.8 Nm)
TOOL DESCRIPTION PART NUMBER Worm Drive Exhaust 31 in-lbs (3.5 Nm)
Electrical Tester Kit PV-43536 Clamps
Fuel Pressure Adapter PV-48656
Fuel Pressure Gauge PU-43506–A Service Specifications
Relay Bypass PU-49466 ITEM SPECIFICATIONS
Smartlink Module Kit PU-47471 Fuel Pump Pressure 3.51 BAR (350 kPa) (51 psi)
USB to Serial Adapter PU-50621 Idle Speed 800 rpm ± 50rpm

Bosch Automotive Service Solutions: 1-800-328- Fuel Pump Amp Draw

3 - 5 Amps
6657 or https://polaris.service-solutions.com/ (Normal Operation)
Recommended
Torque Specifications 91 Octane Minimum
Octane

DESCRIPTION TORQUE Injector Resistance 11.4 - 12.6 Ohms

SPECIFICATION
Air Box Cover 84 in-lbs (9.5 Nm)
Air Filter Element 62 in-lbs (7.0 Nm)
Air Filter Retainer Plate 31 in-lbs (3.5 Nm)
CHT 70 in-lbs (8.0 Nm)
Console Panel Screws 84 in-lbs (9.5 Nm)
CPS 88.5 in-lbs (10.0 Nm)
Evaporative Emissions 84 in-lbs (9.5 Nm)
Canister
Fuel Filter Screws 12 in-lbs (1.4 Nm)
Fuel Pump Nut 24 in-lbs (2.7 Nm)
Fuel Tank Screw 18 ft-lbs (24.4 Nm)
Gear position Switch 43 in-lbs (4.9 Nm)
Head Pipe Nuts 12 ft-lbs (16.2 Nm)
Muffler Hanger Bolts 19 ft-lbs (25.7 Nm)
Muffler Clamps 40 ft-lbs (54.2 Nm)
Ignition Coil 84 in-lbs (9.5 Nm)
Oil Pressure Switch 88 in-lbs (10.0 Nm)
Oxygen Sensor 14 ft-lbs (19.0 Nm)

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SERVICE PRECAUTIONS
EFI System Precautions
NOTICE: While electronic fuel injection is durable
and reliable, the components can be damaged or
problems may occur if the following precautions are
not taken.
It is not advisable to “jump start” the machine with Anti-static wrist strap PV-43541
another battery. Although problems are unlikely to NOTICE: Some tests require probing of the ECM
occur if everything is done carefully, the electrical wiring harness connector. Do not touch or probe the
component could be damaged. exposed pins on the ECM. Static electricity from your
Never disconnect the battery while the engine is body or the meter can easily damage the ECM.
running. Always use the proper adapter from the Connector
When connecting and disconnecting the battery Test Adapter Kit when probing the terminals. Most of
cables refer to Chapter 15 for complete battery the connectors are sealed and cannot be back probed.
connection and charging information. See Battery Be extremely careful not damage the connectors by
Installation, page 15.11. forcing meter probes into the connectors.

Make sure that the ignition is powered down before

connecting and disconnecting connections. Best 5
practice is to disconnect the battery before connecting
or disconnecting the electrical connections.
Fuses and circuit breakers protect critical electrical
components and circuits. Never replace the fuse with a Connector test adapter kit PV-43526
larger value fuse or “jumper” the fuse with wire, Poor connections are the most common cause of
aluminum foil or any other means. Always investigate Electronic Fuel Injection malfunctions. Inspect
the cause of the problem and repair before replacing connector and wiring connections carefully during
the fuse. troubleshooting.

The ECM and sensors are sensitive pieces of

Carefully inspect the connections of the failed circuit
electronic equipment. Dropping or hitting them may
before doing any other troubleshooting steps. Wire
cause irreparable damage.
terminals should be corrosion free and fully seated
into the connectors. Connector should snap together
and lock.

Static electricity can damage the electronic controllers

beyond repair. The human body can easily store
enough static electricity to damage sensitive
electronic components. Before working with any
components of the Fuel Injection system, ground
yourself to dissipate any static charge. Also take care
not to touch any of terminal pins on the ECM.

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ASSEMBLY VIEWS
Fuel Line Routing (49 State Models)

NUMBER PART DESCRIPTION

1 Fuel Supply Line (Pump to Fuel Rail)
2 Vapor Vent Line, Upper (from tank)
3 Drain Line, Fuel Cap (from fuel cap recess)
4 Vapor Vent Line, Lower (to atmosphere)

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Fuel Line Routing (CA)

NUMBER PART DESCRIPTION

1 Evaporative Emissions Canister
2 Vapor Supply Line, Lower (from canister)
3 Canister Purge Valve
4 Vapor Vent Line, Lower (to canister)
5 Vapor Supply Line, Upper (to tank)
6 Vapor Vent Line, Upper (from tank)
7 Fuel Supply Line (Pump to Fuel Rail)

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Fuel System

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Evaporative Emissions Canister — M6 x 1.0 x 16 (QTY.2) 7 ft-lbs (9.5 Nm)
2 Evaporative Emissions Canister (CA Models ONLY) —

3 Purge Line (CA Models ONLY) —

4 Purge Valve (CA Models ONLY) —

5 Screw, Fuel Pump — M5 x 0.8x 16 (QTY.10) 43 in-lbs (4.8 Nm)

6 Fuel Pump —

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Fuel Tank

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Fuel Cap— M5 x 0.8 x 25 (QTY.4) 43 in-lbs (4.8 Nm)
2 Fuel Cap –

3 Adapter, Vent –

4 Isolator, Tank –
5 Fuel Pump –

6 Screw, Fuel Pump 43 in-lbs (4.8 Nm)

7 Assembly, Tank Mount –

8 Screw, Fuel Tank — M8 x 1.25 x 16 (QTY.4) 18 ft-lbs (24.4 Nm)

9 Screw, Tank Mount Assembly— M6 x 1.0 x 10 7 ft-lbs (9.5 Nm)
(QTY.4)

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Air Box

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Air Filter 24 in-lbs (2.7 Nm)
2 Filter, Air –
3 Airbox Assembly –

4 Hose, Breather Engine –

5 Clamp, Worm Drive –

6 Seal, Airbox Frame –

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Sensors - Powertrain Management

NUMBER SENSOR / LOCATION TORQUE (IF APPLICABLE)

1 TMAP - (Temperature / Manifold Absolute Pressure) Sensor - 25 in-lbs (2.8 Nm)
Located on the left side of the intake manifold
2 Ignition coils - Located in the top center of the valve covers 89 in-lbs (10 Nm)
3 ECM (Engine Control Module) - Located under the driver —
seat on the right side of the battery.
4 Fuse Box - Located under the driver seat. NOTE: Master 40 —
Amp Fuse Holder located behind battery box
5 Fuel Injectors - Located at the cylinder head intake ports —

6 Canister Purge Valve (CA models only) -Located below the —

battery box
7 Oil Pressure Switch - Located at the front of the LH engine 89 in-lbs (10 Nm)
case
8 Gear Position Switch - Located inside the drive sprocket 25 in-lbs (2.8 Nm)
cover, below the drive sprocket
9 Oxygen Sensor, Rear - Located on the rear head pipe 14 ft-lbs (19.0 Nm)
10 Side Stand Switch - Located behind the side stand hinge 60 in-lbs (6.8 Nm)
11 CPS (Crank Position Sensor) - Located on the left side of the 89 in-lbs (10 Nm)
engine forward of the drive sprocket.
12 Oxygen Sensor, Front - Located on the front head pipe 14 ft-lbs (19.0 Nm)

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NUMBER SENSOR / LOCATION TORQUE (IF APPLICABLE)

13 Vehicle Speed Sensor - Located on the top rear of the 89 in-lbs (10 Nm)
engine.
14 CTS (Coolant Temperature Sensor) -Located on the front face 17 ft-lbs (22.5 Nm)
of the rear cylinder head
15 ABS (Anti-Lock Brake) Module - Located in front of the vapor —
canister. INTERNATIONAL MODELS ONLY
16 Load / Tip Over Module - Located below battery box. —

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Exhaust System

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Nut, Muffler Hanger — M8 x 1.25 C10 (QTY.1) 19 ft-lbs (25.7 Nm)
2 Clamp, Exhaust (QTY.3) 40 ft-lbs (54.2 Nm)
3 Bolt, Muffler Hanger — M8 x 1.25 x 20 (QTY.3) 19 ft-lbs (25.7 Nm)
4 Nut — M16 x 1.5 (QTY.1) 50 ft-lbs (67.8 Nm)
5 Nut — M8 x 1.25 (QTY.4) 12 ft-lbs (16.3 Nm)
6 Oxygen Sensor (QTY.2) 14 ft-lbs (19.0 Nm)

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EXHAUST SERVICE 3. Remove the Bottom Muffler Bolt (3) and Nut (4).
Loosen lower muffler clamp & remove muffler.
Muffler Removal

WARNING

Engine and exhaust components get hot and remain

hot for a period of time after the engine is stopped.
Wear insulated protective clothing or wait for
components to cool sufficiently before working on
the machine.

1. Remove upper muffler Support Bolts (1) located on

the back side of mufflers.

Muffler Installation
1. Slide the Bottom Muffler into position so Bolt (3)
and Nut (4) can be installed. Slide Bottom Muffler
Clamp onto Head Pipe. Hand tighten.

2. Loosen the upper Muffler Clamp (2) between the

head pipe and upper muffler. Remove Upper
Muffler.

2. Slide the Top Muffler into position. Install Top

Muffler Support Bolts (1). Slide Upper Muffler
Clamp onto Head Pipe. Hand tighten.

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3. Torque Top and Bottom Support Bolts to 3. Cut zip tie located underneath radiator and
specification. disconnect front Oxygen Sensor (2).

Support Bolts: 19 ft-lbs (25.7 Nm)

4. Torque upper and lower Muffler Clamps (2) to

specification.

4. Remove two Rear Head Pipe Nuts (3).

Muffler Clamps: 40 ft-lbs (54.2 Nm)

Head Pipe Removal

5. Loosen Front to Rear Head Pipe Clamp (4).
1. Remove mufflers. See Muffler Removal, page 5.14.
2. Disconnect rear Oxygen Sensor (1).

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6. Remove two Front Head Pipe Nuts (5). Head Pipe Installation
1. Install new exhaust Gaskets (7) on front and rear
exhaust tube.

7. Remove head pipe to bracket fastener (6).

2. Connect Front Oxygen Sensor (2).

8. Remove rear exhaust tube from engine bolts first,

then swing the Head Pipe assembly forward
allowing room to remove front Head Pipe from the
engine. NOTE: Install new zip tie securing Front
Exhaust Sensor to frame
9. Remove old exhaust Gaskets (7) from front and
rear exhaust tube.
3. Install Front Head Pipe to engine and secure Head
Pipe Nuts (5).

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4. Install Rear Head Pipe to engine and secure with
two Head Pipe Nuts (3).

8. Torque fittings to specifications.

5. Connect Rear Oxygen Sensor (1).

5
Head Pipe Nuts:12 ft lbs (16.2 Nm)
Muffler Clamps: 40 ft-lbs (54.2 Nm)
Head Pipe to Bracket Screw: 12 ft lbs (16.2 Nm)

6. Tighten Front to Read Head Pipe clamp (4).

7. Install head pipe to bracket fastener (6).

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AIR CLEANER SERVICE
Air Box Removal
1. Place a suitable jack under motorcycle frame.

7. Disconnect the breather hoses (6) from the airbox

fitting and lift the back of the airbox to remove.

2. Remove seat. See Seat Removal. Seat Removal /

Installation, page 3.7
3. Remove fuel tank. See Fuel Tank Removal. Fuel
Tank Removal, page 5.21
4. Remove the two bolts (1), two nuts (3) and bolt (2)
retaining the right frame tube (4).

Air Box Installation

1. Connect the breather hoses (6) to the airbox fitting
and slide the front of the airbox in place.

5. Remove both frame tubes.

6. Loosen the clamp (5) securing the airbox to the air
inlet boot.

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2. Tighten the clamp (5) securing the airbox to the
air inlet boot.

3. Install both frame tubes.

4. Install the two bolts (1), two nuts (3) and bolt (2) 5
retaining the right frame tube (4).

Items 1 and 3:35 ft lbs (47.4 Nm)

Item 2:19 ft lbs (25.7 Nm)

5. Install fuel tank. See Fuel Tank Installation. Fuel

Tank Installation, page 5.26
6. Install seat. See Seat Installation. Seat Removal /
Installation, page 3.7

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FUEL DELIVERY SERVICE 9. Torque the intake manifold clamps and boots to
specification.
Intake Manifold, Removal / Installation
1. Place a suitable jack under motorcycle frame.

Intake Manifold Clamps: 20 in-lbs (2.3 Nm)

Intake Manifold Boots: 22 ft-lbs (30.0 Nm)

Fuel Pump Pressure Inspection

2. Remove the seat. See Seat Removal / Installation, WARNING

page 3.7
3. Remove the fuel tank. See Fuel Tank Removal, Gasoline is extremely flammable. Work in a well
page 5.21. ventilated area. Open flames, sparks and cigarettes
must be kept away from gasoline. KEEP GASOLINE
4. Remove the air box / throttle body assembly. See OUT OF THE REACH OF CHILDREN!
Air Box Removal, page .
5. Remove the fuel injectors and fuel rail assembly.
See Fuel Injector, Removal / Installation, page CAUTION
5.43.
6. Loosen the two clamps (1) securing the intake Wear safety glasses or a face shield when working
manifold to the rubber boots at the front and rear around the fuel system to protect your eyes.
cylinders.
1. Depressurize fuel system and disconnect fuel line
at fuel rail. See Fuel System Depressurization,
page 5.21 .
2. Install fuel pressure gauge PU-43506– A and fuel
pressure gauge adapter PV-48656.
3. Start engine and record fuel pressure (or press the
power switch ON and cycle the Engine Stop switch
to read pressure when pump cycles for 2-3
seconds).

Minimum Fuel pressure 3.51 BAR (351 kPa) (51

psi)

7. Remove the two bolts securing the intake boots to

the cylinder head.
8. INSTALLATION is performed by reversing the
removal procedure.

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4. Turn ignition switch off. Disconnect gauge adapter 2. Squeeze both release buttons (one on each side of
and re-connect fuel line ( Fuel Tank Installation, fitting) and hold. Gently slide fitting straight off
page 5.26). fuel rail.

FUEL PRESSURE TROUBLESHOOTING

FUEL PRESSURE TOO FUEL PRESSURE TOO
LOW: INSPECT HIGH: INSPECT
* Low fuel level (add * Plugged fuel return
fuel) (in tank on pressure
* Pump not running regulator)
(Fuel pump or circuit * Pressure regulator
malfunction) malfunction (located
* Restricted fitting, fuel on pump).
supply line, or gauge
adapter hose
* Fuel line kinked or
restricted (from tank
fitting to rail)
* Fuel line leaking 3. Cover fuel fittings to keep debris out.
(leaking air in or fuel
out)
5
* Vent restriction Fuel Tank Removal
* Plugged fuel pickup
filter (located in fuel
tank) WARNING
* Pressure regulator
malfunction (located on
pump) Allow engine and exhaust to cool completely before
*Fuel pump malfunction disconnecting fuel line or removing tank. Protect fuel
(Pump should run for tank finish when removing, storing, and installing
about 2–3 seconds the tank.
instant that the key
switch and Engine Stop Be prepared to place the fuel tank in a secure location
switch are turned ON. with a drain pan positioned to catch any fuel that may
leak or drip from disconnected hoses or fittings.
1. Remove seat. See Seat Removal / Installation,
Fuel System Depressurization page 3.7.
2. Remove the fuel tank filler pad.

WARNING

Allow engine and exhaust to cool completely before

disconnecting fuel line or removing tank. Wear eye
protection.

1. Wrap a clean shop towel around fuel line fitting

(1).

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3. Remove the four bolts (1) at the rear of the fuel 5. Place the handlebars in the straight ahead
tank. position. Place a protective cloth on front of the
fuel tank to prevent damage. Lift the rear of the
tank approximately 2”. to access the fuel supply
line connector (4) and fuel pump electrical
connector (5).

4. Disconnect the fuel tank vent line (2) and fuel cap
recess drain line (3) at the rear of fuel tank.

6. Support the tank and disconnect fuel pump

electrical connector.
7. Wrap a shop towel around the fuel fitting and
disconnect the fuel supply line connector from the
fuel pump by squeezing release tabs on both sides
of the fitting.
8. Install Special Tool PV-50567 Fuel Tank Fitting Plug
onto the fuel pump fitting to the protect the fitting
and prevent fuel from seeping out of the tank.

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9. Lift the rear of the fuel tank and slide rearward to 2. Disconnect but do not remove fuel hoses (1).
release from the front isolators.

3. Remove tank mount assembly by removing four

bolts (2).
10. Lift the fuel tank off the motorcycle and place on a
suitable flat surface to prevent tank damage. 5
Fuel Pump Removal

WARNING

Replace all mounting screws and pump seal O-ring

any time pump is removed for service or fuel filter
maintenance. Do not kink or bend fuel pickup hose
upon removal. Review gasoline warnings outlined in
the beginning of this chapter. See SERVICE
PRECAUTIONS, page 5.5.

4. Remove fuel pump bolts (3).

CAUTION

Be careful when performing this procedure to avoid

damaging the fuel pump, electrical wiring, or hoses.
Always inspect wires and hoses closely for damage
after removing the fuel pump.

NOTE: The fuel filter element can only be

replaced one time at the specified 50,000 mile
(80,467 km) service interval.

1. Remove the fuel tank. Fuel Tank Removal, page

5.21.

5. Lift the fuel pump assembly out of the retaining

bracket and carefully remove fuel tank.

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Fuel Filter Replacement 8. Install new filter / motor cage assembly to the
pump assembly.
IMPORTANT: The fuel filter element should be
replaced every 25,000 miles (40,234 km). 9. Reinstall the retaining ring and seat with a small
deep well socket.
Removal 10. Remove seal from outlet of fuel pump and replace
1. Remove fuel pump from the fuel tank. See Fuel with new seal.
Pump Removal, page 5.23. 11. Install the pump cage onto the flange assembly. Be
2. Insert a small screwdriver and gently pry the careful not to severely bend or kink wire exiting
retaining tabs (Item 1) to release it from the snap the thermistor.
detent on both sides of the pump cage. 12. Connect the fuel pump connector.
13. Install the pump assembly into the fuel tank.

Fuel Tank Vent Inspection

1. Refer to Chapter 2 for tank vent inspection and
hose routing information. See Fuel Tank Vent
Inspection (49 State), page 2.25.

Fuel Pump Installation

1. Install fuel pump assembly into bottom of gas tank.
Insert fuel filter (4) first before pushing the rest of
the fuel pump into fuel tank. Verify the filter is
properly nested in the tank cavity before installing
the pump bolts at the bottom of the tank and not
hung up on any internal tank geometry which
would prevent the filter from being properly
3. Slide the pump and filter assembly (Item 3) to positioned..
release it from the flange assembly.
4. Disconnect the fuel pump electrical connector
(Item 2).
5. Remove the filter element retaining ring (Item 4).

6. Insert a large flat blade screwdriver and pry near

the filter tee fitting to separate the filter element
assembly from the motor. Use caution not to break
or permanently deform the plastic.
7. Remove the filter element and seal. Remove motor
from remaining assembly.

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2. Install fuel pump bolts (3) and tighten to 3. Install tank mount assembly using four bolts (2).
specification following the torque sequence Torque to specification.
shown.

5
Fuel Tank Mount Assembly Bolts: 7 ft-lbs (9.5 Nm)

4. Connect fuel hoses (1).

5. Install the fuel tank. See Fuel Tank Installation,

page 5.26
6. Prime the fuel system and verify fuel pump
operation. See Priming the Fuel System, page
Fuel Pump Bolts: 43 in-lbs (4.8 Nm) 5.29.

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Fuel Tank Installation 4. Connect the fuel supply line to the fuel pump (4)
1. Secure the handlebars in the straight ahead and fuel pump electrical connector (5) to the fuel
position. tank.

2. Apply alcohol, soapy water solution, or rubber

lubricant to the isolators and carefully lower the
fuel tank onto the tank isolators.

5. Verify the fuel line is routed and slide tank forward

until fully seated on forward isolators.
6. Connect the fuel tank vent line (2) and the fuel cap
3. Remove Special Tool PV-50567 Fuel Tank Fitting recess drain line (3). Install rubber tank filler
Plug from the fuel pump. panel prior to fully lowering the rear of the tank
down into place.

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7. Install the fuel tank mounting bolts (1) and torque can be tested using a digital multimeter. Resistance
to specification. readings obtained with tank installed will be in
proportion to the amount of fuel in the tank (the
temperature of the thermistor). The sensor wires are
located in the 4-pin connector with the fuel pump
wires, at rear of fuel tank.
If fuel level readings are inaccurate when the
motorcycle is powered up, or if the fuel gauge isn’t
indicating fuel level at all, perform the following test
and refer to resistance values located at the end of this
procedure.
1. Remove the fuel pump. See Fuel Pump Removal,
page 5.23.
2. Set multimeter to measure resistance. Attach
suitable test probe adaptors to meter leads (from
kit PV-43526).
3. On the fuel pump side of the connector, measure
resistance across the sensor and compare to the
table. 5
Fuel Tank Mounting Bolts: 18 ft-lbs (24.4 Nm)

Fuel Level Sensor Resistance Test

OVERVIEW OF OPERATION: The fuel level sensor (A)
is located inside the fuel tank on the fuel pump.

ID COLOR ASSIGN-
MENT
1 White Fuel Pump (-)
2 Yellow Fuel Pump (+)
3 Black Thermistor (-)
4 Red Thermistor (+)

SENSOR APPROXIMATE
TEMPERATURE RESISTANCE LIMITS
The sensor is a thermistor with inverse temperature 23° C 1000 ± 15% Ω
characteristics (as temperature increases, sensor
resistance decreases). When the fuel level falls below 50° C 190 ± 15% Ω
the sensor, temperature increases, lowering the
resistance to provide a ground path for the Low Fuel
lamp bulb which is powered when the ignition key is
on. The lamp will start to glow dimly when the fuel
level falls below the sensor, and will brighten as the
fuel level continues to fall (low resistance).
With fuel tank empty and key ON the lamp will take
approximately 30 seconds to 1 minute to reach full
intensity (depending upon temperature). The sensor

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Fuel Pump Supply Voltage Test Fuel Pump Current Draw Test
Before performing this test, verify that battery is fully
charged and in good operating condition. NOTE: Fuel pump current draw is an indicator of
pump condition. Perform draw test if fuel pump
1. Remove the seat assembly. (See Seat Removal) operation is suspect, or if fuel pump fuse is found
2. Remove the fuel tank assembly. (See Fuel Tank open (blown).
Removal).
3. Disconnect the fuel pump / level sensor electrical NOTE: When meter leads are inserted the pump
connector. will run, and current draw will be displayed on the
meter, even with key and stop switch off. Fuel tank
4. Connect meter across terminals 2 & 4 on the wire must be completely installed and have enough fuel
harness side of connector. in it to cover the fuel pickup screens for an
accurate test.

1. Remove the seat to access fuse box. Remove fuse

box cover (1).

5. Turn the ignition switch to the “ON” position to

power up the motorcycle electrical system.
6. Turn Engine Stop switch to RUN and read DC
voltage on meter when switch is first turned on.
Voltage reading should be close to battery voltage
for 2-3 seconds after switching Engine Stop switch
to RUN.
2. Remove Fuel Pump Relay (2) by pulling straight
7. If low or no voltage is delivered to the fuel pump, upward.
verify ground wire (Pin 2, BK/DG) has good
continuity to battery (-) post.
8. If ground is OK, check Gray wire from fuel pump
relay terminal B4 to ECM Pin #142 . The Gray wire
receives a momentary ground from the ECM (for
2-3 seconds) and activates the fuel pump relay
which supplies power to the pump on the VT/YE
wire.
9. Trace both power and ground circuits to
determine fault if battery voltage is not present for
2-3 seconds after ignition switch and STOP / RUN
switch are turned on.
10. When a CPS signal is received by the ECM
(engine is cranking or running) the ECM maintains
the ground on Pin # 142 (Gray wire), keeping the
pump powered. 3. Set meter to DC Amps. Be sure red meter lead is in
the 10A jack, and black meter lead is in common
(-) jack.

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4. Insert red meter lead in pin socket B5 (7) and Priming the Fuel System
black meter lead in pin socket A4 (4) of relay Prime procedure should be performed:
block.
• If a new fuel pump is installed or if tank is run
completely dry.
• Whenever fuel system is serviced (fuel line is
disconnected).
• Whenever battery disconnected.
1. Fill the fuel tank.
2. Turn Engine Stop switch OFF.
3. Turn the ignition switch to ON.
4. Turn stop switch to RUN.
5. Allow switch to remain in RUN position until pump
stops running (about 2-3 seconds).
6. Turn stop switch OFF.
5. Read fuel pump current draw on meter and
compare to specification. 7. Turn the ignition switch to OFF. 5
6. Inspect fuel pump circuit wiring or replace fuel 8. WAIT approximately 10 seconds.
pump if current draw exceeds specification. 9. Repeat Steps 4-8 about 4 times to complete the
priming procedure.
SPECIFICATION: Fuel Pump Current Draw
Maximum: 6 DC Amps NOTE: Fuel level in tank must be high enough
to submerge pickup screen on fuel pump.

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EFI SYSTEM COMPONENTS switch is turned ON to pressurize the system for start-
up.
Fuel Injection System - Overview Of The fuel injectors inject fuel when they are grounded
Operation by drivers inside the ECM. The duration of an injector
The Electronic Fuel Injection (EFI) system functions to pulse (length of time the injector circuit is grounded)
provide the engine with precisely metered fuel under is controlled by the ECM. Pulse duration determines
varying loads and conditions. the amount of fuel delivered to the engine (longer
cycles = more fuel). The ECM selects the correct fuel
The Engine Control Module or “ECM”, is located injector pulse by calculating the airflow from the MAP
beneath the battery box. It is programmed to provide sensor measurement and referencing a three
the correct fuel/air mixture and ignition timing based dimensional “map” for the desired air-to-fuel ratio
on several sensor input signals (engine load, temp, (AFR). The ECM calculates an injection time based on
altitude, manifold pressure etc.). The ECM also the measured airflow and desired AFR.
provides grounds or voltage to other EFI related
circuits of the electrical and fuel delivery systems. Although TMAP and engine RPM are the most
influential inputs for selecting a map reference point,
An Electronic Throttle Control (ETC) system takes the the ECM also evaluates feedback from minor sensors
place of a conventional, cable-operated throttle body. in the system, to obtain a more accurate “picture” of
The ETC controls throttle blade angle and provides the fuel needs at any given moment.
rate-of-change feedback to the ECM.
The fuel control system is closed loop. When the
The ETC also serves as a plausibility check for the engine is at a warm idle and typical cruising engine
TMAP sensor. The MAP portion of the TMAP sensor is speeds and loads, the ECM will operate in “closed
the primary air flow and load sensing device. loop fuel control” mode. The oxygen sensors in each
An electric fuel pump, mounted inside the fuel tank headpipe will provide feedback to the ECM and the
supplies fuel pressure to the injectors continuously injection time will be adjusted for each cylinder to
when the engine is running or cranking. A pressure achieve the target AFR.
regulator incorporated on the pump keeps fuel The locations of sensors and other EFI system related
pressure steady at approximately 4 Bar (400 kPa / 58 components are outlined in this chapter. See Sensors -
PSI). The fuel pump cycles “ON” for 2-3 seconds when Powertrain Management, page 5.11.
the motorcycle is powered up and the Engine Stop

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ECM Connector Map

PIN COLOR FUNCTION PIN COLOR FUNCTION

ECM 1 ECM 2
1 - NOT USED 1 BK CPS NEGATIVE SIGNAL

2 - NOT USED 2 GY/DB FRONT HEATED O2 SENSOR SIGNAL 2

3 YE/BK PPS 2 RETURN 3 OG/YE TPS 1 OUTPUT

4 BN/GN TMAP SENSOR RETURN 4 BN/YE TIPOVER SENSOR SIGNAL RETURN

5 BN/WH TPS SIGNAL RETURN 5 BG/WH REAR HEATED O2 SENSOR RETURN 2

6 WH/BK PPS 1 RETURN 6 BK/BU FUEL LEVEL SENSOR SIGNAL RETURN

7 YE/WH START SWITCH OUTPUT (TO ECM) 7 BG REAR HEATED O2 SENSOR RETURN 1

8 VT/OG RIGHT TURN SIGNAL SWITCH OUTPUT 8 OG/BK ENGINE COOLANT TEMP SENSOR RETURN
(TO ECM)

9 - NOT USED 9 - NOT USED

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PIN COLOR FUNCTION PIN COLOR FUNCTION

ECM 1 ECM 2
10 - NOT USED 10 WH/RD PPS 1 - +5 VOLT REF

11 YE/GN PPS 2 OUTPUT 11 - NOT USED

12 - NOT USED 12 DB LEFT FRONT TS LAMP OUTPUT

13 - NOT USED 13 RD CPS SIGNAL POSITIVE

14 - NOT USED 14 - NOT USED

15 GY/BK ENGINE RELAY CNTL 15 OG/DB ENGINE COOLANT TEMP SENSOR SIGNAL OUTPUT

16 PK ECM SWITCHED POWER INPUT 16 - NOT USED

17 - NOT USED 17 BK/YE BRAKE PRESSURE SWITCH OUTPUT (TO ECM)

18 - NOT USED 18 OG/WH TIPOVER SENSOR SIGNAL

19 DB/YE CLUTCH SWT OUTPUT (TO ECM) 19 OG/BN TMAP SENSOR SIGNAL OUTPUT

20 VT/WH LEFT TURN SIGNAL SWITCH OUTPUT (TO 20 VT/RD TPS 2 SIGNAL
ECM)

21 WH/GN PPS SIGNAL 1 OUTPUT 21 - NOT USED

22 - NOT USED 22 - NOT USED

23 RD/BK RUN / STOP SWITCH (ECM INPUT) 23 BN/PK TMAP SENSOR B+ POWER

24 YE/VT FRONT BRK SWT OUTPUT (TO ECM) 24 DB/RD RIGHT FRONT TS LAMP OUTPUT

25 YE/RD PPS 2 - 5 VOLT REF 25 - NOT USED

26 BN/GN TIPOVER SNR - 5 VOLT REF 26 - NOT USED

27 - NOT USED 27 OG/DG TMAP INTAKE AIR TEMP SENSOR SIGNAL OUTPUT

28 - NOT USED 28 - NOT USED

29 - NOT USED 29 - NOT USED

30 - NOT USED 30 GY/RD REAR HEATED O2 SENSOR OUTPUT 1

31 BK/OG COOLING FAN RELAY CONTROL 31 - NOT USED

32 YE CAN HIGH 32 DG/BN VEHICLE SPEED SENSOR OUTPUT

33 - NOT USED 33 BK/PK NEUTRAL SWITCH OUTPUT (TO ECM)

34 - NOT USED 34 - NOT USED

35 - NOT USED 35 DB/BK CANISTER PURGE VALVE (CPV) CONTROL

36 - NOT USED 36 DB LEFT REAR TS LAMP GROUND OUTPUT

37 - NOT USED 37 - NOT USED

38 BN/DB TPS - +3.3 VOLT REF 38 - NOT USED

39 - NOT USED 39 GY/YE FRONT HEATED O2 SENSOR CONTROL 2

40 DG/DB HEADLIGHT RELAY CONTROL 40 SECONDARY AIR GROUND OUTPUT

41 WH/YE STARTER SOLENOID RELAY CNTL 41 - NOT USED

42 GY FUEL PUMP RELAY CNTL 42 - NOT USED

43 - NOT USED 43 WH/GY FRONT FUEL INJECTOR DRIVER 2

44 DG CAN LOW 44 WH/DB REAR FUEL INJECTOR DRIVER 1

45 - NOT USED 45 - NOT USED

46 - NOT USED 46 GY/WH REAR HEATED O2 SENSOR CONTROL 1

47 - NOT USED 47 BK/WH ECM ELECTRONIC GROUND

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

49 - NOT USED 49 - NOT USED

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PIN COLOR FUNCTION PIN COLOR FUNCTION

ECM 1 ECM 2
50 - NOT USED 50 BK/WH ECM GROUND 1

51 PK/DB STOP LAMP POWER OUTPUT 51 PK/RD ETC MOTOR (+)

52 - NOT USED 52 YE ETC MOTOR (-)

53 BK/WH ECM GROUND 2 53 - NOT USED

54 BK/WH ECM GROUND 3 54 WH FRONT COIL SIGNAL 2

55 VT/PK ECM SWITCHED POWER 3 55 - NOT USED

56 VT-PK ECM SWITCHED PWR 2 56 WH REAR COIL SIGNAL 1

Diagnostic Trouble Codes

P-CODE SPN FMI COMPONENT CONDITION MIL

P0123 3 Voltage Too High ON

P0122 4 Voltage Too Low ON

P0121 2 Signal Out of Range (Not Plausible) ON 5

P1123 51 0 Throttle Position Sensor 1 Voltage Above Critical Level ON

P1122 1 Voltage Below Critical Level ON

P0120 10 Abnormal Rate of Change ON

P1120 13 Calibration / Adaption Failure ON

P0500 ON
0 Vehicle Speed Too High
C1057 ON
P0502 1 Vehicle Speed Too Low ON

P0503 ON
2 Data Erratic or Intermittent (or Missing)
C1058 84 Vehicle Speed Signal ON
P0501 8 Sensor Frequency Outside Normal Range ON

P160A 9 Abnormal Update Rate ON

C1069 ON
19 Received Vehicle Speed has error
P106B ON
P0463 3 Voltage Too High ON

P0462 4 Voltage Too Low ON

P1462 96 16 Fuel Level Signal Above Normal Operating Range ON

P1463 18 Below Normal Operating Range ON

P0461 2 Signal Fault ON

P1527 3 Pressure Too High ON

P1526 98 4 Engine Oil Level Sensor Switch Pressure Too Low ON

P250F 17 Oil Level Low OFF
P0108 3 Voltage Too High ON

P0107 4 Manifold Absolute Pressure Voltage Too Low ON

102
Sensor
P0106 2 Signal Out of Range ON

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P-CODE SPN FMI COMPONENT CONDITION MIL

P0109 10 Abnormal Rate of Change ON

P1106 7 Pneumatic Fault ON

P0113 3 Voltage Too High ON

P0112 4 Voltage Too Low ON

105 Intake Air Temperature Sensor
P0114 10 Abnormal Rate of Change ON

P0111 2 Signal Out of Range ON

P0118 3 Voltage Too High ON

P0117 4 Voltage Too Low ON

P0116 2 Signal Out of Range ON

P0119 10 Abnormal Rate of Change ON

110 Engine Temperature Sensor
P0217 16 Temperature Too High OFF

P1217 0 Engine Overheat Shutdown OFF

P1116 15 Temperature Above Normal Range OFF

P0128 17 Temperature Too Low ON

P0563 OFF
3 Voltage Too High
C1063 ON
P0562 OFF
4 Voltage Too Low
C1064 ON
System Power (Battery
168 Potential / Power Input)
P1562 0 Voltage Above Critical Level ON

P1564 16 Voltage Above Warning Level ON

P1563 1 Voltage Below Critical Level ON

P1565 18 Voltage Below Warning Level OFF

P0219 0 Speed Exceeded Max Limit ON

C1059 0 Engine Speed Too High OFF

C1060 1 Engine Speed Too Low OFF

C1061 190 2 Engine Speed Data Erratic or Intermittent (or Missing) OFF

P1219 7 CVT Threshold Exceeded ON

P121C 31 Error in Engine Speed Computation ON

C1066 19 Received Engine Speed has Error OFF

P0917 3 Voltage Too High ON

P0916 4 Voltage Too Low ON

523 Gear Sensor Signal
P1914 9 Abnormal Update Rate ON

P0914 2 Signal Fault ON

P0704 598 2 Clutch Switch Signal Signal Fault ON

P1602 628 12 ECU Memory EEPROM Read / Write Failure ON

P0336 8 Circuit Fault ON

636 Crankshaft Position Sensor
P0335 2 Plausibility Fault ON

P0261 651 5 Injector 1 (Front) Driver Circuit Open/Grounded ON

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P-CODE SPN FMI COMPONENT CONDITION MIL

P0262 3 Driver Circuit Short to B+ ON
P1262 4 Driver Circuit Grounded ON
P0264 5 Driver Circuit Open/Grounded ON

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

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

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

P0616 4 Driver Circuit Grounded ON
P0327 731 4 Knock Sensor 1 Voltage Too Low ON

C1030 5 Open / Short ON

904 Wheel Speed Sensor (Front)
C1031 2 Input Abnormal / Signal Failure ON

C103D 2 Plausibility Fault ON

C113D 3 Short to B+ ON
C123D 4 Open/Short to GND ON
5
907 Wheel Speed Sensor (Rear)
C1036 5 Open/Short ON

C133D 8 Abnormal Frequency ON

C143D 14 Incorrect Sensor / Improper Mounting ON

C1045 1023 5 Trip Sudden Decelerations Open / Short ON

P1481 5 Driver Circuit Open/Grounded ON

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

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

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

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

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

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

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

P0231 4 Driver Circuit Grounded ON
P1714 5 Driver Circuit Open/Grounded OFF
Left Turn Indicator Driver
P1715 2367 3 Driver Circuit Short to B+ OFF
Circuit
P1716 4 Driver Circuit Grounded OFF
P1710 5 Driver Circuit Open/Grounded OFF
Right Turn Indicator Driver
P1711 2369 3 Driver Circuit Short to B+ OFF
Circuit
P1712 4 Driver Circuit Grounded OFF
P0130 2 Signal Fault ON

P113A 3056 12 Oxygen Sensor 1 (Front) Bad Component ON

P0132 3 Voltage High ON

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P-CODE SPN FMI COMPONENT CONDITION MIL

P0131 4 Voltage Low ON

P16A2 3 Voltage Too High ON

P16A1 4 Voltage Too Low ON

P16A3 0 Voltage Above Critical Level ON

3597 ECU Output Supply Voltage 1
P16A5 16 Voltage Above Warning Level ON

P16A6 1 Voltage Below Critical Level ON

P16A7 18 Voltage Below Warning Level ON

P16A9 3 Voltage Too High ON

P16A8 4 Voltage Too Low ON

P16AA 0 Voltage Above Critical Level ON

3598 ECU Output Supply Voltage 2
P16AB 16 Voltage Above Warning Level ON

P16AC 1 Voltage Below Critical Level ON

P16AD 18 Voltage Below Warning Level ON

P17AA 3 Voltage Too High ON

P17AB 4 Voltage Too Low ON

P17AC 0 Voltage Above Critical Level ON

3599 ECU Output Supply Voltage 3
P17AD 16 Voltage Above Warning Level ON

P17AE 1 Voltage Below Critical Level ON

P17AF 18 Voltage Below Warning Level ON

ETC Accelerator Position

P1135 65613 2 Sensor Outputs 1 & 2 Correlation Fault ON
Correlation
P0223 3 Voltage Too High ON

P0222 4 Voltage Too Low ON

P1223 0 Voltage Above Critical Level ON

P1222 520198 1 Throttle Position Sensor 2 Voltage Below Critical Level ON

P0221 2 Signal Out of Range (Not Plausible) ON

P0220 10 Abnormal Rate of Change ON

P1220 13 Calibration / Adaption Failure ON

P181C 31 Condition Exists (engine disabled due to extended ON

520267 Kickstand Switch kickstand)

P1501 2 Signal Fault ON

P1503 3 Voltage High ON

520200 Tipover Sensor
P1502 4 Voltage Low ON

P1504 14 Condition Exists (tip over condition detected) ON

P0444 5 Driver Circuit Open/Grounded ON

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

P0445 4 Driver Circuit Grounded ON
P0171 520204 17 Fuel Correction System Too Lean 1 (Front) (Pre) ON

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P-CODE SPN FMI COMPONENT CONDITION MIL

P0172 15 System Too Rich 1 (Front) (Pre) ON

P0174 17 System Too Lean 2 (Rear) (Post) ON

520205
P0175 15 System Too Rich 2 (Rear) (Post) ON

P1611 5 Driver Circuit Open/Grounded ON

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

P1613 4 Driver Circuit Grounded ON
P0135 2 Plausibility Fault ON

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

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

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

520210 (rear)
P0038 3 Driver Circuit Short to B+ ON
P0037 4 Driver Circuit Grounded ON
5
C1022 520250 7 ABS Pulsar (front) COG Chip ON

C1023 520251 7 ABS Pulsar (rear) COG Chip ON

C1024 520252 5 ABS Solenoid (RRI) Open / Short ON

C1025 520253 5 ABS Solenoid (RRO) Open / Short ON

C1026 520254 5 ABS Solenoid (FFI) Open/Short ON

C1027 520255 5 ABS Solenoid (FFO) Open/Short ON

C1028 520256 5 ABS Solenoid (RFI) Open/Short ON

C1029 520257 5 ABS Solenoid (RFO) Open/Short ON

C1032 520258 11 ABS Actuator (front) Wheel Lock (or VSS failure) ABS On ON

C103A 520313 11 ABS Actuator (front) Wheel Lock (or VSS failure) ABS Off ON

C1033 520259 11 ABS Actuator (rear) Wheel Lock (or VSS failure) ABS On ON

C103B 520314 11 ABS Actuator (rear) Wheel Lock (or VSS failure) ABS Off ON

C0020 8 Motor Lock ON

C1020 520260 3 ABS Motor Off Stick ON
C1021 4 On Stick ON
C1034 520261 7 ABS Fail Safe Relay On/Off Stick ON

C1038 4 Drop ON
520262 ABS Source Voltage
C1039 3 Raise ON
C1040 520263 31 ABS Tire Irregular Tire Size ON

C1041 520264 12 ABS ECU ECU Error ON

C1042 520265 7 ABS Module Incomplete Evacuation and Fill ON

Accelerator Position/Brake
P150A 520275 31 Condition Exists ON
Position Interaction
P0228 3 Voltage Too High ON
91 Accelerator Position 1
P0227 4 Voltage Too Low ON

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P-CODE SPN FMI COMPONENT CONDITION MIL

P0225 2 Not Plausible ON
P1228 3 Voltage Too High ON

P1227 29 4 Accelerator Position 2 Voltage Too Low ON

P1225 2 Not Plausible ON

P150B 12 Throttle Position Sensor (1 or 2 Neither Position Sensor Passed Test ON
520276 Indeterminable)
P150C 2 Position Sensor Correlation Fault (One okay, one failed) ON

P150D 3 Maximum ON
P150E 4 Minimum ON
P151A 2 Throttle Body Control - Power Not Plausible ON
520277 Stage
P151B 8 Signal Error ON

P153F 31 Deactivated power stages due to 5V sensor supply error ON

31 Throttle Body Control - Return Condition Exists

P151C 520278 Spring Check Failed ON

31 Throttle Body Control - Condition Exists

P151D 520279 Adaption Aborted ON

31 Throttle Body Control - Limp Condition Exists

P151E 520280 ON
Home Position Check Failed
31 Throttle Body Control - Condition Exists
P15A 520281 Mechanical Stop Adaptation ON
Failure
P152B 520282 31 Throttle Body Control Condition Exists ON

P152C 3 Maximum ON
P152D 520283 4 Throttle Body Control Minimum ON
P152F 2 Outside of Pedal Range(Level 1) ON

P152E 31 Throttle Body Control - Position Condition Exists ON

520284
Deviation Fault
P153E 2 Brake Switch (1 or 2 Brake Switch Correlation Fault ON
520285 Indeterminable)

P1540 520286 31 ECU Monitoring Error Condition Exists ON

P1541 520287 31 ECU Monitoring Error (Level 3) Condition Exists ON

P1542 31 ECU Monitoring of Injection Condition Exists ON

520288 Cut Off(Level 1)

P1543 31 ECU Monitoring of Injection Condition Exists ON

520289 Cut Off(Level 2)

P1544 31 Controller Option Settings not Condition Exists ON

520290 Programmed

C1075 5 Open Circuit / Short to B+ ON

520291 Left Fog Lamp
C1076 6 Grounded Circuit ON
C1078 5 Open Circuit / Short to B+ ON
520292 Right Fog Lamp
C1079 6 Grounded Circuit ON
P153D 527 31 Cruise Control Panel Switches Switch/Switches Stuck ON
P1590 596 31 Cruise Control Enable Switch Switch Stuck ON
P1591 31 Cruise Control Set/Decel Switch Stuck ON
599
Switch

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P-CODE SPN FMI COMPONENT CONDITION MIL

P1592 31 Cruise Control Resume/Accel Switch Stuck ON
601
Switch
C107B 5 Open Circuit / Short to B+ ON
2350 Low Beam Lamp
C107C 6 Grounded Circuit ON
C107E 5 Open Circuit / Short to B+ ON
2348 High Beam Lamp
C107F 6 Grounded Circuit ON
C122A 5 Open Circuit / Short to B+ ON
520293 Horn
C122B 6 Grounded Circuit ON
P1075 5 Open Circuit ON

P1076 524083 3 Secondary Air Control Valve Shorted to Battery ON

P1077 4 Shorted to Ground ON

C1222 5 Open Circuit / Short to B+ ON
520294 Windshield Motor Driver
C1223 6 Grounded Circuit ON
C1225 520295 2 Windshield Motor Switch Both inputs are closed ON 5
C1125 520296 12 Accelerometer Bad Component ON

C1512 524046 31 Start Button Switch Stuck ON

C1530 520297 31 System On Button Switch Stuck ON

C1047 5 Open Circuit / Short to B+ ON

520298 Heated Grips
C1048 6 Grounded Circuit ON
C1226 5 Open Circuit / Short to B+ ON
520299 Power Lock Motor
C1227 6 Grounded Circuit ON
C1083 12 Battery Voltage too Low (Replace) OFF

C1084 520300 17 Tire Pressure Sensor (Front) Pressure to Low OFF

C1085 9 Abnormal Update Rate OFF

C1088 12 Battery Voltage too Low (Replace) OFF

C1089 520302 17 Tire Pressure Sensor (Rear) Pressure to Low OFF

C1090 9 Abnormal Update Rate OFF

P1633 520304 12 Key Fob Battery Voltage too Low (Replace) OFF

P1530 31 Throttle Body Control - Condition Exists ON

520305 requested throttle angle not
plausible

P1537 31 ECU Fault – Hardware Condition Exists ON

520311 Disruption

C1229 520312 31 Power Lock Motor Switch Switch Stuck ON

P1593 5 Open Circuit ON

P1594 520320 3 Brake Light Shorted to Battery ON

P1595 4 Shorted to Ground ON

P1596 5 Open Circuit ON

P1597 520321 3 Tail Light Shorted to Battery ON

P1598 4 Shorted to Ground ON

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P-CODE SPN FMI COMPONENT CONDITION MIL

P1599 3 Voltage Too High ON

P159A 520322 4 Front Brake Switch Voltage Too Low ON

P159B 2 Signal Fault ON

P159C 3 Voltage Too High ON

P159D 520323 4 Rear Brake Switch Voltage Too Low ON

P159E 2 Signal Fault ON

U1405 31 Cruise Control Input Message Counter not incremented ON

524080
Counter
U0405 31 Cruise Control Input Checksum does not match ON
524079
Checksum
P1062 5582 9 Static Roll Angle Abnormal Update Rate ON

P1063 9 Operator Switch Status Abnormal Update Rate ON

520329 (pOSS1)

P1064 13 Out of Calibration ON

520330 Immobilizer
P106A 9 Abnormal Update Rate ON

P1327 3 Voltage Too High ON

520331 Knock Sensor Positive Line
P1328 4 Voltage Too Low ON

P132A 3 Voltage Too High ON

520332 Knock Sensor Negative Line
P132B 4 Voltage Too Low ON

P1136 2 Signal Fault ON

P1139 12 Bad Component ON

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

P1138 4 Voltage Low ON

ECU Monitoring (Pedal Map

P1545 520336 31 Mismatch) Condition Exists ON

P2279 520338 31 Gross Air Leak Condition Exists ON

Data Valid But Above Normal Operating Range - Least
P116C 15 Severe Level (System Too Rich) ON
520342 Idle Fuel Correction Bank 1
Data Valid But Above Normal Operating Range - Least
P116D 17 Severe Level (System Too Lean) ON

Data Valid But Above Normal Operating Range - Least

P116E 15 Severe Level (System Too Rich) ON
520343 Idle Fuel Correction Bank 2
Data Valid But Below Normal Operating Range - Least
P116F 17 Severe Level (System Too Lean) ON

Data Valid But Above Normal Operating Range - Least

P0170 15 Severe Level (System Too Rich) ON
Adaptive Fuel Correction Bank
520344
1 Data Valid But Below Normal Operating Range - Least
P1170 17 Severe Level (System Too Lean) ON

Data Valid But Below Normal Operating Range - Least

P0173 15 Severe Level (System Too Rich) ON
Adaptive Fuel Correction Bank
520345
2 Data Valid But Below Normal Operating Range - Least
P1173 17 Severe Level (System Too Lean) ON

Upstream O2 Sensor Signals

P1416 52036 31 Swapped Condition Exits ON

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Sensor Diagnostics • Always use the appropriate test connector from

the Electrical Connector Test Adapter Kit (PV-
If a sensor fails or reads outside a “normal” range, a
43526) or an appropriate test probe that will not
“pre-programmed” (default) value is substituted by
damage (expand) the connector pin socket.
the ECM until sensor reading returns to normal.
• DO NOT attempt to use standard meter probes
Sensor values can be viewed in Digital Wrench® on
or other devices to probe connector pin sockets.
the “Sensor Data Grid Or Graphs” screen. Since the
this could expand a terminal socket or damage
sensor reading may either be actual feedback from
the connector, create a problem where none
the sensor OR a default value set by the ECM in the
existed before, and complicate the diagnostic
event of a fault in the sensor or wiring, it is important
process.
to verify the condition of the sensor.
• Sensor tests on the following pages can often be
The Malfunction Indicator Light (MIL) may or may not
performed at the sensor connector itself or at
illuminate to alert the rider of a possible problem,
the ECM connector based on accessibility of the
depending on which system fault has occurred. The
connector or wiring.
first step following illumination of the MIL is to perform
a visual inspection to see if a cause can be • If a sensor tests within the specified range (OK),
determined. then test the circuit wiring. This usually
Connect Digital Wrench® to see what codes are
originates at the ECM connectors, but may 5
include other connections.
present in memory, and focus your diagnostics on that
sensor and the related wiring for that circuit. Refer to
wiring diagrams and system break-out diagrams to
narrow a problem search.
ECM Connector Removal
1. To disconnect the two 56–pin ECM connectors:
If multiple codes are set, refer to the wiring diagram
and focus your efforts on wiring and connections • Locate the ECM connectors (1).
common to each of the sensors, such as a power
supply or common ground. Multiple sensor failure is
extremely unlikely.
Many sensor tests described in this section are
performed at the ECM wire connector. This method
ensures that the data from a sensor is reaching the
ECM. Sensor tests can be performed at the sensor if
easily accessible, but the wiring between the sensor
and the two 56–pin ECM connectors should always be
closely examined and the path between the sensor
and ECM verified if the sensor itself passes the test.
Poor or corroded connections are the most common
cause of system faults. Always check the integrity of
the male pins and female receptacles of the
connectors in the affected circuit. These may include
the sensor connector, the ECM connector, and any • Slide the lock lever toward the rear of the
wiring between the two, such as jumper harnesses vehicle until connector is disengaged from the
where applicable. ECM.

ECM Pinout Testing • Lift the connector straight off of the ECM.

NOTICE: Tests in this section may require reading ECM Connector Installation
resistance and voltages at ECM connector. Once ECM
connector has been removed from the ECM: 2. Carefully align the ECM connector straight with
the flange on the ECM. (Do not tip or rotate the
• Do not touch pins on ECM. Static electricity from connector into the ECM).
your body can damage the ECM.
3. Gently apply straight inward pressure on the
• Do not attempt to perform tests on the ECM unit. connector while sliding the lock lever back toward
the connector until the lever stops and the
connector is fully seated.

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ECM Removal / Installation The TMAP sensor is a non-serviceable item. If it is
1. Remove the battery box. See Battery Box faulty, it must be replaced
Removal, page 15.11. IMPORTANT: This sensor should only be tested
2. Disconnect the ECM connectors. See ECM using Digital Wrench Diagnostic Software.
Connector Removal, page 5.41.
3. Remove the ECM (1) from the 4 posts securing it to TMAP Sensor Replacement
the frame. 1. Remove the ignition coil assembly and associated
bracket. See Ignition Coil Removal / Installation,
page 16.6.
2. Disconnect vehicle harness from TMAP sensor.
3. Remove TMAP sensor screw (2) and remove
sensor from the intake manifold.

4. Reverse the removal procedure to install.

Temperature & Manifold Absolute

Pressure Sensor (TMAP) Replacement
Operation Overview
Mounted on the intake manifold, the TMAP sensor (1) 4. INSTALLATION is performed by reversing the
performs two functions in one unit. removal procedure.
5. Torque TMAP sensor screw to specification.

TMAP Sensor Screw: 62 in-lbs (7.0 Nm)

Air passing through the intake is measured by the

TMAP and relayed to the ECM. These signals,
comprised of separate air temperature and manifold
absolute pressure readings, are processed by the
ECM and compared to its programming for
determining the fuel and ignition requirements during
operation. The TMAP sensor provides the ECM with
engine load data.
TMAP Sensor Test

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Coolant Temperature Sensor, Test /
Replace

CHT TEST OVERVIEW 5

INDICATES INSPECT LOCATION
Voltage received at ECM from CTS Resistance readings through sensor and wiring at ECM Under rear
sensor is outside of parameters. 2 connector (ECM disconnected). This will test will cylinder
inspect the wiring, connectors, and CHT sensor intake port.
resistance.
1. Disconnect ECM #2 connector. See ECM 5. If resistance is out of specified range, disconnect
Connector Removal, page 5.41. sensor and measure the resistance through each
wire from ECM connector to the sensor connector.
2. Attach test lead adapters to meter leads. Resistance should be less than 1 Ohm (good
3. Set multimeter to measure resistance. continuity).
4. Measure resistance between pin 208 and pin 215 6. If Step 5 continuity is good, measure the resistance
of the ECM #2 connector and compare to through the sensor and compare to specification.
specification. See ECM Connector MAP, page
5.31.
METER TEST SPECIFICATIONS (±10%)
COMPONENT
SETTING CONNECTIONS
COOLANT TEMPERATURE 30.5 K Ohms +/- 13% @ 25o C (77o F)
OHMS Pin #208 to #215
SENSOR
Fuel Injector, Removal / Installation
1. Remove the seat assembly. See Seat Removal /
Installation, page 3.7
2. Remove fuel tank. See Fuel Tank Removal, page
5.21.
3. Remove the air box. See Air Box Removal, page
5.18.
4. Remove the ignition coil(s) assembly. See Ignition
Coil Removal / Installation, page 16.6.
5. Disconnect electrical connectors from fuel
injectors.

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6. Remove fuel rail screws (1). 15. Install and torque the fuel injector screws to
specification.

Fuel Injector Retaining Screws: 88.5 in-lbs (10.0 Nm)

Fuel Injector Resistance Test

IMPORTANT: Take note of front and rear fuel
injector harness connectors before disconnecting
them.

The fuel injectors are non-serviceable. If diagnosis

7. If still attached, disconnect the fuel supply line indicates a problem with either injector, test the
from the fuel rail quick connect. resistance of the fuel injector (s) by measuring
between the two pin terminals (1).
8. Lift fuel rail off injectors to remove it. Cover
injector ends and fuel rail quick connect with
plastic wrap rail to prevent contamination.
9. Clean the area around injectors with compressed
air to prevent foreign material from entering the
engine. Pull injectors out of cylinder heads,
keeping them in order (front and rear) for
assembly.
10. INSTALLATION is the reverse of the removal
procedure.
11. Install new o-ring on each fuel injector and
lubricate with engine oil.
12. Install the injector retainer (2) onto the injector (3)
as illustrated.

13. Insert the assembled injector into the fuel rail (4).
14. Install the fuel rail assembly to the engine.

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2. Remove regulator / rectifier assembly and bracket.
Fuel Injector Resistance Specification: 11.4 Ω - See Rectifier / Regulator Replacement, page
12.6 Ω 15.29.
3. Disconnect the CPS sensor from the vehicle
harness and release flying lead from plastic darts
Crankshaft Position Sensor, Test / Replace and cable ties.
Crankshaft Position Sensor CPS Test 4. Remove the screw (3) securing the CPS sensor to
the engine case and remove sensor.
1. Locate the CPS connector (1) under the Belt Guard,
and disconnect.

5. Installation is performed by reversing the

2. Connect an ohmmeter between the pin terminals removal procedure.
(2) and compare resistance readings to IMPORTANT: Apply rubber lubricant to the
specification below. CPS sensor o-ring to ease installation.

6. Torque the CPS retaining screw to specification.

Crankshaft Position Sensor Retaining Screw: 88.5 in-

lbs (10.0 Nm)

Throttle Body (ETC) Removal

1. Remove seat assembly.
2. Remove fuel tank.
3. Remove air box assembly. See Air Box Removal,
3. If resistance is correct, check to see that the sensor page .
is mounted properly and that the tone wheel has
not been damaged and is securely mounted to the 4. Disconnect the electronic throttle control
crankshaft assembly. connector.

Crankshaft Position Sensor: 860 Ohms @ 20°C

(68°F)

CPS Replacement
1. Remove starter motor. See Starter Motor, Removal
/ Installation, page 15.21.

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5. Remove four electronic throttle control fasteners
(Item 4).

6. Remove electronic throttle control (Item 2) and

replace gasket (Item 3).

Load / Tip Over Module

The Load / Tip Over Module adds load to standard
high-current hand control switches for terminal clean-
ing and to provide ECM interface signal integrity. The
Tip Over Sensor incorporated into this module inter-
rupts the ignition/fuel supply which prevents engine
operation after a tip over event.

See Chapter 17 Chassis Electrical for additional

information.

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DIGITAL WRENCH Digital Wrench Communication Errors
If you experience problems connecting to a vehicle or
Digital Wrench Diagnostic Software any other Digital Wrench related problem, visit the
Overview Digital Wrench Knowledge Base for the most current
troubleshooting information, FAQs, downloads and
NOTE: Refer to Section 2, 3 and 4 in the software updates at: http://polaris.diagsys.com/.
Instruction Manual provided in the Digital Wrench
Diagnostic Kit to install the Digital Wrench
diagnostic software on your computer.

The Digital Wrench diagnostic software allows the

technician to perform the following tests and
observations:
• View or clear trouble codes
• Analyze real-time engine data
• Reflash ECU calibration files
• Perform guided diagnostic procedures
• Create customer service account records 5
• Perform output state control tests (some models)

Diagnostic Software Version Digital Wrench Diagnostic Connector

The diagnostic connector (1) is located behind the
Always use the most current version of the Digital battery.
Wrench software to ensure you have the latest updates
or enhancements. New reprogramming files and
guided diagnostic procedures are added to these
updates as they become available. For information on
how to determine if you have the latest update
available, see Digital Wrench Version and Update ID,
page .

ECM Replacement
Although the need for ECM replacement is unlikely, a
specific replacement procedure is required to ensure
that all essential data contained within the original
ECU is transferred to the replacement ECU.
Refer to procedure and carefully follow all instructions
provided in Digital Wrench.

Guided Diagnostic Available Follow these steps to connect the diagnostic interface
cable to the vehicle:
Guided diagnostics are available within Digital
Wrench for most supported Diagnostic Trouble Codes 1. Assemble the SmartLink Module and attach the PC
(DTCs). That is, any fault that will turn on the ‘Check Interface Cable to your laptop.
Engine’ indicator. 2. Unplug the Digital Wrench connector from it’s
In addition, guided diagnostics are also available for protective receptacle.
many other electrical sub systems. 3. Connect the Vehicle Interface Cable to the Digital
Diagnostic procedures are added to subsequent Wrench diagnostic connector.
versions of Digital Wrench as they become available. 4. Press the ON button to power up the motorcycle
Check your release version often and upgrade when electrical system and switch the STOP / RUN
available to be sure you are using the most current switch to the RUN position.
software available.

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5. Select the appropriate vehicle and wait for the 2. Proceed to http://polaris. diagsys. com to see if a
status to display ‘Connected’ in the lower left newer update is available.
corner of the screen.
6. Once connected, proceed with using Digital
Wrench.

Digital Wrench Serial Number Location

Open the configuration screen by clicking on the
wrench icon. The serial number is located on the right
side of the screen.

3. If a newer update is available, it should be

downloaded before using Digital Wrench.
NOTE: Always operate with the latest update.

Digital Wrench Updates

Updates are released for Digital Wrench via the
Internet at: http://polaris. diagsys. com. The Digital
Wrench website can also be accessed through the
Digital Wrench Version and Update ID dealer website at: www.polarisdealers.com.
Knowing what Digital Wrench version and update is NOTE: Only authorized Indian Motorcycle
installed will help determine which updates are dealers and distributors can access the dealer
required. website.
NOTE: Versions and updates are subject to
1. Log on to www.polarisdealers.com.
change.
2. Locate the Service and Warranty drop-down
1. Open the Digital Wrench software. Locate the menu.
version ID shown on the lower right side of the
Digital Wrench start-up screen. 3. Click on Digital Wrench Updates.

4. The Digital Wrench portal website should appear

in a new web browser.

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

8. When the update is complete, the version shown

on the right side of the Digital Wrench start-up
screen should match the update you just
downloaded.

NOTE: You must already have the current

version installed before adding an update.
Updates will not install if you are using an
older version loaded on your PC.
5
6. If the update file date listed is newer than your
current version and update, download the file.

NOTE: Versions and updates are subject to

change.

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Digital Wrench Feature Map

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Engine Controller Reprogramming • KNOW THE PROCESS: If you are not familiar
(Reflash) with the entire reprogramming process, review
the HELP section of the diagnostic software
Process Overview before you attempt reprogramming. Click on the
The reprogramming feature is in the Special Tests ? on the tool bar or press F11. The information in
menu on the Digital Wrench screen. Start Digital the on-line help is the most current and
Wrench and click on the Special Tests menu icon (red complete information available. This should be
tool box). A technician should be familiar with the your first step until you are familiar with the
process and with computer operation in general process.
before attempting to reprogram an ECM. • COMMUNICATION PROBLEMS: If you have had
The Digital Wrench Engine Controller problems communicating with a vehicle while
Reprogramming (or “Reflash”) feature allows performing diagnostic functions, do not attempt
reprogramming of the ECM fuel and ignition map. To reprogramming until the cause has been
successfully reprogram the ECM, an Authorization Key identified and fixed. Check all connections, and
must be obtained by entering a Request Code in the be sure battery voltage is as specified.
box provided on the Reflash Authorization site. The
Request Code is automatically generated by Digital • Proceed to http://polaris. diagsys. com for
Wrench during the reprogramming process. The specific information and FAQs on how to
Reflash Authorization site is located under the Service troubleshoot communication problems.
and Warranty drop down menu on the dealer website
at: www.polarisdealers.com. • DON’T DISTURB THE PC: While reprogramming 5
is in progress, don’t move the mouse and don’t
NOTE: Failure to follow the reprogramming touch the keyboard. The process only takes a
instructions completely and correctly can result in few minutes, and is best left alone until
an engine that does not run! Replacement ECMs complete.
are programmed as “no-start” and require a
reflash for them to work.
Reprogramming (Reflash) Procedure:

Reprogramming (Reflash) Tips: If you are not familiar with the reprogramming
process, review the “Reprogramming (Reflash) Tips”
• BATTERY VOLTAGE: The majority of problems before you begin. Follow the on-screen instructions as
with reprogramming can be attributed to a low you progress through the steps. If you encounter a
battery. Be sure the battery voltage (no load) is problem, always check the On-Line help for current
at least 13 volts and at least 12.5 volts with the tips and information.
key ‘ON’. Connect a battery charger if
1. Verify the most current update has been
necessary to bring voltage level above
downloaded and loaded into Digital Wrench.
minimum. Fully charge the battery before you
attempt to reprogram. 2. Connect SmartLink Module cables to PC and
vehicle.
• DEDICATED LAPTOP: Best results are obtained
using a laptop computer that is “dedicated to 3. Open the Digital Wrench program.
Digital Wrench”. A laptop that is used by a
variety of people and in several applications 4. Select the model year, product line and vehicle
around the dealership is more likely to cause a description by selecting the “Change Vehicle
reprogramming problem than one dedicated to Type” icon.
Digital Wrench diagnostics only. 5. Select the “Special Tests” icon.
• OBTAINING THE LATEST UPDATE: 6. Select “Engine Controller Reprogramming”.
Reprogramming updates are provided
periodically and contain the most recent 7. Select the file you want to load into the ECU then
calibrations. click the “Continue” icon to proceed to the
Integrity Check and obtain a Request Code.
• CLOSE NON-ESSENTIAL PROGRAMS: It is
recommended that you DO NOT install non- 8. Copy (CTRL +C) the Request Code that will be
essential programs on a Service Department required on the dealer website in the next step.
laptop. Camera detection software, Virus DO NOT CLOSE Digital Wrench or the Request
Scanners, Tool Bars, etc. may clog up memory if Code will be invalid. NOTE: All characters are
running in the background and make it harder letters; there are no numbers in a request code.
for the diagnostic software to operate. NOTE: Request Codes and Authorization Keys
must be entered EXACTLY as they appear on
the screen.

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

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TROUBLESHOOTING
Fuel System Troubleshooting, Part 1

PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED

Engine turns over with Compression too low See engine section
electric starter, but won’t
start No spark at spark See ignition system
plugs
No fuel reaching intake Out of fuel Add Fuel
tract Blown Fuse Replace
Plugged fuel filters / Clean/Replace
lines Test / Replace
Fuel pump not working Test / Replace
Fuel pressure regulator Test / Replace
Faulty fuel pump relay Inspect / Repair
Open wiring / connector Inspect / Repair
Faulty connection at ECM
Excessively rich or
lean fuel mixture
Fuel pump
Fuel pressure regulator
Test / Replace
Test / Replace
5
Crank Position Sensor Test / Replace
Low Battery Test / Replace
TMAP sensor Test / Replace
CHT sensor Test / Replace
Fuel Injector Test / Replace
Spark at wrong time or Timing Wheel or CPS Install correctly, inspect for
no spark. installed incorrectly, proper air gap (gap is preset
Fuel delivery timing damaged, or dirty; faulty but cover, sensor, and timing
incorrect. CPS wheel must be clean and in
good condition).
Poor idle Excessively rich or Air Leaks Inspect IAC system
lean fuel mixture Air restriction in IAC Inspect IAC hoses and
Fuel Pump fittings
Fuel injector or fuel rail Inspect fuel pressure
obstructed or leaking Replace
Air Filter Replace
Wrong Fuel / Old Fuel Inspect / Replace
Crank Position Sensor Inspect / Replace
Poor Running in Higher Air intake restriction Air filter Inspect
RPM Range Oil Overfilled Ignition Coil(s) / plug Refer to ignition section.
Ignition problemsLow wires Charge or replace
Battery Voltage Battery Unplug connections - inspect
Loose, corroded, or ECM and wiring harness Inspect cylinder head &
wet connector(s) Valve springs, valve, valves
Valve train problems head

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Fuel System Troubleshooting, Part 2

PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED

Engine Stalls Fuel Pump Problem Low battery voltage Battery/Charging system
Faulty fuel pump Check fuel pressure
No signal from ECM Repair Wiring
Wiring problem Repair/Chk Pump Relay
Excessive rich or lean TMAP Sensor Repair / Replace
fuel/air mixture Plugged fuel filter Replace
Fuel pump (pressure) Test / Replace
Fuel pressure regulator Test / Replace Pump Assembly
Vacuum leak Repair / Replace hoses
Wiring problem Repair
Air Filter Replace
Low battery voltage Ck battery & charging system
Control Circuit/ Fuel pressure regulator Test Pressure / Replace
Sensors not TPS Test / Replace
functioning correctly Engine speed sensor Test / Replace
Fuel pump relay Test / Replace
Rotor Inspect / Install correctly
Fuse Replace
ECM Relay Replace
Low battery voltage ECM Inspect Charging system
Valve train problems Refer to chapter 7
or Compression low
Backfiring Low Battery Voltage Battery, spark plug Refer to battery section
Ignition Problem fouled, poor wire Replace plugs / diagnose
Air leaks connection for ignition or Inspect wiring connections
Restricted air intake or fuel injection, loose pin in Disconnect and check pin
throttle body multi-pin connector for connections
ECM or wiring harness Seal intake or exhaust leaks
Clean air inlet tract and throttle
Inlet and Exhaust body
Intake tract / Throttle
body

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Fuel System Troubleshooting, Part 3

PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED

Poor Running in upper Control Circuit/ CPS Test / Replace
rpm ranges Sensors not ETC Test / Replace
functioning correctly Air temperature sensor Test / Replace
Manifold Absolute Test / Replace
Pressure sensor Repair/Replace
Intermittent wiring Test / Replace
/connector problem ECM
Fuel delivery incorrect Plugged or kinked fuel Repair/Replace
and/or vent hoses Test / Replace
Fuel pump Test Pressure / Replace
Fuel regulator Test / Replace
Fuel filter Charge/Replace
Battery/Charging System Clean/Replace
Fuel Injector plugged Clean/Replace
Contaminated fuel (water, Use correct fuel
additives, etc.) Test / Replace
Inadequate octane Charging system 5
Defective ETC
Low battery voltage
Air intake restriction Dirty Air Cleaner Clean
Intake restriction Repair
Air Leak ETC gasket surfaces Repair/Replace
Intake manifold Repair/Replace
ETC Repair/Replace
Engine lacks power Engine component See chapters 7–10
problems See chapter 16
Ignition problems See chapter 2
Overfilled with oil
Improper fuel delivery Plugged fuel injector Repair / Replace
Dirty air cleaner Replace
Vacuum leaks Repair
Fuel pump Test / Replace
Fuel pressure regulator Test / Replace
Air temperature sensor Test / Replace
TMAP sensor Test / Replace
Plugged vent hose Clear
Low battery voltage ECM Test batt./Charging system

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Fuel System Troubleshooting, Part 4

PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED

Engine overheats Internal Engine Parts Cooling System Refer to chapter 4
Lubrication & Cooling Engine Oil Refer to chapter 4
system Brake systems Refer to chapter 14
Low or incorrect oil Drive Belt Refer to chapter 12
Brakes dragging Ignition Coils Refer to chapter 16
Drive belt too tight Faulty ECM Replace
Ignition timing Charging System Test / Repair
incorrect Faulty Battery Replace
Spark plug(s) Faulty Wiring Repair
Low battery voltage
Lean Air/Fuel mixture Fuel pressure regulator Repair/Replace
Air leak Repair
Fuel injector plugged Clean/ReplaceReplace
CHT Test / Replace
Vent hose plugged / kinked Repair
Air leak at throttle body to Test / Repair
manifold seal
Won’t Accept Non-Current Go to Dealer website and
New Calibration Calibration File Set download the most current
Low Battery Voltage Indian Motorcycle Calibration
Attempting Re-Flash File Set
Without Proper VIN,
Calibration I.D. Attach Battery Charger
number, or calibration During Re-Flash, and Re-
authorization code Charge Battery When Re-
Flash Is Completed

Enter Authorization Code Sent

With Accessory Kit

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CHAPTER 6
ENGINE REMOVAL / INSTALLATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
ENGINE BRACKETS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PREPARATION FOR ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
REMOVING ENGINE FROM FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

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GENERAL INFORMATION TOOL DESCRIPTION PART NUMBER

Service Notes 12"x12" Platform Jack Commercially Available

A floor jack or commercially available motorcycle Engine Hoist (Cherry Commercially Available
engine lift or hoist is required for engine removal. Picker)
Arrange for assistance when removing and installing
Engine Stand Commercially Available
the engine.
Once the engine is removed from frame, an engine Bosch Automotive Service Solutions: 1– 800– 328–
stand is recommended for engine disassembly and 6657 or https://polaris.service-solutions.com/
assembly.
Engine removal and installation methods may differ Torque Specifications
slightly depending on available equipment, but
always be sure the engine and chassis are securely PART DESCRIPTION TORQUE
supported at all times. SPECIFICATION
REQUIRES ENGINE CAN BE SERVICED ABS Module Bracket — 8 ft-lbs (11 Nm)
REMOVAL FOR WITH ENGINE IN M6 x 1.0 x 12 (QTY.4)
SERVICE FRAME
Battery Box — M6 x 1.0 x 8 ft-lbs (11 Nm)
Camshaft(s) / Bearings Airbox Removal 12 (QTY.3)
Crankshaft & Crankshaft Camshaft Chain / Guide Brake Line Routing Tabs 84 in-lbs (9.5 Nm)
Component Service / Tensioner Assembly — M6 x 1.0 x 12 (QTY.4)
Cylinder Heads Fuel Injectors / Throttle Down Tube, Lower (Both 45 ft-lbs (60.0 Nm)
Body / Fuel Rail Sides) — M10 x 1.5 x 60
(QTY.4)
Cylinders Voltage Regulator,
Stator, Rotor (Flywheel) Down Tube, Lower LH — 45 ft-lbs (60.0 Nm)
M10 x 1.5 x 25 (QTY.1)
Lifters Clutch
Down Tube, Upper LH — 45 ft-lbs (60.0 Nm)
Oil Pump Gearshift Linkage
M10 x 1.5 x 100 (QTY.2)
(External)
Engine Mounts, Front — 18 ft-lbs (24.4 Nm)
Balance Shaft Ignition System
M8 x 1.25 x 20 (QTY.2)
Piston/Cylinder Oil Pump Drive
Engine Mounts, Rear — 75 ft-lbs (101.7 Nm)
Pushrods Output Shaft Seal M12 x 1.75 x 50 (QTY.4)

Transmission/All Torque Compensator Ground Wire — M6 x 1.0 84 in-lbs (9.5 Nm)

Internal Transmission Assembly x 12 (QTY.1)
Parts
Side Stand Bumper — 84 in-lbs (9.5 Nm)
Valve Covers M6 x 1.0 x 12 (QTY.1)
Starter, Starter One-Way Side Stand Switch — M5 43 in-lbs (4.9 Nm)
Clutch, Starter Torque x 0.8 x 16 (QTY.2)
Limit Clutch
Starter Solenoid — M6 x 84 in-lbs (9.5 Nm)
Crankshaft Position 1.0 x 12 (QTY.2)
Sensor Timing Wheel

Service Specifications
Special Tools
ITEM SPECIFICATIONS
TOOL DESCRIPTION PART NUMBER
Approximately 200 lbs
Engine Stand Adapter PF-51240 Engine Dry Weight
(91 kg)
Motorcycle Table Lift / Commercially Available Approximately 4.5
Wheel Vise Oil Capacity (Dry Fill)
Quarts (4.3 Liters)

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ASSEMBLY VIEWS
Engine Brackets / Fasteners
Engine Mounting Brackets / Fasteners

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Bolt, Engine Mount - M12 x 1.75 x 250 8.8 (QTY.2) 51 ft-lbs ( 69 Nm)
2 Bolt, Engine Mount - M12 x 1.75 x 95 8.8 (QTY.2) 51 ft-lbs ( 69 Nm)
3 Nut, Hex - M12 x 1.75 (QTY.2) -

4 Spacer - 280D x 131D x 12.5(QTY.3) -

5 Screw, Hex, - M8 x 1.25 x 30 (QTY.1) 19 ft-lbs (25 Nm)

6 Screw, Hex - M8 x 1.25 x 35 8.8 (QTY.1) 19 ft-lbs (25 Nm)
7 Sidestand Assembly, Mount -

8 Nut, Hex - M12 x 1.75 (QTY.1) -

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ENGINE REMOVAL 19. Remove the ignition switch cover bracket
fasteners (1) and bracket (2).
Preparation For Engine Removal
NOTE: Different methods can be used to remove
the engine depending on the equipment available
to the technician. All methods require the front
wheel to be held securely in an upright position.

1. Support motorcycle securely in an upright

position. Clamp front tire securely in a wheel vise.
2. Remove thermostat housing cover. See
Thermostat Housing Cover Removal / Installation,
page 3.10.
3. Remove ignition side cover. See Ignition Side
Cover Removal / Installation, page 3.10
4. Remove the seat. See Seat Removal / Installation,
page 3.7.
20. Remove the thermostat cover bracket fasteners (3)
5. Remove the battery. See Battery Removal, page and bracket (4).
15.11.
6. Remove the fuel tank. See Fuel Tank Removal,
page 5.21.
7. Drain the cooling system. See Coolant Drain / Fill,
page 4.19.
8. Remove the radiator assembly. See Radiator
Removal / Installation, page 4.21
9. Remove the mufflers. See Muffler Removal, page
5.14.
10. Remove the exhaust head pipe assembly. See
Head Pipe Removal, page 5.15
11. Remove the sprocket cover. See Drive Sprocket
Cover, Removal / Installation, page 12.8.
12. Loosen axle nut and remove belt from drive
sprocket. See Drive Belt Adjustment, page 2.33 21. Disconnect the radiator outlet hose (5), oil cooler
coolant feed hose (6), front head coolant outlet
13. Remove air box. See Air Box Removal, page 5.18. hose (7), rear head coolant outlet hose (8) and
14. Reinstall the frame tubes removed in previous step bypass hose (9) from the engine.
and torque all fasteners to specifications. See Air
Box Installation, page 5.18.
15. Remove both driver foot controls. See Footpeg
(Driver), Removal / Installation, page
16. Remove brake line from right side of engine.
17. Disconnect clutch cable from clutch lever on
engine.
18. Remove horn assembly. See Horn Removal /
Installation, page 17.12.

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22. Disconnect the overflow reservoir hose (10) and 28. Disconnect the starter motor battery cable at the
remove the thermostat housing (11). terminal (17).

23. Disconnect the TMAP sensor connector (12). 29. Disconnect the oil pressure switch connector (18).
See Sensors - Powertrain Management, page 5.11.
30. Disconnect the crankshaft position sensor
connector (19).
31. Disconnect the vehicle speed sensor connector
(20). 6
32. Disconnect the gear position switch connector
(21). See Sensors - Powertrain Management, page
5.11.
33. Disconnect the side stand switch connector (22).
34. Disconnect the stator connector (23).

Removing Engine From Frame

1. Perform the preliminary engine removal steps
outlined in this chapter. See Preparation For
24. Disconnect the CTS sensor connector (13). Engine Removal, page 6.4.
25. Disconnect both fuel injector connectors (14). 2. Place a platform jack beneath the engine and raise
enough to support crankcase (Jack should just be
26. Disconnect both ignition coil connectors (15). touching the crankcase).
27. Disconnect the electronic throttle body connector
(16).

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3. Remove the two front motor mount bolts (1) and 8. Remove spacers (7) located between the right side
nuts (2) from the engine case. engine case and mid frame.

4. Retain the right side spacer (3) for reassembly. 9. Push engine slightly to the RH side to free up from
alignment dowels. With an assistant, lower the
5. Remove side stand fasteners (4,5).
engine from the frame and remove from vehicle.

6. Place a suitable platform jack under engine cases.

7. Remove engine mount bolts (6) from right side of
frame and remove sidestand assembly.

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ENGINE INSTALLATION 6. Install the two engine mounting bolts (2) into the
RH frame panel with sidestand assembly and
Engine Installation tighten until the engine is fully drawn into the
frame panel. Do not torque bolts at this time.
The following procedure is written assuming the en-
gine has been assembled and is resting on an engine
stand, ready for installation.
Refer to Engine Brackets / Fasteners, page 6.3 in this
chapter for torque values and assembly views.

CAUTION

Arrange for assistance when installing engine. The

engine must be held securely to prevent damage to
engine, frame, wiring, or hoses. The engine is very
heavy and could cause severe personal injury if not
handled properly. Be sure engine is properly
supported before proceeding.

NOTE: IMPORTANT! Be sure alignment dowels

are in place in the RH rear engine mounts prior to
installation. CAUTION
1. Clean mating surfaces of frame and engine
crankcase. Install alignment dowels (1) between
Be sure engine is aligned at the proper height and
angle with the dowel pins. DO NOT force engine
6
right side engine case and mid frame. alignment using the mounting bolts, or the dowel
pins may be damaged! Adjust engine height and
angle continuously as required while drawing up
the bolts.

7. Install side stand fasteners (3,4).

2. Place motorcycle in an upright position with the

front wheel clamped in a wheel vise.
3. Position the engine on a platform jack to the left of
the motorcycle and slide into position so the
engine is orientated correctly front to back.
4. Slide the engine back until the rear mounting ears
are aligned with the mounting holes in the mid
frame. Adjust height of engine as needed to align
rear mounts and dowel pins.
5. Be sure all wiring and hoses are properly routed
before installing rear spacers and mounting bolts.

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8. Install the two front motor mount bolts (5), nuts (6), 16. Connect the starter motor battery cable at the
and spacer (7) into the engine case. Torque to terminal (17).
specification. See Engine Brackets / Fasteners,
page 6.3.

17. Connect the electronic throttle body connector

(16).
9. Torque the RH rear engine mounting bolts to
18. Connect both ignition coil connectors (15).
specification.
19. Connect both fuel injector connectors (14).
20. Connect the CTS sensor connector (13).
21. Connect the TMAP sensor connector (12).
Rear Engine Mounting Bolts: 75 ft-lbs (101.7 Nm)

10. Connect the stator connector (23).

11. Connect the side stand switch connector (22).
12. Connect the gear position switch connector (21).
See Sensors - Powertrain Management, page 5.11.
13. Connect the vehicle speed sensor connector (20).
14. Connect the crankshaft position sensor connector
(19).
15. Connect the oil pressure switch connector (18).
See Sensors - Powertrain Management, page 5.11.

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22. Connect the overflow reservoir hose (10) and 24. Install the thermostat cover bracket fasteners (3)
remove the thermostat housing (11). and bracket (4). Torque fasteners to specification.

23. Connect the radiator outlet hose (5), oil cooler

coolant feed hose (6), front head coolant outlet
hose (7), rear head coolant outlet hose (8) and
bypass hose (9) from the engine.
Thermostat Cover Bracket Fasteners: 8 ft-lbs (11 Nm)

25. Install the ignition switch cover bracket fasteners

6
(1) and bracket (2). Torque fasteners to
specification.

Ignition Switch Cover Bracket Fasteners: 8 ft-lbs (11

Nm)

26. Install horn assembly. See Horn Removal /

Installation, page 17.12.
27. Connect clutch cable from clutch lever on engine.
28. Install both driver foot controls. See Footpeg
(Driver), Removal / Installation, page

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29. Install air box and frame tubes and torque all
fasteners to specifications. See Air Box Installation,
page 5.18.
30. install belt from drive sprocket and install axle nut.
Align the drive belt. See Drive Belt Adjustment,
page 2.33
31. Install the sprocket cover. See Drive Sprocket
Cover, Removal / Installation, page 12.8.
32. Install the exhaust head pipe assembly. See Head
Pipe Installation, page 5.16
33. Install the mufflers. See Muffler Installation, page
5.14.
34. Install the radiator assembly. See Radiator
Removal / Installation, page 4.21
35. Fill and bleed the cooling system. See Coolant
Drain / Fill, page 4.19.
36. Install the fuel tank. See Fuel Tank Installation,
page 5.26.
37. Install the battery. See Battery Installation, page
15.11.
38. Install the seat. See Seat Removal / Installation,
page 3.7.
39. Install ignition side cover. See Ignition Side Cover
Removal / Installation, page 3.10
40. Install thermostat housing cover. See Thermostat
Housing Cover Removal / Installation, page 3.10.

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CHAPTER 7
CYLINDER HEAD / VALVES
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
CAM CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
CYLINDER HEAD / CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
CAMSHAFT TIMING MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
CAM CHAIN SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
CAM CHAIN SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
CAM CHAIN GUIDE (UPPER), REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
CAMSHAFT SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
CAM DRIVE SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
CAM DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
CAM CHAIN GUIDE (LOWER), REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
7
CAM CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
CAM DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
CAM CHAIN GUIDE (LOWER), INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
CAM DRIVE SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
CAMSHAFT SPROCKET INSTALLATION / TIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
CAM CHAIN GUIDE (UPPER), INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
CYLINDER HEAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
VALVE CLEARANCE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.24
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.28
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
VALVE SPRING FREE LENGTH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.30
VALVE INSPECTION - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.31
VALVE GUIDE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
VALVE SEAT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
VALVE SEAT RECONDITIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32

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CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
INTAKE VALVE LASH - TAPPET SELECTION MATRIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
EXHAUST VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.36
TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37

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 CYLINDER HEAD / VALVES
GENERAL INFORMATION • Valve guide and seat reconditioning should be
performed by a technician proficient in cylinder
head reconditioning techniques using high
Service Notes quality equipment with grinding stones. Do not
attempt cylinder head repair without the proper
• This chapter covers service of the cylinder
equipment or experience in cylinder head
heads, camshafts, cam chains, tensioners and
reconditioning techniques.
guides.
• The intake and exhaust valves cannot be re-
• Refer to Chapter 6 for engine removal and
faced.
installation.
• Cleanliness of parts is critical to engine life and
• If cylinder heads are removed the cylinder base
accurate parts inspection. Use clean solvent to
gasket must be replaced also.
clean all disassembled parts. Dry parts with
• Mark and store all mating parts for correct compressed air and lubricate before engine
engine assembly. inspection and engine assembly.
• Use Moly Assembly Paste - P/N: 2871460 or
Indian Motorcycle Synthetic 15W60 Engine Oil
to lubricate parts where indicated.
Special Tools
• Handle and store all parts in such a way that they TOOL DESCRIPTION PART NUMBER
will not be damaged or contaminated.
Valve Spring Compressor Commercially
• Some fasteners have a pre-applied locking Available
agent, and must be replaced if loosened or
removed. Always replace fasteners that have a Crankshaft Locking Tool PF-51235-A
pre-applied locking agent or as directed in this Crankshaft Rotation Tool PF-51239
service manual.
Seal and Bearing Driver Set PV-43558
• There are some precision machining steps to be
performed in this section. If you are not sure of
your capabilities in these areas, have a Bosch Automotive Service Solutions: 1-800-345-
competent machinist perform these operations. 2233 or https://polaris.service-solutions.com/ 7

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Torque Specifications

PART DESCRIPTION TORQUE SPECIFICATION

Cam Carrier Screw (QTY.9) 88.5 in-lbs (10.0 Nm)
Cam Chain Guide Screws (ALL) 88.5 in-lbs (10.0 Nm)
Cam Chain Tensioner (QTY.2) 26 ft-lbs (35.0 Nm)
Cam Drive Carrier Bolts (QTY.4) 14 ft-lbs (19.0 Nm)
Cam Drive Sprocket Bolt (QTY.1) 52 ft-lbs (70.0 Nm)
Camshaft Sprocket Screws (ALL) 11 ft-lbs (15.0 Nm)
Cylinder Head Bolt, Primary (QTY.4) 1) 21 ft-lbs (28.0 Nm)
2) 26 ft-lbs (35.0 Nm)
3) Plus 180 degrees
Cylinder Head Bolt, Secondary (QTY.2) 88.5 in-lbs (10.0 Nm)
Valve Cover Screws (QTY.3) 88.5 in-lbs (10.0 Nm)

Service Specifications
Camshaft Data
DESCRIPTION SPECIFICATION
Over Head Valve / 4 valves per cyl
Valve Train
2 Intake Valve / 2 Exhaust Valve
Intake Valve Opens At 1 mm Lift 9.0° BTDC
Intake Valve Closes At 1 mm Lift 41.0° ABDC
Exhaust Valve Opens At 1 mm Lift 49° BBDC
CAMSHAFT DATA Exhaust Valve Closes At 1 mm Lift 1° ATDC
Max Lobe Lift
INTAKE (10.10 mm)
EXHAUST (10.10 mm)
Max Valve Lift
INTAKE (10.10 mm)
EXHAUST (10.10 mm)

Cylinder Head & Valve Train Data

ITEM STANDARD SERVICE LIMIT
Cam Chain
Tensioner Hydraulic / Self-Adjusting - -
(s)
.9844" (25.003
INTAKE mm)
Cam Shaft Lobe Height .9763” (24.800 mm)
EXHAUST .9920" (25.197
mm)

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 CYLINDER HEAD / VALVES

ITEM STANDARD SERVICE LIMIT

.9028 - .9036"
Journal O.D. (Exhaust) (22.933 - 22.954 .9016” (22.900 mm)
mm)
.9028 - .9036"
Journal O.D. (Intake) (22.933 - 22.954 .9016” (22.900 mm)
mm)
Cylinder Warpage (Distortion) - .004” (.10 mm)
Head
0.006” ± 0.001”
INTAKE (0.152 mm ± 0.05
mm)
Valve Clearance -
0.008” ± 0.001”
EXHAUST (0.023 mm ± 0.05
mm)
Guide Height from Valve Spring Seat
11.4 –11.8 mm -
(Installed)
.2155 — .2161”
INTAKE (5.474 – 5.489 mm)
Valve,
Valve Valve Stem O.D. -
.2147 — .2153”
Guide, EXHAUST (5.453 – 5.468 mm)
Valve Seat
Valve Stem Deflection (INTAKE &
- .005” (.13 mm)
EXHAUST)

INTAKE
.0354 - .0432"
.0551" (1.399 mm)
7
(.899 - 1.097 mm)
Valve Seat
Width .0551 - .0629"
EXHAUST .0748" (1.899 mm)
(1.399 - 1.598 mm)

Valve Stem Runout - .0005” (.013 mm)

Valve Head Radial Runout - .002” (.05 mm)

Free Length (INTAKE & EXHAUST) 1.9330” (49.1 mm) 1.9094” (48.5 mm)

Valve Intake Valve Maximum Lift .3976” (10.1 mm) -

Spring .3976” (10.1 mm) -
Exhaust Valve Maximum Lift
Spring Installed Height 1.3543” (34.4 mm) -

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ASSEMBLY VIEWS
Cam Chains

NUMBER PART DESCRIPTION NUMBER PART DESCRIPTION

1 Cam Drive Shaft Assembly 12 Chain, Cam Silent 6.35 pitch
2 Bearing Support Plate 13 Sprocket, Cam Driven
3 Water Pump Driven Gear 14 Bolt, Cam Chain Guide
4 Shaft Assembly 15 Gear, Cam Idler Assembly
5 Guide, Cam Chain Tensioner Front 16 Screw, M5x0.8x12
6 Guide, Cam Chain Tensioner Rear 17 Screw, M6x1.0x30
7 Guide, Cam Chain Fixed Rear 18 Bolt, M8x1.25x25
8 Guide, Cam Chain Fixed Front 19 Screw, M6x1.0x10
9 Guide, Cam Chain Fixed Cover 20 Bolt, Shoulder M6x12x15
10 Guide, Cam Chain Lower 21 Screw, M10x1.5x40
11 Tensioner, Cam Chain Hydraulic 22 Washer, 34x10x4

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Cylinder Head / Camshafts

NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS 7

(IF APPLICABLE)
1 Valve, Intake (QTY.2 per head) -
2 Valve, Exhaust (QTY.2 per head) -
3 Cylinder Head Assembly (Front shown) -
4 Spring Seat w/seal (QTY.4 per head) -
5 Valve Spring (QTY.4 per head) -
6 Valve Retainer (QTY.4 per head) -
7 Keeper, Valve (QTY. 8 per head) -
8 Tappet, Valve (QTY.4) -
9 Seal, Cam Carrier (QTY.1 per head) -
10 Camshaft, Intake (QTY.1 per head) -
11 Camshaft, Exhaust (QTY.1 per head) -
12 Carrier, Camshaft -
13 Cam Carrier Bolt, Short (QTY.7) 88.5 in-lbs (10.0 Nm)
14 Cam Carrier Bolt, Long (QTY.2) 88.5 in-lbs (10.0 Nm)

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Cylinder Head

NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS

(IF APPLICABLE)
1 Stud, Exhaust -
2 Cylinder Head ASM, Front -
3 Cylinder Head ASM, Rear -
6 Cylinder Head, Front -
7 Cylinder Head, Rear -
9 Coolant Diverter -
10 Head Gasket, Front -
11 Base Gasket, Front -
12 Base Gasket, Rear -
13 Head Gasket, Rear -
14 Primary Head Bolt 1) 20.6 ft-lbs (28 Nm)
2) 25.8 ft–lbs (35 Nm)
3) Plus 180 degrees
15 Secondary Head Bolt 88 in-lbs (10.0 Nm)

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Camshaft Timing Marks

Camshaft Timing Front Cylinder 7

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Camshaft Timing Rear Cylinder

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CAM CHAIN SERVICE Cam Chain Tensioner Removal
Cam Chain Service Notes
CAUTION
Read the following tips to ease the removal,
installation and timing procedures when servicing the
cam chain and / or cylinder head assembly on the Do not rotate engine with tensioner(s) removed.
Indian Scout.
• Drain the engine oil prior to servicing the cam IMPORTANT: Protection has been built into the
chain. cam chain guide system to prevent the chain from
jumping time with the tensioner (s) removed if the
• If the cam chain (s) or cylinder head (s) will be
engine remains static. This does not guarantee the
removed, loosen all camshaft sprocket bolts
chain will not jump time with tensioner (s)
prior to removing tensioners. Loosen exposed
removed. Do NOT rotate the crankshaft with
camshaft sprocket bolts 1/2 turn, rotate
tensioner(s) removed or the chain may jump time.
crankshaft to expose remaining bolts and loosen
Two methods of tensioner removal are provided
1/2 turn.
below. Method 1 (recommended) is the only way to
• ALWAYS rotate the crankshaft CLOCKWISE by guarantee the cam chain timing is correct upon
turning the primary drive gear stake nut. Use a 1 reassembly. Method 2 may result in incorrect valve
1/4” wrench. timing and engine damage if the chain jumps
time.
• Rotate the front piston to TDC on the
compression stroke and lock the crankshaft Method 1 (Recommended)
prior to servicing the cam chain (s) / cylinder
head (s). See Locking the Crankshaft for 1. Remove valve covers. See Valve Cover Removal,
Service, page 10.4. page 7.23.
• DO NOT rotate the crankshaft if one or both of 2. Lock the crankshaft for service with the front
the cam chain tensioners has been removed. piston at TDC on the compression stroke. See
Locking the Crankshaft for Service, page 10.4.

Cam Chain Guide (upper), Removal

3. Remove the cam chain tensioners (1) and sealing 7
washers (2).
1. Remove valve cover(s). See Valve Cover Removal,
page 7.23.
2. Remove screws (1) and lift guide off of cylinder
head.

Method 2
1. Remove cam chain tensioners and sealing washers.

Cam Chain Tensioner Inspection

1. Visually inspect inner plunger (1) for damage,
scoring or burns.

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2. Lubricate inner plunger with engine oil. Move 6. Rotate the crankshaft to expose sprocket bolts (1)
plunger in and out of outer plunger (2) to check and loosen 1/2 turn.
for smooth movement without binding.
NOTE: Use a piece of nylon webbing or rope to
3. Verify the oil passage opening is free from debris. create an interference between the crank drive
4. Replace tensioner assembly if worn or damaged. gear and clutch gear, thus locking the
crankshaft while loosening sprocket bolts.

Camshaft Sprocket Removal 7. Repeat step 6 for remaining camshaft sprocket

1. Place motorcycle in an upright position with front bolts.
wheel clamped in a wheel vise.
8. Rotate crankshaft so the front piston is TDC on the
2. Drain engine oil and dispose of properly. compression stroke and lock in position. See
Locking the Crankshaft for Service, page 10.4.
3. Remove valve cover(s). See Valve Cover Removal,
page 7.23. 9. Remove the cam chain tensioner (s). See Cam
Chain Tensioner Removal, page 7.11.
4. Remove the primary cover. See Primary Drive
Cover Removal, page 9.7.
5. Remove upper cam chain guide(s). See Cam Chain CAUTION
Guide (upper), Removal, page 7.11.
Do not rotate the crankshaft with tensioner(s)
removed. Engine damage may occur.

10. Remove the camshaft sprocket bolts completely.

NOTE: It will be necessary to use a thin 10mm
spanner to remove the sprocket bolts that are
not exposed. The bolts cannot be completely
removed until the sprocket is out of the cylinder
head.

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11. Remove sprocket(s) (2) from camshaft(s) using care 3. Remove four bolts (2) securing the cam drive
not to drop the chain into the camchain gallery. carrier to the crankcase.

4. Remove the cam drive carrier (3) from the

crankcase assembly.
Cam Drive Sprocket Removal
1. Lock the crankshaft for service. See Locking the
Crankshaft for Service, page 10.4.
2. Remove bolt and washer (1) securing cam drive
gear to cam drive shaft.

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5. Using a pin punch or similar tool, release the 4. Slack the cam chains enough to remove the cam
preload from the split gear teeth and slide the cam drive shaft (3) and slide out of bearing bore to
drive gear (4) off of the cam drive shaft. remove.

Cam Drive Shaft Removal Cam Chain Guide (lower), Removal

1. Remove the camshaft sprockets. See Camshaft 1. Start with the front cylinder and remove bolts (1)
Sprocket Removal, page 7.12. from the guides.
2. Remove the cam drive sprocket. See Cam Drive
Sprocket Removal, page 7.13.
3. Remove the screw (1) securing the cam chain
guide (2) from the crankcase assembly.

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2. Remove the guide (s) through the top of the 2. Lay the chains over the camshaft hubs or hang
cylinder head. them in position using string to keep them from
falling into the crankcase.

3. Repeat steps 1 and 2 for the rear cam chain

guides.
Cam Drive Shaft Installation
Cam Chain Removal 1. Apply a thin coat of assembly lube to the bearing
1. Remove the cam drive shaft. See Cam Drive Shaft end of the cam drive shaft (1).
Removal, page 7.14.
2. Remove lower cam chain guides. See Cam Chain
Guide (lower), Removal, page 7.14
3. Lift cam chain(s) out of engine.
7
Cam Chain Installation

CAUTION

The engine used in Indian Scout models is an

INTERFERENCE ENGINE. If the camshafts and
crankshaft must be turned independently of each
other to set valve timing, the camshafts must be set to
TDC prior to rotating the crankshaft. Failure to do this
may cause the pistons to contact the valves resulting
in engine damage.

1. Feed the cam chain (s) in through the top of the

cylinder head (s) keeping the front chain on the
outside (right side) of the rear chain.

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2. Install the cam drive shaft (2): 4. Install the cam chain guide and spacer (3) and
torque screw (4) to specification.
• Loop cam chains around respective sprockets
• Engage water pump gear teeth with cam drive
shaft
• Slide cam drive shaft into bearing bore until
fully seated

Cam Chain Guide Screw: 88.5 in-lbs (10.0 Nm)

3. Turn the cam drive shaft so the woodruff key is

pointing at 12 o’clock. Cam Chain Guide (lower), Installation
1. Inspect the guides to verify the guide face isn’t
cracked or grooved from the chain. Replace
guides if damaged.
2. Lower the guides into position through the top of
the cylinder head(s).

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3. Starting with the rear cylinder, hand-tighten the 3. Using a small screw driver (2) or equivalent,
screws (1) until seated and torque to specification. preload the gear teeth of the cam drive sprocket.

4. Align the timing marks on the primary gear and

cam drive sprocket as shown and slide the cam
sprocket onto the cam drive shaft.

Cam Chain Guide Screws (lower): 88.5 in-lbs (10.0

Nm)

Cam Drive Sprocket Installation 7

1. Rotate the primary drive gear so the timing mark
(1) is pointing at 12 o’clock.

2. Lock the crankshaft in position for service. See

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5. Slide the cam drive sprocket carrier (3) into
position and hand tighten the four bolts (4) until
seated. Torque bolts to specification.

Cam Drive Carrier Bolts: 14 ft-lbs (19.0 Nm)

6. Install the cam drive sprocket bolt (5) and washer.

Torque to specification.

Cam Drive Sprocket Bolt: 52 ft-lbs (70.0 Nm)

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Camshaft Sprocket Installation / Timing
Procedure

7
IMPORTANT: Camshaft sprockets are 2. Rotate camshafts so the lobes are positioned as
interchangeable (identical for all camshafts) and indicated in the image below.
drilled offset so that they cannot be installed
incorrectly.
Letters / Timing Marks on sprockets will appear
right-side up if timed correctly and the respective
cylinder is at TDC.

CAUTION

DO NOT rotate crankshaft / primary drive gear

counterclockwise while timing the camshafts.

1. Lock the crankshaft so that the front piston is at

TDC. See Locking the Crankshaft for Service, page
10.4.

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3. Starting with the front cylinder, install the INTAKE 6. Rotate the EXHAUST camshaft until the screw holes
sprocket to the camshaft. Torque screws (1) to line up and install one screw (3) into the exposed
specification. hole and torque to specification.
NOTE: Threaded holes in camshaft hubs must
be free from oil and debris.

Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)

Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)

4. Take up the slack on the intake side of the cam

chain and lay it over the INTAKE sprocket. Verify
that the timing marks (2) line up with the chain
installed and slack removed.

7. Install the front cam chain tensioner and torque to

specification. See Cam Chain Tensioner
Installation, page 7.21.
8. Supporting the rear cam chain, remove the
crankshaft locking pin, rotate the crankshaft 300°
(CLOCKWISE) and re-lock the crankshaft with the
5. Engage the cam chain with the EXHAUST sprocket rear piston in the TDC position. See Locking the
teeth and fit the sprocket to the camshaft hub. Crankshaft for Service, page 10.4.
Verify the timing marks on both sprockets align
9. The timing mark on the primary drive gear will be
with the machined valve cover gasket surface when
at approximately 10 o’clock. Note: Disregard
slack is removed from the intake side of the chain. location of double dots on the crankshaft gear.

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10. Working on the rear cylinder, install the INTAKE 13. Rotate the EXHAUST camshaft until the screw holes
sprocket to the camshaft. Torque screws (4) to line up and install one screw (6) into the exposed
specification. hole and torque to specification.
NOTE: Threaded holes in camshaft hubs must
be free from oil and debris.

Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)

Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)

11. Take up the slack on the intake side of the cam

chain and lay it over the INTAKE sprocket. Verify
that the timing marks (5) line up with the chain
installed and slack removed.

14. Install the rear cam chain tensioner and torque to

specification. See Cam Chain Tensioner 7
Installation, page 7.21.
15. Rotate the crankshaft and install the remaining
camshaft sprocket screws. Torque to specification.

12. Engage the cam chain with the EXHAUST sprocket

teeth and fit the sprocket to the camshaft hub.
Verify the timing marks on both sprockets align
with the machined valve cover gasket surface when
slack is removed from the intake side of the chain. Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)

16. Rotate the crankshaft several times and stop on

TDC of both cylinders to verify that the timing
marks still match up and that the engine turns
freely.

Cam Chain Tensioner Installation

1. Verify that the engine is at TDC and the timing
marks are properly aligned. See Cylinder Head,
page 7.8.
2. Install the tensioner (s) with new sealing washers
and torque to specification.

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3. Install tensioner bolt and torque to specification.

Cam Chain Tensioner: 25.8 ft-lbs (35.0 Nm)

Cam Chain Guide (upper), Installation

1. Install guide (s) and torque screws (2) to
specification.

Cam Chain Guide Screws (upper): 88.5 in-lbs (10.0

Nm)

2. Install valve cover(s). See Valve Cover Installation,

page 7.23.

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CYLINDER HEAD SERVICE Valve Cover Installation
1. Assemble new cover gasket (4) on the valve cover.
Valve Cover Removal
1. Secure the vehicle in an upright position.
2. Remove the seat. See Seat Removal / Installation,
page 3.7.
3. Remove the fuel tank. See Fuel Tank Removal,
page 5.21.
4. Remove air box. See Air Box Removal, page 5.18.
5. Use a T40 Torx to remove the three valve cover
screws (1).

2. Assemble spark plug tube seal (5) on cylinder

head.
3. Install valve cover (2) on cylinder head with new
isolators (3) and hand tighten the valve cover
fasteners (1).
4. Reference the torque sequence and torque valve
cover screws to specification.

7
6. Remove the valve cover (2) and gaskets.
7. Discard and replace the valve cover isolators (3),
gasket seal (4), and the spark plug tube seal (5).

Valve Cover Screws: 88.5 in-lbs (10.0 Nm)

5. Install ignition coils. See Ignition Coil Removal /

Installation, page 16.6.
6. Install airbox. See Air Box, page 5.10.
7. Install fuel tank. See Fuel Tank Installation, page
5.26.
8. Install the seat. See Seat Removal / Installation,
page 3.7.

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Valve Clearance Assembly

NOTE: Always inspect valve clearance prior to

camshaft installation or final engine assembly. Camshaft Carrier Bolts: 88.5 in-lbs (10.0 Nm)
1. Reference the camshaft intake and exhaust
markings made during disassembly. If installing 6. Rotate the camshaft until the cam lobes above the
new camshafts or if camshafts were not marked, valves you are inspecting are facing up (Item 6).
reference the part number stamped on the 7. Measure the valve clearance (Item 7) using a
camshaft ends. thickness (feeler) gauge. Record the measurement
if clearance is out of specification.
Intake Camshaft - PN 3022484
Exhaust Camshaft - PN 1204693 8. Repeat steps 6 and 7 until all eight valves have
been inspected.
2. Lubricate the camshaft bearing journal surfaces
with Indian Motorcycle engine oil prior to
installation.
3. Carefully install the camshafts into the cylinder
head. The camshaft lobes (Item 1) should be Intake Valve Clearance (cold): 0.006” ± 0.001”
positioned as shown. (0.152 mm ± 0.05 mm)
Exhaust Valve Clearance (cold): 0.008” ± 0.001”
(0.023 mm ± 0.05 mm)

9. If any of the valve clearance measurements are out

of specification, remove the camshaft carriers and
camshafts and proceed with this procedure.
NOTE: If all valve clearance measurements
are within specification, remove the camshaft
carriers and proceed to .

10. Remove the valve tappet from a valve that was out
of specification.
NOTE: Keep mated parts together and in order
with respect to their location in the cylinder
head for assembly purposes. Mark each
4. Carefully install the camshaft carrier onto the component or place them in an organized rack
camshafts. as you remove them.

11. Record the 3 digit number on the bottom of the

tappet. (Item 8).
12. Reference the valve clearance measurement
recorded for that valve, along with the 3-digit
tappet number.
13. Refer to the appropriate tappet selection matrix
(Intake or Exhaust) on the following pages and
select the proper tappet.
14. Install the proper tappet.
NOTE: Lubricate the outer portion of the valve
tappet upon installation.

15. Repeat steps 10-14 until all necessary valves have

been adjusted.
5. Install the camshaft carrier bolts (Item 4 & 5) and 16. Reinstall the camshafts and camshaft carriers and
tighten the bolts evenly to specification. tighten the bolts evenly to specification.

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Camshaft Carrier Bolts: 88.5 in-lbs (10.0 Nm)

17. Measure and confirm that valve clearance is now

within specification for each valve.
18. If valve clearance is not within specification, repeat
this procedure.
19. If all valve clearance measurements are now within
specification, remove the camshaft carriers and
proceed to .

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Camshaft Inspection
For the following camshaft inspection procedure,
refer to the camshaft service specifications sec-
tion. See Service Specifications, page 7.4.

1. Visually inspect camshaft journal surfaces for Cylinder Head Removal

scoring or signs of insufficient lubrication. Replace
camshaft if heavy scoring or damage is noted.
2. Inspect height of each cam lobe for INTAKE and CAUTION
EXHAUST camshafts.
3. Measure O.D. of each camshaft journal for INTAKE Cylinder and Cylinder Head assemblies may have
and EXHAUST camshafts. extremely sharp machined surfaces. Gloves should
be worn whenever handling these components to
4. Inspect the camshaft hub face for damage or prevent personal injury.
surface roughness.
5. Inspect decompression device (EXHAUST IMPORTANT: Removing the cylinder head (s)
camshaft only). releases pressure on the cylinder base gasket (s).
6. Inspect camshaft thrust face (s) for uneven wear Cylinder base gasket(s) should always be replaced
and scoring. in conjunction with cylinder head removal /
service.
7. Wash the camshaft in solvent.
8. Oil the camshaft. 1. Remove engine from frame and place on an
engine stand. See Removing Engine From Frame,
page 6.5.
2. Remove the intake manifold assembly. See Intake
Manifold, Removal / Installation, page 5.20.

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3. NOTE: Repeat STEPS 3 - 11 for each cylinder 9. Using a long extension, remove the two screws (2)
head being serviced. Cylinder heads can be from inside the cam chain gallery.
removed individually.
Remove the ignition coil from the cylinder (s)
being serviced. See Ignition Coil Removal /
Installation, page 16.6.
4. Remove the camshaft sprockets. See Camshaft
Sprocket Removal, page 7.12.
5. Remove the lower cam chain guides. See Cam
Chain Guide (lower), Removal, page 7.14.
6. Carefully lower the cam chain into the cam chain
gallery.
7. Remove the seven remaining screws (1) and the
camshaft carrier.

10. Alternately loosen and remove cylinder head bolts

(2).

8. Paying attention to location / orientation, remove

camshafts from cylinder head.

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11. Remove the cylinder head assembly and cylinder 2. NOTE: If tappets will be reused, wipe excess
head gasket by carefully lifting off of cylinder. oil off using solvent and a clean towel. Mark
each tappet with a marker so it can be matched
to it’s respective bore upon reassembly.
Remove the tappets (1) by lifting out of the bore.

Cylinder Head Disassembly

3. Using valve spring compressor PV-1253 remove

CAUTION keepers (2), upper spring retainer (3) and valve
spring (4) from valves.
Wear eye protection while removing valve springs.

NOTE: Keep mated parts together for assembly.

1. Remove the cylinder head (s) to be serviced. See

Cylinder Head Removal, page 7.26.

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4. Slide valve (5) out through the bottom of the Cylinder Head Inspection
cylinder head. 1. Visually inspect cylinder head for cracks or
damage. Pay close attention to the areas around
spark plug (1) and valve seats (2).

5. Remove and discard the spring seat / valve stem

seal assembly (6).
2. Inspect cylinder head for distortion with a straight
edge and feeler gauge. Check in different
directions and locations on the cylinder head. For
cylinder head service limits, see Service
Specifications, page 7.4.

Valve Spring Free Length Inspection 7

1. Measure free length of valve springs. Replace
springs that do not meet specification. See
Service Specifications, page 7.4.

6. Clean carbon deposits from combustion chamber.

7. Clean gasket surfaces.

NOTE: Intake and exhaust springs are

identical.

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Valve Inspection 6. Measure valve stem deflection (Item 3) for all
valves to determine if valve or valve guide
NOTE: Valve service specifications can be found requires replacement.
at the beginning of this chapter. See Service
Specifications, page 7.4.

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

valve stem runout (1) using a runout gauge or
similar tool.

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

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

4. Insert valves into their original locations in

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

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Valve Inspection - Quick Reference
CONDITION ILLUSTRATION POSSIBLE CAUSE CORRECTIVE ACTION
Uneven seat width Bent valve stem, worn Replace valve and reface
valve guide seat

Damaged valve face Burnt, pitted, foreign Replace valve and reface
material damage seat

Contact area too high Wear, settling of valve seat Lower with 30o stone

Contact area too low Wear, settling of valve seat Raise with 60o stone

Contact area too wide Wear, settling of valve seat Narrow with both 30o stone
and 60o stone

Contact area too narrow Use 45o stone

Contact area free of pitting Correct None

and damage, centered in
seat, proper width.

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Valve Guide Removal / Installation 5. Tap valve several times to make a clear impression
on the valve face. Do not rotate valve.

CAUTION 6. Remove valve and measure contact area (valve

seat width). See Service Specifications, page 7.4.

Replacement of valve guides requires an oven,

special equipment and experience to do the job
correctly. If you are unsure of your ability to do the
repair professionally it is best to sublet the labor to a
competent machinist. Valve seat reconditioning is
required when valve guides are replaced.

1. Support cylinder head and place valve guide

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

CAUTION
7. If valve seat is incorrect, recondition as needed.
The cylinder head can be easily damaged if the
procedure is done carelessly.
Valve Seat Reconditioning
3. Apply 90 weight oil to outside of new valve guides.
NOTE: Valve seat reconditioning should be
4. Drive or press new guides from rocker arm side of performed by a technician proficient in cylinder
head. head reconditioning techniques using grinding
stones. The use of carbide cutters is not
5. Measure valve guide height from spring seat:
recommended. Follow recommendations of the
manufacturer of the valve seat reconditioning
equipment being used. Do not grind seats more
than necessary to provide proper seat width and
contact point on valve face.

Guide Height from Valve Spring Seat (Installed): 11.4

–11.8 mm Cylinder Head Assembly
6. Ream new valve guides to size to obtain specified
stem-to-guide clearance. Ream from combustion CAUTION
chamber side of head.
7. Clean cylinder head thoroughly with clean Wear eye protection during assembly.
solvent.
8. Inspect and recondition valve seats. 1. Lubricate valve stems with assembly lube.
2. Install valve in head before installing seal. Hold
Valve Seat Inspection valve against seat wipe off the portion that extends
above the guide.
NOTE: Valves cannot be ground. If valve face is
burned or badly worn, replace the valve. 3. Apply Indian Motorcycle engine oil to valve guide
seal and install seal on valve, rotating the seal as
1. Remove carbon deposits from valves and seats. you install it.
2. Inspect valve face for burning, pitting or uneven 4. Press seal firmly in place on top of guide. Be
contact. careful not to dislodge spring from seal.
3. Apply a light coating of machinist’s layout fluid or
paste to valve face.
4. Install valve into valve guide.

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5. Install valve spring and upper retainer. 2. Thoroughly clean cylinder and cylinder head
mating surfaces.
CAUTION NOTE: Gaskets and gasket sealing surfaces
must be free of oil and grease during assembly.
Do not compress valve springs more than necessary
to install keepers. 3. Install a new head gasket (2).
Support cylinder head so valves will not be 4. Set cylinder head in place on cylinder and press
damaged. down over the locating dowels until fully seated.

6. Compress valve springs using a valve spring

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

Cylinder Head Installation

CAUTION

Torque-to-Yield cylinder head bolts can only be 5. Apply a thin coat of Indian Motorcycle engine oil
reused / re-torqued once following removal. to the cylinder head bolt threads and install bolts
Attempts to reuse bolts beyond one re-torque may (3) finger-tight. 7
result in lower sealing pressure and potential oil /
coolant leaks.

NOTE: The base gasket seal is broken when the

cylinder head is removed and must be replaced.
See Cylinder Installation, page 8.12.

1. Verify that locating dowels (1) are in position on

the cylinder deck.

6. Torque cylinder head bolts in an “X” pattern

following the specified sequence:
1. 1st pass - 21 ft-lbs (28.0 Nm)
2. 2nd pass - 26 ft-lbs (35.0 Nm)
3. 3rd pass - Torque an additional 180°

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7. Install screws (4) into cam chain gallery and 9. Lubricate camshaft lobes and bearing journals
torque to specification. with Indian Motorcycle engine oil and install into
cylinder head.

10. Insert the spark plug seal into the cam carrier and
install carrier onto cylinder head.
11. Temporarily install the upper cam chain guide and
Cam Chain Gallery Screws: 88.5 in-lbs (10.0 Nm) torque the carrier screws per the specified
sequence.
8. Apply a thin coat of Indian Motorcycle engine oil
to each of the tappets (5) and install them in the
same position from which they were removed.

Cam Carrier Screws: 88.5 in-lbs (10.0 Nm)

12. Check valve lash and adjust if necessary. See

Valve Clearance Assembly , page 7.24
13. Remove upper cam chain guide.
14. Install cam chain. See Camshaft Sprocket
Installation / Timing Procedure, page 7.19.

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15. Install upper cam chain guide and re-torque per Intake Valve Lash - Tappet Selection
STEP 11. Matrix
16. Install valve cover (s). See Valve Cover Tappet Thickness: Example 440 equals thickness of
Installation, page 7.23. 4.40 mm. Part Number: 5138477-XXX (X’s represent 3
17. Install intake manifold. See Intake Manifold, digits on tappet)
Removal / Installation, page 5.20.
18. Install engine in frame. See Engine Installation,
page 6.7.

Intake Valve Clearance (cold):

.006 ± .002″ (0.150 ± .05 mm)

Existing Valve Lash Tappet Marking (3 digits on tappet)

440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525

Correct Valve Lash Tappet Marking (3 digits on tappet)

0.000-0.024 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512

0.025-0.049 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515
Intake Valve Clearance Before Adjusting (mm)

0.050-0.074 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518

0.075-0.099 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520
0.100-0.200
(Standard)
0.201-0.225 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532

0.226-0.250 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535

0.251-0.275 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538
0.276-0.300 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540

0.301-0.325 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542
7
0.326-0.350 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.351-0.375 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.376-0.400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.401-0.425 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.426-0.450 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.451-0.475 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.476-0.500 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.501-0.525 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.526-0.550 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.551-0.575 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.576-0.600 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.601-0.625 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.626-0.650 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.651-0.675 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.676-0.700 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.701-0.725 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.726-0.750 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.751-0.775 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.776-0.800 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.801-0.825 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.826-0.850 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.851-0.875 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.876-0.900 515 518 520 522 525 528 530 532 535 538 540 542 545
0.901-0.925 518 520 522 525 528 530 532 535 538 540 542 545

0.926-0.950 520 522 525 528 530 532 535 538 540 542 545

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0.951-0.975 522 525 528 530 532 535 538 540 542 545

0.976-1.000 525 528 530 532 535 538 540 542 545

Exhaust Valve Lash - Tappet Selection

Matrix
Example:
Tappet Thickness: Example 440 equals thickness of Exhaust Valve Clearance (cold):
4.40 mm. Part Number: 5138477-XXX (X’s represent 3 .008 ± .002″ (0.200 ± .50 mm)
digits on tappet)

Existing Valve Lash Tappet Marking (3 digits on tappet)

440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525

Correct Valve Lash Tappet Marking (3 digits on tappet)

0.000-0.024 420 422 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505

0.025-0.049 422 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508
Exhaust Valve Clearance Before Adjusting (mm)

0.050-0.074 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510
0.075-0.099 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512

0.100-0.124 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515
0.125-0.149 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518
0.150–0.250
(Standard)
0.251–0.275 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530
0.276–0.300 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532
0.301–0.325 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535
0.326–0.350 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538
0.351-0.375 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540
0.376-0.400 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542

0.401-0.425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.426-0.450 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.451-0.475 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.476-0.500 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.501-0.525 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.526-0.550 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.551-0.575 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.576-0.600 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.601-0.625 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.626-0.650 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.651-0.675 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.676-0.700 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.701-0.725 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.726-0.750 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.751-0.775 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.776-0.800 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.801-0.825 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.826-0.850 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.851-0.875 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.876-0.900 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.901-0.925 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545

0.926-0.950 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545

0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545

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Troubleshooting, Cylinder Head and Valve Train
NOTE: Cylinder head, valve train and piston/cylinder problems are usually detected by an engine
compression test. Other problems associated with this area of the engine are external fluid leaks,
excessive oil consumption or abnormal noises.
The troubleshooting tables that follow list possible causes of engine mechanical problems. Always
thoroughly investigate before disassembling an engine.

PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Worn Valve Guide(s) Replace Valve Guide(s)
Poor Seating of Valve(s) Repair or Replace
Broken Valve Spring(s) Replace
Spark Plug Not Seated Torque to Specification
Incorrect Valve Timing Repair / Retest
Valve Stuck Open Repair / Retest
Cylinder Head Gasket Repair / Retest
Hard Starting / Won’t Start Low Compression
Leak
Slow Starter Motor Refer to Chapter 15
Worn Rings, Piston, or Refer to Chapter 8
Cylinder
Valve Clearance out of Adjust Valve(s)
Specification 7
Ignition Problem Refer to Chapter 16
Fuel Problem Refer to Chapter 5
Excessive carbon build- De-carbon Combustion
High Compression up in combustion Chamber
Electric Starter Straining chamber
to Turn Engine Over Excessive Starter Load Internal Engine / Drive Determine Cause of
Components Seized or Seizure or Binding
Binding
Valve Clearance out of Adjust Valve(s)
Low Compression Specification
Poor Seating of Valve(s) Repair or Replace
Poor idle Quality (Engine
Valve Guides Replace
Related)
Excessive Oil in Worn Rings, Piston, or Refer to Chapter 8
Combustion Chamber Cylinder
Engine Oil Overfilled Correct Engine Oil Level
Loose or Tight Valve(s) Adjust Valve(s)
Broken or Weak Valve Replace
Engine Noise Valve Train Area Spring(s)
Worn Camshaft or Tappet Replace

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Chain Tensioner and / or Replace
Guide Worn
Cam Bearings Worn or Replace
Damaged
Worn Pistons and / or Replace
Cylinders
Worn Wrist Pin, Wrist Pin Replace
Piston / Cylinder Area Bore and / or Connecting
Rod
Worn Piston Rings or Replace
Piston Ring Lands
General Exhaust Leak Reseal Exhaust
Chain / Sprocket Worn Replace
Timing Chain Area Replace
Chain Tensioner and / or
Guide Worn
Bottom End Area Main Bearings Refer to Chapter 10
Rod Bearings Refer to Chapter 10
Loose Side Clearance Refer to Chapter 10
Transmission Area Bearings Refer to Chapter 10
Air Intake Problem - Refer to Chapter 5
Fuel Injection Problem - Refer to Chapter 5
Ignition Problem - Refer to Chapter 16
Poor High-Speed Running Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft / Tappet Replace
Valves Opening and Incorrect Valve Timing Correct
Closing at Wrong Time
Low Compression Worn Piston, Rings, Repair / Replace
Cylinder, Poor Valve
Seating
Valve Timing Incorrect Cam Chain and Sprockets Correct
Lack of Power in all RPM Valve Float Weak Valve Springs Replace
Ranges
Insufficient Valve Lift Worn Camshaft / Tappets Replace
Ignition / Fuel Injection — Refer to Chapter 5 (EFI)
System or Chapter 16 (Ignition)
Oiling Problem Oil Overfilled Correct Engine Oil Level

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CHAPTER 8
CYLINDER / PISTON
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CYLINDER / PISTON SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
PISTON RING PROFILE AND ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
CYLINDER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
PISTON TO CYLINDER CLEARANCE WORKSHEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
CYLINDER WARPAGE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
PISTON & PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
PISTON & PISTON RING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
PISTON PIN / PIN BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
TROUBLESHOOTING, CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14

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GENERAL INFORMATION Special Tools
Service Notes TOOL DESCRIPTION PART NUMBER

NOTE: Clean the machine thoroughly before Piston Ring Compressor PV-43570-A
removing engine from frame. Engine Lock Tool - PF-51612
Transmission
• This section covers service of the cylinder,
piston and rings. The engine must be removed Engine Lock Tool - PF-51235-A
from the frame to perform the procedures in this Crankshaft
section. Refer to Chapter 6 for engine removal
Cylinder Bore Gauge PV-3017
and installation.
• Mark and store all mated parts for assembly. Engine Case Splitting Tool PF-51234-A
Assemble engine by putting used parts that pass Straightedge, Feeler Commercially
inspection back in the same location. Gauge Available
• Machined mating surfaces are very delicate.
Handle and store all parts in such a way that the Bosch Automotive Service Solutions: 1-800-328-
mating surfaces will not be damaged. 6657 or https://polaris.service-solutions.com/
• Many parts require assembly lubrication. Follow
the assembly lubrication procedures carefully. Torque Specifications
• There are many precision measuring steps in
DESCRIPTION TORQUE
this section. If you are not sure of your
SPECIFICATION
capabilities in these areas, have a competent
machinist perform the precision part inspection Connecting Rod STEP 1: 22 ft-lbs (30.0 Nm)
operations. Bearing Cap STEP 2: : Additional 90°
• Cleanliness of parts is critical to engine life and
proper parts inspection. Use clean solvent and
hot, soapy water to clean parts. Dry with
compressed air before inspection and engine
assembly. Coat parts with fresh lubricant to
prevent oxidation after cleaning.

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Service Specifications

ITEM STANDARD SERVICE LIMIT

98.992 - 99.008 Check taper and
I.D. (3.8973 - 3.8979”) out-of-round

Cylinder Out of Round Measure 50 mm down from 0.05 mm (.002")

head surface
Taper 0.05 mm (.002")
Gasket Surface Warpage - .1mm max. (.0039")
Piston Mark Direction Piston orientation is determined by arrow on piston
crown.
Position BOTH pistons so arrows point to front of engine.
Piston O.D. (Nominal) 98.933 - 98.947 mm Replace if piston-to-
(Measured 12 mm up (3.8949 - 3.8955") cylinder clearance is
from bottom of skirt, 90 excessive with good
degrees to pin) cylinder
Piston Piston Pin Hole I.D. 22.004 - 22.010 mm 22.047 mm
(.8663 - .8665") (.8679")
Piston Pin O.D. 21.995 - 22.000 mm 21.96 mm
(.8659 - .8661") (.864")
Piston to Cylinder .045 - .075 mm .15 mm
(.0017 - .0029") (.006")
Piston to Piston Pin .004 - .015 mm .030 mm
Ring End Gap - Top .15 - .31 mm .80 mm
(Installed) (.006 - .012") (.031")
Ring End Gap - 2nd .25 - .50 mm 1.11 mm
(Installed)Ring End Gap - (.009 - .019") (.043")
Piston Ring Clearances 3rd (Oil Control Rails) .25 - 1.02 mm .80 mm
(Installed) (.009 - .040") (.031") 8
Piston Ring Marks - DOT mark must face UP on
all rings.
Top Ring .03 - .095 mm
.15 mm (.0059")
(1.2mm ring thickness) (.0001 - .0037")

Piston Ring to Ring 2nd Ring .02 - .066 mm

.10 mm (.0039")
Land (1.2mm ring thickness) (.0007 - .0025")
.03 - .13 mm
Oil Control Ring .25 mm (.0098")
(.001 - .0051")

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ASSEMBLY VIEWS
Cylinder / Piston

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Circlip, Piston (QTY.4) -

2 Wrist Pin, Piston (QTY.2) -

3 Piston (QTY.2) -

4 Oil Control Ring / Expander (QTY.2) -

5 Compression Ring #2 -

6 Compression Ring #1 -

7 Gasket, Cylinder Base (QTY.2) -

8 Cylinder, Rear -

9 Bolt, Connecting Rod - M9 x 1.0 STEP 1: 22 ft-lbs (30.0 Nm)

(Single Use Fastener) STEP 2: : Additional 90°
10 Connecting Rod -

11 Cylinder, Front -

12 Sealing Washer (Front Cyl. Only) -

13 Cam Chain Tensioner (Front Cyl. Only) -

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CYLINDER / PISTON SERVICE
Piston Ring Profile And Orientation

NUMBER DESCRIPTION
1 Arrows on piston crown indicating installation direction. Both arrows point toward the front of the engine.
2 Front piston is installed closest to the primary drive side of the engine.
3 Rear piston is installed closest to the mag side of the engine.
4 Wrist pin circlip. Install the circlip with the gap positioned at 12 o’clock.
5 Oil Control Ring
6 Compression Ring No. 2
7 Compression Ring No. 1

4 Second Compression Ring End Gap

5 Top Compression Ring End Gap
8
6 Piston Marking Faces Front of Engine

Cylinder Removal
1. Remove cylinder head (s). See Cylinder Head
Removal, page 7.26.

NU- DESCRIPTION
MBE-
R
1 Lower Oil Ring Rail End Gap
2 Oil Ring Spring Expander End Gap
3 Upper Oil Ring Rail End Gap

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2. Remove cylinder(s) (1). Support pistons to prevent Cylinder Bore Measurement
damage. Place shop towels around piston/rings to 1. Measure each cylinder bore in 6 places to
prevent damage. determine:

NOTE: Bottom measurement should be taken

2.6 in (66 mm) up from base gasket surface.
3. Remove cylinder base gasket (2).
4. Clean gasket surfaces of cylinders thoroughly. • Cylinder Bore Inside Diameter
• Cylinder Taper
CAUTION • Out of Round

Careless handling of cylinder, pistons or rings may 2. Use maximum measurement to determine wear.
cause irreparable damage. Do not damage gasket 3. Use the worksheet provided to record
surfaces during cleaning. measurements and calculate the clearance.

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

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Piston To Cylinder Clearance Worksheet

Front Cylinder Recorded Measurement Specification

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

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Rear Cylinder Recorded Measurement Specification

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

Compare recorded measurement to specifications. If

measured value exceeds service limit replace the
appropriate part.

NOTE: If the piston-to-cylinder clearance exceeds the service limit, measure a new piston and re-
calculate the clearance. If the piston-to-cylinder clearance exceeds the service limits with a new piston,
the cylinder can be replaced or serviced to accommodate oversize piston/rings by a qualified machine
shop.

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Cylinder Warpage Measurement 3. Push piston pin (2) out to left side of engine and
1. Inspect cylinder for warpage at cylinder head remove the piston (3).
surface and base gasket surface.

4. Rotate rings in piston grooves. Rings should rotate

freely in grooves.

2. Place a straight edge diagonally across cylinder 5. Clean carbon deposits from piston.
mating surfaces in several positions. Attempt to 6. Spread rings only wide enough to remove them
slide a .05mm (.002") feeler gauge under the from piston. Spreading rings too wide will damage
straight edge in each position. them.
3. Replace cylinder if warped beyond the service 7. Clean piston ring grooves. Break or cut a piston
limit. ring in half. File or grind one edge square and
remove all burrs. Use this piston ring to carefully
Piston & Piston Ring Removal clean piston ring grooves.
1. Cover crankcase with a clean shop towel to NOTE: A soft wire brush may be used to only
prevent piston circlip from falling into the clean the top of the piston. Do not use a wire
crankcase. brush to clean the sides of piston or the piston
2. Remove the left piston pin circlip (1). ring grooves. 8

Piston & Piston Ring Inspection

1. Visually inspect piston for cracks, excessive wear,
scoring, etc.

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2. Measure piston skirt O. D. (90° to pin and 12 mm 7. Install rings onto a clean piston. Push rings in until
from bottom of piston skirt). Replace piston if worn they are flush with piston. Using a feeler gauge,
beyond the service limit. See Service measure side clearances for the 1st & 2nd rings.
Specifications, page 8.3.

8. Replace parts that exceed service limit.

3. Calculate Piston to Cylinder Clearance. Subtract
piston O.D. from cylinder bore I.D. and compare to
specifications. See Service Specifications, page Piston Pin / Pin Bore Inspection
8.3. 1. Measure piston pin hole I.D. (as shown) as close to
4. Replace parts that do not meet specification. the circlip groove as possible with a telescoping
gauge. Record the smallest measurement.
NOTE: If piston-to-cylinder clearance exceeds
service limit, measure a new piston and re-
calculate clearance. If piston-to-cylinder
clearance exceeds service limits with a new
piston, cylinder must be replaced.

5. Use a piston to push each ring squarely into

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

6. Measure installed ring end gap with a feeler

gauge and compare to specifications. See Service
Specifications, page 8.3.

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2. Measure piston pin O.D. at three locations. Record 2. Carefully install oil control ring expander with end
largest measurement. gap located as shown. See Piston Ring Profile And
Orientation, page 8.5.
3. Install top and bottom rails with end gap located
as shown. See Piston Ring Profile And Orientation,
page 8.5
4. Install top ring and second ring with pip markings
facing UP.
5. Compress each ring by hand and rotate to be sure
they rotate freely in grooves.
6. Locate ring end gaps as shown below in relation to
arrow on piston crown. See Piston Ring Profile
And Orientation, page 8.5.

Piston Installation
The pistons are marked with an arrow on the crown.
Install pistons on connecting rods with arrow facing
3. Calculate piston pin-to-piston clearance. Subtract the FRONT of the engine.
pin O.D. from pin hole I.D.
4. Measure connecting rod small end I. D. at two
locations.

1. Place a clean shop towel over crankcase to prevent

5. Calculate connecting rod-to-piston pin clearance foreign material from entering crankcase.
by subtracting pin O.D from rod hole I.D.
2. Install a new circlip on one side of the piston with
6. Compare measurements to specifications and end gap facing UP (12:00 position).
replace any worn parts. See Service
Specifications, page 8.3.
CAUTION
Piston Ring Installation
Never reuse piston pin circlips.

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

small end with engine oil or moly lube.

The rings may be damaged if they are over 4. Install piston over connecting rod with arrow on
expanded during installation. piston crown facing FRONT of engine.
5. Push piston pin (2) through rod and piston pin hole
1. Lubricate all rings with engine oil. until it is stopped by circlip.

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6. Install remaining circlip (3) with end gap facing up 5. Apply a small amount of crankcase sealant to the
(12:00 position.) crankcase parting lines on base gasket surface as
shown.

7. Make sure both piston circlips are seated properly

in the groove. 6. Install new cylinder base gaskets onto crankcase.
NOTE: Inspect all sealing surfaces carefully
Cylinder Installation for scratches or imperfections. DO NOT allow
oil or grease to contact gaskets or sealing
NOTE: Be sure all top end parts are ready for surfaces during the assembly process.
assembly. Sealant on crankcase parting line must
not be allowed to dry before top end is assembled 7. Apply a small amount of engine oil to inside
and torqued. surfaces of a piston ring compressor band.

1. First wash cylinders with clean solvent, then with 8. Install piston ring compressor over rings and
hot soapy water. compress rings into ring grooves.

2. Rinse the cylinders with clear water and

immediately dry with compressed air. Cylinder CAUTION
bore should be wiped with a clean white shop
towel and engine oil. Be sure compressor band end gap does not align
with any ring end gap when compressing the rings.
3. Apply a light coat of engine oil to piston and rings.
4. Ensure cylinder alignment dowel pins are in place
and gasket surfaces are clean and oil-free. NOTE: Install cylinders in their original
locations. Cylinder with cam chain tensioner is
the front cylinder.

9. Remove protective covering from crankcase.

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10. Carefully install cylinder (s) over piston/ring
assembly. Do not force cylinder over piston.
Monitor rings carefully. If a piston ring becomes
dislodged from the ring compressor; remove
cylinder, inspect ring carefully for damage.

11. Remove piston ring compressor when rings are

fully captive in cylinder.
12. Slide cylinder down over piston until seated to
base gasket and crankcase surface.
13. Repeat for other cylinder.
14. Install cylinder head (s). See Cylinder Head
Installation, page 7.33.

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Troubleshooting, Cylinder / Piston

PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Worn Valve Guide(s) Replace Valve Guide(s)
Poor Seating of Valve(s) Repair or Replace
Broken Valve Spring(s) Replace
Spark Plug Not Seated Torque to Specification
Incorrect Valve Timing Repair / Retest
Valve Stuck Open Repair / Retest
Cylinder Head Gasket Repair / Retest
Hard Starting / Won’t Start Low Compression
Leak
Slow Starter Motor Refer to Chapter 15
Worn Rings, Piston, or Refer to Chapter 8
Cylinder
Valve Clearance out of Inspect / Adjust as
adjustment necessary
Ignition Problem Refer to Chapter 16
Fuel Problem Refer to Chapter 5
High Compression Excessive carbon build- De-carbon Combustion
up in combustion Chamber
Electric Starter Straining chamber
to Turn Engine Over Excessive Starter Load Internal Engine / Drive Determine Cause of
Components Seized or Seizure or Binding
Binding
Valve Clearance out of Inspect / Adjust as
Low Compression adjustment necessary
Poor Seating of Valve(s) Repair or Replace
Poor idle Quality (Engine Valve Guides or worn Replace
Related) valve stem seals
Excessive Oil in Worn Rings, Piston, or Refer to Chapter 8
Combustion Chamber Cylinder
Engine Oil Overfilled Correct Engine Oil Level
Valve Clearance out of Inspect / Adjust as
adjustment necessary
Broken or Weak Valve Replace
Spring(s)
Engine Noise Valve Train Area Worn Camshaft or Rocker Replace
Arm
Camshaft Bearing Inspect / Repair
Damage / Wear
Cam Sprockets Worn Replace

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Worn Pistons and / or Replace
Cylinders
Worn Wrist Pin, Wrist Pin Replace
Piston / Cylinder Area Bore and / or Connecting
Rod
Worn Piston Rings or Replace
Piston Ring Lands
General Exhaust Leak Reseal Exhaust
Chain / Sprocket Worn Replace
Timing Chain Area Replace
Chain Tensioner and / or
Guide Worn
Bottom End Area Main Bearings Refer to Chapter 10
Rod Bearings Refer to Chapter 10
Loose Side Clearance Refer to Chapter 10
Transmission Area Bearings Refer to Chapter 10
Air Intake Problem - Refer to Chapter 5
Fuel Injection Problem - Refer to Chapter 5
Ignition Problem - Refer to Chapter 16
Poor High-Speed Running Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft / Tappets Replace
Valves Opening and Incorrect Valve Timing Correct
Closing at Wrong Time
8
Low Compression Worn Piston, Rings, Repair / Replace
Cylinder, Poor Valve
Seating
Cam Chain and Sprockets Correct
Valve Timing Incorrect
Damaged Cam Gears Replace
Lack of Power in all RPM
Ranges Valve Float Weak Valve Springs Replace
Insufficient Valve Lift Worn Camshaft / Tappets Replace
Ignition / Fuel Injection — Refer to Chapter 5 (EFI)
System or Chapter 16 (Ignition)
Oiling Problem Oil Overfilled Correct Engine Oil Level

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NOTES

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CHAPTER 9
CLUTCH / PRIMARY / SHIFT
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
PRIMARY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
CLUTCH PINION SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PRIMARY DRIVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PRIMARY DRIVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
CLUTCH PINION SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
CLUTCH PINION SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
CLUTCH PINION SHAFT SEAL REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CLUTCH PINION SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
SHIFT RATCHET REMOVAL & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
SHIFT RATCHET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.11
SHIFT ARM REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
SHIFT SHAFT SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
CLUTCH RACK, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18 9
FLYWHEEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
STATOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
TROUBLESHOOTING, CLUTCH / PRIMARY / SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

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GENERAL INFORMATION Special Tools
Service Information TOOL DESCRIPTION PART NUMBER
• Clutch and external transmission shift linkage Case Splitting / Assembly Tool PF-51234-A
service can be accomplished with the engine in
the frame. Engine Lock Tool - Transmission PF-51612
• Internal transmission or internal shifting Engine Lock Tool - Crankshaft PF-51235-A
mechanism service requires engine removal
and crankcase separation. Engine Stand Adapter PF-51609
• Oil additives of any kind are not recommended Moly Assembly Paste 2871460
by Indian Motorcycle. Using oil additives or oil
of the wrong viscosity can have a detrimental
affect on clutch performance, operation, and Bosch Automotive Service Solutions: 1– 800– 328–
service life. 6657 or https://polaris.service-solutions.com/

• Burnt clutch plates are not an indication of

Torque Specifications
defective clutch plates. Burnt clutch plates
indicate that a problem exists within the clutch
system, the clutch has been used improperly, or PART DESCRIPTION TORQUE
plates were contaminated by improper oil or SPECIFICATION
additives. Clutch Stake Nut 125 ft-lbs (170.0 Nm)
• Indian Motorcycle 15W/60 motorcycle oil is Pressure Plate Screws 88 in-lbs (10.0 Nm)
recommended for all operating temperatures. If
Indian Motorcycle 15W/60 oil is not available, a Primary Cover Screws 88 in-lbs (10.0 Nm
high quality 15W/60 motorcycle oil suitable for
use in wet clutch transmissions can be used. Stator Bolts 88 in-lbs (10.0 Nm)
• Lubricate parts during assembly as described in
the procedures.
• Corroded or sticking shift linkage pivot points
can cause abnormal shifting. Replace any
linkage components that are damaged or do not
move freely, and lubricate at regular intervals.

Service Specifications

ITEM SPECIFICATIONS
Clutch Type Wet, Multi-Disk
Clutch Operating Mechanism Manual / Cable Operated
Primary Reduction Ratio 1.674 : 1
Transmission Shift Mechanism Manually Operated, Spring
Clutch / Gear Shift / Linkage Centered
Gearshift Pattern 1-N-2-3-4-5-6
Clutch Spring (Coil Type, QTY.6) Spring Height - Free: 55.3 mm /
Installed 30.6 mm
Clutch Lever Free Play (Cable) .50-1.50 mm (.019 - .059")

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ASSEMBLY VIEWS
Primary Cover

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Primary Cover - M6 x 1.25 x 75 (QTY.7) 88 in-lbs (10.0 Nm
2 Screw, Primary Cover - M6 x 1.25 x 35 (QTY.6) 88 in-lbs (10.0 Nm
3 Cover, Primary -
-
4 Gasket, Primary Cover 9
5 Screw, Primary Gear Cover 7.3 ft-lbs (10 Nm)
6 Bracket, Clutch Cable Retaining -

7 Bracket, Cable Mount -

8 Cover, Primary Drive -

9 Gasket, Primary Drive Cover -

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Primary Cover Torque Sequence

Primary Drive Cover Torque Sequence

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Clutch Pinion Shaft

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Cover, Primary
2 E-Clip, External –

3 Washer –
4 End Bearing, Pinion Shaft –

5 Bearing, Shaft (Clutch Pinion Shaft) –

–
9
6 Seal, Shaft
7 Pinion Shaft, Clutch –

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Clutch Assembly

NUM- PART DESCRIPTION TORQUE (IF APPLICABLE)

BER
1 Screw, Pressure Plate (QTY.6) 88 in-lbs (10.0 Nm
2 Spring, Clutch (QTY.6) -

3 Pressure Plate, Clutch -

4 Bearing, Clutch Lifter -

5 Lifter, Clutch Rack -

6 Nut, Clutch Retainer (Staking) 125 ft-lbs (170.0 Nm)
7 Washer, Flat -
8 Disc, Clutch Friction -
9 Disc, Clutch Steel -
10 Spring, Judder -

11 Seat, Judder Spring -

12 Clutch Hub, Inner -

13 Washer, Clutch -
14 Collar, Bearing -

15 Basket Assembly, Outer -

16 Spacer, Clutch -

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SERVICE PROCEDURES Primary Drive Cover Installation
1. Clean gasket surfaces of crankcase and cover.
Primary Drive Cover Removal
2. Install a new primary cover gasket (1) with flat
1. Place motorcycle in an upright position with the side towards primary cover (2).
front wheel clamped in a wheel vise.
2. Drain oil from engine. See Engine Oil / Filter
Change, page 2.9.
3. Remove the exhaust system. See Exhaust Removal.
4. Disconnect clutch cable from engine clutch lever.
See Clutch Cable Removal.
5. Remove clutch cover fasteners (1) and cover
assembly (2).

3. Torque the primary cover bolts (3) to specification

following the torque sequence.

Primary Cover Bolts: 88 in-lbs (10.0 Nm)

6. Remove primary drive cover fasteners (3), seal (5)

and cover assembly (4).

4. Clean clutch cover and primary drive cover gasket

mating surfaces.

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5. Install new clutch cover gasket (4) with flat side Clutch Pinion Shaft Removal
facing clutch cover (5). 1. Remove the Primary Cover (1). See Primary Drive
Cover Removal, page 9.7.
2. Remove the E-clip (2) and washer from the end of
the clutch pinion shaft as shown.

6. Install clutch cover fasteners and torque in

sequence to specification.

3. Slide the pinion shaft (3) out of the primary cover.

Primary Cover Bolts: 88 in-lbs (10.0 Nm)

7. Connect the clutch cable. Clutch Pinion Shaft Bearing Inspection

1. Apply engine oil to the bearings.
8. Install exhaust system.
2. Temporarily install pinion shaft into primary cover.
9. Check engine oil level.
3. Turn shaft by hand. Replace bearings that feel
rough, notched, or loose.

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Clutch Pinion Shaft Seal Removal & 2. Install washer (2) and E-clip (3).
Installation
1. Remove clutch pinion shaft. See Clutch Pinion
Shaft Removal, page 9.8.
2. Protect cosmetic surfaces and carefully pry seal
(1) out of primary cover.

Shift Ratchet Removal & Inspection

1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Shift transmission into neutral.
3. Lubricate outer edge of new seal with engine oil
and sealing lip with grease. 3. Remove shift pedal linkage from shift shaft.

4. Drive seal into place with a suitable driver. 4. Gently pry oil seal out of shift shaft bore and
remove external circlip as shown.
Clutch Pinion Shaft Installation
1. Lubricate and install clutch pinion shaft (1) until
fully seated in bearings.

5. Remove primary cover. See Primary Drive Cover

Removal, page 9.7.
6. Remove primary drive cover. See Primary Drive
Cover Removal.
7. Remove clutch assembly. See Clutch Removal,
page 9.13.

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8. Using a 4 mm hex wrench, remove the screw (1) 11. Inspect shift shaft return spring (10) for cracks or
securing the shift star (2) to the shift drum and loss of tension. The spring should have enough
remove shift star (3). Secure locating pin (4) for tension to keep the shift shaft centered.
reassembly.

9. Rotate the detent lever (7) so the spring (8) is

relaxed. Using a 10 mm socket, remove the bolt (5)
and washer (6) securing the detent lever to the
engine case. 12. Inspect shift shaft (11) for wear or damage.
10. Pull the shift shaft and spring assembly (9) out of 13. Inspect ratchet arm return spring (12) for tension.
the bore. The spring should apply enough tension on the
shift ratchet mechanism to keep it engaged with
the shift star.
14. Inspect fit of rivet (13) on shift ratchet assembly. It
should allow for free movement, but not be
excessively loose.

15. Inspect shift star for wear.

16. Inspect detent roller arm for wear or damage.
17. Inspect detent roller arm spring for cracks or
fatigue.

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Shift Ratchet Installation 2. Install circlip (4) and press new oil seal (5) into
1. Lubricate the shift shaft (1) with engine oil and position until flush with crankcase.
slide into bore until fully seated.
IMPORTANT: Verify that the return spring (2)
has properly engaged the dowel (3) as shown.

3. Install the detent roller arm and spring assembly

(6). Torque screw (7) to specification.

Detent Roller Arm Screw: 88.5 in-lbs (10.0 Nm)

4. Rotate the detent roller arm against the spring and

install a suitable locking pin (8) to hold it in
position.
5. Verify that the shift star dowel (9) is in place in the
shift drum and install the shift star (10).

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6. Install the shift star washer (11) and screw (12) and Shift Arm Removal / Installation
torque to specification.
1. Remove shift pedal linkage from shift shaft.

Shift Star Screw: 88.5 in-lbs (10.0 Nm)

7. Remove locking pin (8) to release the detent roller

arm.

Shift Shaft Seal Replacement

1. Remove shift shaft assembly. See Shift Ratchet
Removal & Inspection, page 9.9.
2. NOTE: The Shift Shaft Seal requires removal as
part of the shift shaft removal procedure.
Apply assembly lube to inner & outer surfaces of
new bearing.
8. Install the shift arm.
Moly assembly paste PN: 2871460
9. Install clutch assembly. See Clutch Installation,
page 9.18. 3. Apply a small amount of grease to lip of seal and
apply engine oil to outside of seal.
10. Install the primary cover. See Primary Drive
Cover Installation, page 9.7. 4. Drive seal into place with a seal driver slightly
smaller than the O.D. of seal.
5. Install primary cover. See Primary Drive Cover
Installation, page 9.7.
6. After installing primary cover, be sure shift shaft
returns freely to the centered position after
rotating up or down.

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CLUTCH SERVICE Clutch Removal
1. Remove primary cover. See Primary Drive Cover
Clutch Rack, Removal / Installation Removal, page 9.7.
1. Remove the clutch cover. See Primary Drive 2. Remove bolts (1), springs (2) and pressure plate
Cover Removal, page 9.7. (3).
2. Remove the six pressure plate screws (1) and coil
springs (2).

3. Perform the crankshaft locking procedure

METHOD 1. See Locking the Crankshaft for
Service, page 10.4.
3. Lift the pressure plate off of the clutch basket 4. Remove clutch nut (4) and flat washer (5). Discard
assembly to access the clutch rack from the back the stake nut.
side of the plate.
NOTE: It is not necessary to remove the clutch
plates to service the rack assembly.

4. Remove the slip-fit clutch rack (3) from the back

side of the clutch rack bearing.
5. Using a suitable bearing driver or press, remove
the clutch rack bearing (4) from the back side of
the pressure plate.
9

5. Remove clutch assembly (6) from clutch shaft.

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

6. INSTALLATION: Reverse the removal procedure

to install.

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Clutch Disassembly 4. Remove the inner hub (3) and thrust washer (4).

CAUTION

Clutch is under spring pressure. WEAR EYE

PROTECTION.

1. Remove the clutch. See Clutch Removal, page

9.13.
2. Remove the sleeve (1) from the back side of the
clutch assembly.

5. NOTE: The clutch assembly consists of three

different types of friction plates and one type of
separator plate. See Clutch Assembly, page
9.6.
PART DESCRIPTION QUANTITY
Friction Plate A (5) 1

Friction Plate B (6) 6

Separator Plate A (7) 7

Friction Plate C (10) 1

3. Lift the clutch assembly (2) out of the basket and
set aside. Spring, Judder Clutch (8) 1

Seat, Judder Clutch (9) 1

Remove Friction Plate (5).

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6. Then alternately remove Friction Plates B (6) and 3. Inspect inside surfaces (2) of basket for cracks or
Separator Plates C (7). wear (grooves) from clutch plates.

7. Remove Friction Plate C (10), Judder Spring (8) 4. Replace parts that fail inspection
and Judder Spring Seat (9).
5. Rotate basket bearing (3). Check for smooth
rotation. Inner race should have no detectable
radial movement.
6. Lubricate bearing (3) and collar (4) with engine
oil.

9
Clutch Inspection
1. Clean clutch plates, inner hub, and outer basket.
Clutch Basket
2. Inspect clutch gear teeth (1) for wear, cracks or Clutch Hub
damage.

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7. Inspect surface of steel plate guides (5) on outer 12. Inspect clutch springs for cracks or distortion.
edge of hub for wear, grooves, or damage. Check
Clutch Release Rack and Bearing
all posts (6) for cracks or damage.
NOTE: Clutch rack is serviceable as an
assembly only.

13. Inspect clutch rack for broken or damaged teeth.

14. 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.
15. Replace clutch rack assembly if necessary.

Clutch Assembly
NOTE: Apply a thin coat of engine oil to all clutch
components prior to assembly.

1. Install the bearing collar (1) into the clutch basket

8. Visually inspect friction and steel plates for wear (2) followed by the thrust washer (3) and clutch
or damage on both surfaces. Replace plates as a hub (4).
set if any plate is worn or damaged.
9. Replace steel plates if grooved, distorted or
discolored. Inspect plates for distortion by placing
each plate on a precision flat surface. Insert a
feeler gauge between plate and flat surface in
several places.

Clutch Steel Plate Warp Service Limit: .008 in (.20

mm)

10. Measure thickness of friction plates in several

places. Thickness should be the same at each
place. Replace plates that fail inspection.
2. Apply engine oil to judder spring seat (5) and
spring (6).

Friction Plate Thickness (Minimum): .126 in (3.2

mm)

Clutch Pressure Plate

11. Inspect pressure plate for cracks, scoring, or wear
on friction surface.
Clutch Springs

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3. Install judder spring seat (flat ring), then judder 6. Continue stacking oiled clutch plates into clutch
spring. basket alternating Friction Plate B (9) and
Seperator Plate B (8).
NOTE: Judder spring must be installed with
concave side facing UP (toward outside of
clutch). The tallest edge of spring will be
outermost.

7. Install Seperator Plate A (8) followed by Friction

Plate B (9) and Seperator Plate A (8).
8. Install the final Friction Plate A (10).

4. NOTE: Refer to the Clutch Assembly View

outlined in this chapter for clutch plate
orientation. See Clutch Assembly, page 9.6.
Apply engine oil to Friction Plate C (7) and install.

9. Apply engine oil to hub bearing.

NOTE: Friction Plate C has an inner diameter

that is larger than the other friction plates,
allowing it to fit around the judder spring.

5. Place an oiled Seperator Plate B (8) into clutch

basket followed by Friction Plate B (9).
NOTE: If friction plates are new, soak them in
clean engine oil for a few minutes before
installing.

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10. Install the pressure plate (11) and clutch springs 4. Install washer (3) and a new stake nut (4).
(12) and screws (13). Alternately tighten the
clutch spring screws in a star pattern until fully
seated.

5. Lock the crankshaft as outlined in chapter 7. See

Locking the Crankshaft for Service, page 10.4.
11. Torque clutch spring screws to specification. 6. Torque the stake nut to specification.

Clutch Spring Screws: 88.5 in-lbs (10.0 Nm) Clutch Stake Nut: 125 ft-lbs (170.0 Nm)

7. Install clutch pressure plate assembly and torque

screws to specification.
Clutch Installation
1. Remove the pressure plate from the clutch
assembly and set aside.
2. Using a pin punch or similar tool (1), preload the
teeth of the primary drive split gear and hold in
Pressure Plate Screws: 88.5 in-lbs (10.0 Nm)
place.
3. Slide the clutch assembly (2) onto the transmission 8. Install primary cover. See Primary Drive Cover
input shaft until fully seated. Installation, page 9.7.
9. Check engine oil and fill to proper level.

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FLYWHEEL SERVICE
Stator Cover Removal
1. Drain cooling system. See Coolant Drain / Fill,
page 4.19.
2. Remove Crankshaft Position Sensor from the stator
cover. See Crankshaft Position Sensor, Test /
Replace, page 5.45.
3. Remove three (3) Ignition Cover fasteners (Item 1)
and remove the Ignition Cover (Item 2).

Stator Cover Installation

1. Assemble new gasket (1) into stator cover (2) with
the flat surface facing the engine.

4. Disconnect the radiator outlet hose (Item 3) at the

left engine cover.

2. Install fasteners (3) and (4) in the locations

illustrated.
9
3. Torque all stator cover fasteners in sequence to
specifications.

5. Disconnect the bypass hose (Item 4) at the left

engine cover.
6. Disconnect the stator harness connector.
7. Remove the stator cover fasteners (Item 5) and
stator cover (Item 6).

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3. Remove flywheel bolt and washer (3).

Stator Cover Fasteners: 88.5 in-lbs (10.0 Nm)

4. Connect coolant hoses to stator cover.

5. Install the crankshaft position sensor and torque
fastener to specifications.

Crankshaft Position Sensor Fastener: 88.5 in-lbs

(10.0 Nm)

6. Connect the stator connector.

4. Install flywheel remove tool PA-49316 (4) on the
7. Fill the cooling system with 50/50 Premix Extended flywheel (5) and remove flywheel assembly.
Life Coolant. See Coolant Fill / Bleeding, page
4.21

Flywheel Removal

WARNING

The flywheel contains powerful magnets. Use caution

when lifting stator cover off of flywheel to avoid
personal injury.

1. Remove stator cover. See Stator Cover Removal,

page 9.19.
2. Remove the torque limiter gear pin (1) and torque
limiter assembly (2).
5. Grasp flywheel assembly and lift off the
crankshaft.

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Flywheel Installation 5. Check engine oil level. See Engine Oil Level
Check, page 2.8

CAUTION

The flywheel contains powerful magnets. Use caution

when installing flywheel onto crankshaft to avoid
personal injury.

1. Clean flywheel and crankshaft taper thoroughly

with alcohol.
2. Install woodruff key (1) and install flywheel
assembly (2) onto crankshaft.

3. Install flywheel bolt with washer (3) and torque to

specification.

Flywheel Bolt: 133 ft-lbs (180 Nm)

4. Install stator cover assembly. See Stator Cover

Installation, page 9.19

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Troubleshooting, Clutch / Primary / Shift

PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Clutch lever pivot, Clutch lever pivot points Lubricate
bushings need
lubrication
Drive plates catching on Clutch primary driven Replace necessary parts
Clutch Lever Pulls primary driven gear gear / clutch plates
Excessively Hard basket
Clutch rack bearing Clutch rack Replace
damage
Clutch pinion shaft Pinion shaft bearings Replace
bearing binding
Clutch springs weak Clutch springs Replace
Pressure plate worn or Pressure plate Replace
distorted
Clutch plates worn, Clutch Friction / Replace plates as
warped or distorted Seperator Plates necessary
Clutch Slips Clutch rack mechanism Clutch rack mechanism Replace
sticking
Engine oil level low Oil level Correct oil level
Oil additives present in Oil quality Replace oil & filter (clutch
oil or used previously plates may need to be
replaced
Clutch lever, pivot, cable, Lever, pivots, bushings, Inspect
or lifter arm sticking bearings, cable
Oil additives present in Oil quality Replace oil & filter (clutch
oil or used previously plates may need to be
replaced

Dragging clutch (doesn’t Oil level too high Oil level Correctcc
disengage completely,
Oil viscosity too high Oil quality Replace oil & filter
creeping)
Pressure plate worn, Pressure plate Replace
warped or distorted
Clutch plate(s) worn, Driven plates and / or Replace
warped or distorted drive plates
Weak clutch springs Clutch springs Replace

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Transmission Will Not 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)

Damaged/broken bearings Transmission, shift cam Replace bearings that fail

bearings inspection

Worn gear shift pawl ratchet Shift pawl mechanism Replace parts that fail
mechanism inspection

Broken or dislodged shift shaft Shift shaft return spring Repair or replace
return spring

Roller detent arm stuck Roller detent arm Repair or replace parts

Bent shift shaft (internal) Shift shaft Repair or replace

External shift linkagebinding or External shift linkage Repair or replace

damaged

Bent or distorted shift forks Shift fork Replace

Bent or distorted shift fork rails Shift fork rail Replace

Broken transmission components Transmission components Repair or replace

Transmission Hard to Shift Improper clutch operation Clutch Inspect, repair

Incorrect oil viscosity Oil quality Replace engine oil

Incorrect clutch cable adjustment - Adjust

Shift shaft damaged Shift shaft components Repair or replace

Sticking pivot point, bent external External shift linkage Repair or replace
shift linkage

Bent or distorted shift forks Shift forks Replace

Damaged shift drum grooves Shift drum Repair or replace

Shift detent plunger stuck Shift detent plunger Repair or replace

Bent/binding shift fork rails Shift fork rails Repair or replace 9

Transmission Jumps Out of Broken / loose stop pin Shift stop pin Replace
Gear
Worn shift drum or shift drum Shift drum or shift linkage Replace
ratchet
Broken shift return spring Shift return spring Replace

Damaged shift drum grooves Shift drum Replace

Bent or worn shift forks Shift forks Replace

Bent/binding shift fork rails Shift fork rails Replace

Worn engagement dogs on Transmission gears Replace

transmission gears

Transmission Noise Drive belt tension incorrect Drive belt Adjust or replace

Clutch plates bind or drag when Clutch plates / hubs Adjust / repair / replace
clutch is disengaged

Gear/bearing wear/damage Transmission components Inspect / replace

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NOTES

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CHAPTER 10
TRANSMISSION / CRANKSHAFT
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
LOCKING THE CRANKSHAFT FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
CRANKCASE BOLT LENGTH AND TORQUE PATTERN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
SHIFT DRUM / SHIFT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
GEAR TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BALANCE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
BALANCE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
STARTER DRIVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER DRIVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER DRIVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
CRANKSHAFT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
TRANSMISSION REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
CONNECTING ROD SIDE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CONNECTING ROD REMOVAL / IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CONNECTING ROD INSPECTION (BIG END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CONNECTING ROD BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CONNECTING ROD BEARING CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
10
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
CRANKSHAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
MAIN BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
MAIN BEARING OIL CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
LEFT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
RIGHT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
STAKE NUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38

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TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39

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GENERAL INFORMATION • All torque specifications are "dry" unless
specified for oil or locking agent. Refer to
Service Notes exploded views
• Remove engine from frame to service internal • When locking agents are required, use Loctite®
transmission and/or crankshaft components. See Primer N to clean fastener before applying
ENGINE REMOVAL, page 6.4. locking agent Primer N reduces cure time of
thread locking agent in addition to preparing
• The crankcase must be separated to access
the surfaces
internal transmission components and
crankshaft.
• Label and store parts neatly to speed the Special Tools
assembly process and ensure that matched
parts like connecting rods, camshafts and TOOL DESCRIPTION PART NUMBER
bearings and pushrods can be installed in their
original location Case Splitting / Assembly PF-51234-A
Tool
• Crankshaft main bearing replacement requires
line boring. This procedure requires full Clutch Holding Tool PF-51612
machine shop capabilities and specialized
Crankshaft Locking Pin PF-52135-A
knowledge. It is recommended that a qualified
machine shop perform this procedure if it Drive Sprocket Seal Installer PF-51243
becomes necessary or replace the crankcase
assembly Bosch Automotive Service Solutions: 1-800-345-
• Crankshafts and connecting rods are color 2233 or https://polaris.service-solutions.com/
coded for manufacturing tolerances with a white
or red paint mark (or stamped “R” or W”). Service Specifications
Connecting Rod / Crankshaft Specifications
PART PART SPECIFIC STANDARD SERVICE LIMIT
Connecting Rod Connecting Rod to .22 - .42 mm (.0087 - .65 mm (.025")
Crankshaft Side Clearance .0165")
Connecting Rod Bearing to .0254 - .0635 mm (.001 - .11 mm (.0043")
Crankshaft Oil Clearance .0025")
Connecting Rod Small End 22.01 - 22.02 mm (.8665 - 22.09 mm (.8694")
I.D. .8670")
Connecting Rod Width 21.01 - 21.11 mm (.8271 - 20.76 mm (.8173")
.8310")
Connecting Rod Big End I. 54.992 - 55.000 mm 55.030 mm (2.1665")
D. (White) (2.1650 - 2.1653")
10
Connecting Rod Big End I. 55.000 - 55.008 mm 55.038 mm (2.1668")
D. (Red) (2.1653 - 2.1656")
Crankshaft Main Connecting Rod Journal 42.42 - 42.50 mm (1.670 - 43.46 mm (1.627")
Bearing / Rod Journals Width 1.673")
Crankshaft Rod Journal O. 51.9920 - 51.9999 mm 51.9620 mm (2.0457")
D. (White) (2.0469 - 2.0472")
Crankshaft Rod Journal O. 52.0000 - 52.0080 mm 51.970 mm (2.0460")
D. (Red) (1.8888 - 1.8891")
Main Bearing Oil Left .013 - .060 mm (.0005 - .10 mm (.004")
Clearance .0023")
Right .014 - .061mm (.0005
- .0024")

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PART PART SPECIFIC STANDARD SERVICE LIMIT

Left Main Bearing Journal 59.9523 - 59.9703 mm 59.9323 mm (2.3595")
O.D. (2.3603 - 2.3610")
Right Main Bearing Journal 64.9523 - 64.9703 mm 64.9273 mm (2.5561")
O.D. (2.5571 - 2.5578")
.05 - .30 mm (.0019 -
Crankshaft End Play -
.0118")
Balance Shaft Journal O.D., Left (Primary 24.980 - 24.992 mm /
Side) / Journal O.D., Right 24.969 - 24.979 mm -
(Cam Side)
Transmission
Shift Fork 12.00 - 12.026 mm (.4725 - 12.05 mm (.4744")
Shift Fork I.D. (Rail)
.4732")
6.036 - 6.136 mm (.2376 - 6.02 mm (.2370")
Shift Fork Pin O.D. .2416")
Shift Fork Rail 11.948 - 11.972 mm (.4704 11.92 mm (.4693")
Shift Fork Rail O.D. - .4713")
Shift Fork Rail Runout - .025 mm (.001")
Shift Drum Shift Drum Groove - Replace drum if any wear
is evident

Transmission Information
ITEM SPECIFICATIONS
Drive Train (General) Transmission 6 Speed / Sliding Mesh
Primary Reduction Ratio 1.674: 1
Final Reduction Ratio 2.357: 1
Drive Train (Gear Ratios) Gear Ratio: 1st Gear 2.769: 1
Gear Ratio: 2nd Gear 1.882: 1
Gear Ratio: 3rd Gear 1.500: 1
Gear Ratio: 4th Gear 1.273: 1
Gear Ratio: 5th Gear 1.125: 1
Gear Ratio: 6th Gear (Overdrive) 1.036: 1

Locking the Crankshaft for Service

This procedure describes how to lock the crankshaft in
the Top Dead Center (TDC) position for the front or
rear pistons using the Crankshaft Locking Tool: PF-
51235-A or equivalent (5/16” punch).
1. Remove the spark plugs. See Spark Plug Removal,
page 2.26.
2. Remove the clutch and primary drive covers. See
PRIMARY COVER REMOVAL, page 9.7.

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3. Using a 32mm wrench or socket, rotate the 5. Lock the crankshaft by inserting the Crankshaft
crankshaft clockwise (primary side) until the front Locking tool (PF-51235-A) or equivalent into the
piston is at TDC. See the Camshaft Timing, page desired locking hole.
7.9 illustration for details.

4. Locate the two holes (1 and 2 in the illustration), NOTE: It may be necessary to rotate the
marked “R” for rear piston and “F” for front crankshaft slight forward or back to properly
piston, beneath the primary drive gear. align holes.

10

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ASSEMBLY VIEWS
Crankcase

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Dowel, Hollow
2 Bearing, Needle Shift Shaft
3 Seal, Shaft Water Pump Oil —
4 Seal, Water Pump
5 Nut, Special (18 Nm)
6 Bearing, Water Pump Shaft —
7 Plate, Bearing Retainer —
8 Screw, Bearing Retainer (10 Nm)
9 Bearing, Ball Transmission Output Shaft
10 Bearing, Needle Shift Drum —
11 Bearing, Cam Idler —
12 Bearing, Ball Transmission Output Shaft —
13 Plate, Oil Deflector —
14 Bearing, Ball Transmission Input Shaft —
15 Dowel, Hollow —
16 Pin, Alignment —
17 Pin, Solid M8x20 —
18 Pin, Solid M8x30 —
19 Seal, Shift Shaft —

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)
20 Bearing, Needle Shift Shaft —
21 Bearing, Needle Water Pump Shaft —
22 Bearing, Ball Shift Drum —
23 Bearing, Ball Balance Shaft Right —
24 Screw, Bearing Retainer (10 Nm)
25 Retainer, Bearing —
26 Bearing, Ball Balance Shaft Left —
27 Bearing, Ball Transmission Input Shaft —

Crankshaft

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Bearing, Crankshaft Main (LH) — Non-Serviceable — 10
2 Bearings, Connecting Rod (big end) —

3 Crankshaft, Assembly —

4 Circlip, Wrist Pin —

5 Wrist Pin, Piston —

6 Piston, Assembly —

7 Rod, Connecting Assembly —

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

8 Bolt, Connecting Rod Bearing Cap (QTY.4) 22 ft-lbs (30.0 Nm) + 90° (tighten bolts
simultaneously)
9 Bearing, Crankshaft Main (RH) — Non-Serviceable —

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Crankcase Bolt Length And Torque
Pattern

NOTE: Left crankcase bolts 2, 3 and 5 in

tightening sequence are M8x1.25x40 all other bolts
are M8x1.25x75.

10

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NOTE: Right crankcase bolt 13 in the tightening

sequence is a M8 x 1.25x60.

Torque case bolts to specification following the torque

sequence.

Crankcase Bolts: 22 ft-lbs (30.0 Nm)

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Transmission
Input Shaft

NUMBER DESCRIPTION
1 Plug, Input Shaft
2 Input Shaft, Transmission
3 Gear, 5th Input
4 Washer, Flat
5 Ring, Retaining
6 Gear, 3rd & 4th Input
7 Washer
8 Bushing, Plain
10
9 Gear, 6th Input
10 Washer
11 Ring, Retaining
12 Gear, 2nd Input

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Output Shaft

NUMBER DESCRIPTION
1 Washer, Flat
2 Gear, 1st Output
3 Washer, Flat
4 Gear, 5th Output
5 Ring, Retaining
6 Washer, Flat
7 Gear, 4th Output
8 Bushing, Splined
9 Washer, Lock 15T
10 Washer, Thrust 15T
11 Bushing, Splined
12 Gear, 3rd Output
13 Washer, Flat
14 Ring, Retaining
15 Gear, 6th Output
16 Ring, Retaining
17 Washer, Lock 1T

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NUMBER DESCRIPTION
18 Gear, 2nd Input
19 Bushing, Plain
20 Output Shaft, Transmission

10

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Shift Drum / Shift Fork

NUMBER DESCRIPTION
1 Bearing, Shift Drum - Drive Sprocket Side
2 Bearing, Shift Drum - Primary Side
3 Shift Rail
4 Shift Rail
5 Shift Fork, 1st and 4th
6 Shift Fork, 5th & 6th
7 Shift Fork, 2nd & 3rd
8 Gear, 6th Output
9 Gear, 3rd & 4th Input
10 Gear, 5th Output
11 Shift Drum

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Balance Shaft
Balance shaft service requires engine removal and
crankcase separation.

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Bolt, Balance Shaft Gear - M10 x 1.5 x 40 (QTY.1) 59 ft-lbs (80.0 Nm)
2 Washer -
3 Bearings, Balance Shaft -

4 Washer, Bearing Retainer Plate -

5 Screw, Bearing Retainer Plate - M5 x 0.8 x 12 (QTY.3) -

6 Snap-Ring, Balance Shaft Split GearGear, Balance -

shaft (Inner) - Non-Serviceable
-
10
7 Gear, Balance Shaft (Inner) - Non-Servicable
8 Springs, Pre-Load - Non-Serviceable -

9 Gear, Balance Shaft (Outer) - Non-Serviceable -

10 Balance Shaft -
11 Key, Balance Shaft Retaining -

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Gear Train
1st Gear

5th Gear

2nd Gear

6th Gear

3rd Gear

4th Gear

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BALANCE SHAFT SERVICE 2. Install the balance shaft assembly (1) until fully
seated in bearing bore.
Balance Shaft Removal
1. Remove the engine from the chassis. See Engine
Removal.
2. Separate the engine cases. See Crankcase
Separation, page 10.21.
3. Remove crankshaft assembly. See Crankshaft
Removal, page 10.27.
4. Remove transmission input and output shaft
assemblies. See Transmission Removal, page
10.23.
5. Remove balance shaft retaining bolt (1) and
washer (2).

3. Preload the teeth of the split-gear on the balance

shaft and lock in place with a pin punch or similar
tool (2).

6. Grasp balance shaft assembly (3) and remove

from right engine case assembly.
7. Inspect sprocket teeth for wear or damage.
8. Check shaft for runout, or twisting.
9. Rotate right and left balance shaft bearings by
hand while observing bearing rotation. Bearings
should run smooth and quiet and shaft should be a
snug fit in bearings.
10. Visually inspect bearings for damage. 10
Balance Shaft Installation
1. Lubricate balance shaft bearings with engine oil.

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4. Fit the crankshaft assembly into the engine case 5. Install the balance shaft washer (4) and bolt (5).
and align the timing marks (3) on the crank and Torque to specification.
balance shaft gears as shown.

Balance Shaft Bolt: 83 ft-lbs (112.0 Nm)

6. Install the transmission and output shaft

assemblies. See Transmission Installation, page
10.35.
7. Assemble the crankcase. See Crankcase
Assembly, page 10.36.
8. Rotate the engine to verify smooth operation and
install in motorcycle chassis.

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STARTER DRIVE SERVICE 2. Inspect shaft surfaces (2) and bushing surfaces
(1,3) for excessive wear and scoring.
Starter Drive Removal
1. Remove the stator cover. See Stator Cover
Removal, page 9.19.
2. Slide the torque limiting gear pin (3) out of the
torque limiting gear (2) and remove from the
engine.

3. Inspect one-way clutch hub surfaces (4) for wear,

scoring or damage.
4. Inspect one-way clutch cams (5) for wear, scoring
or damage.

3. Remove the flywheel assembly to access the

starter crank drive gear (4) and one-way clutch
(5). See Flywheel Removal, page 9.20
4. Lift and rotatet the starter crank drive gear (4) to
remove from the one-way clutch (5) and flywheel
(6).

5. Replace any worn or damaged components.

10

Starter Drive Inspection

1. Inspect gear teeth for chips, cracks or excessive
wear.

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Starter Drive Installation 4. Install the starter torque limiter gear (6) and insert
1. Install one-way starter clutch assembly (1) onto the shaft (7) into the crankcase bore.
flywheel and torque fasteners (2) to specification..

5. Install the stator cover. See Stator Cover

Torque Specification Installation, page 9.19.
7.3 ft-lbs (10 Nm) 6. Check engine oil and fill to proper level. See
2. Insert the starter drive gear (3) into the one-way Engine Oil Level Check, page 2.8.
clutch (1).
3. Install flywheel (4) onto crankshaft and torque
fastener (5) to specification.

Torque Specification
133 ft-lbs (180 Nm)

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CRANKSHAFT SERVICE 20. Remove three (Qty 3) M8x1.25x40 engine case
bolts (1).
Crankcase Separation
1. Drain engine oil. See Engine Oil / Filter Change,
page 2.9.
2. Drain cooling system. See Coolant Drain/Fill.
3. Remove engine from frame. See ENGINE
REMOVAL, page 6.4.
4. Mount engine securely on an engine stand using
Engine Stand Adapter tool PF-51609.
5. Remove the cam chains/chain guides. See Cam
Chain Removal, page 7.15.
6. Remove cylinder heads. See Cylinder Head
Removal, page 7.26.
7. Remove cylinders. See Cylinder Removal, page
8.5.
21. Remove nine (Qty 9) M8x1.25x75 engine case
8. Remove primary cover. See Primary Drive Cover bolts (2).
Removal, page 9.7.
22. Remove one (Qty 1) M8x1.25x60 engine case bolt
9. Remove clutch assembly. See Clutch Removal, (3) from primary drive side of engine case.
page 9.13.
23. Place the Engine Case Splitting / Assembly tool
10. Remove flywheel. See Flywheel Removal, page PF-51234-A on a flat surface and assemble the M6
9.20. threaded spacers (4) and M12 threaded spacers
11. Remove stator cover. See Stator Cover Removal. (5) into the main plate (6) as shown. Use only
holes marked with the letter B.
12. Remove the starter drive. See Starter Drive
Removal, page 10.19.
13. Remove the balance shaft driven gear and drive
gear. See Balance Shaft Removal, page 10.17.
14. Remove the drive sprocket. See Drive Sprocket
Removal, page 12.8.
15. Remove the oil filter. See Oil/Filter Change.
16. Remove the oil cooler assembly. See Oil Cooler
Removal.
17. Remove the shifter shaft assembly. See Shift Shaft
Removal.
NOTE: Severe damage to the engine cases and
shift shaft assembly may occur if attempting to
10
separate cases with shift shaft installed..
24. Rotate the engine stand so the engine is lying flat
18. Remove the speed sensor. See Speed Sensor with the output shaft pointing UP.
Removal.
19. Remove the gear position switch. See Sensors -
Powertrain Management, page 5.11.
NOTE: Collect the two switch contact pins and
springs from the end of the shift drum so they
do not get lost.

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25. Position the main plate assembly (6) onto the 28. Install M6 bolts (8) and M12 bolt (9) into threaded
engine case as shown. The threaded spacers spacers and torque to specification.
should line up with the corresponding engine case
bolt holes.

26. Install the case splitting adapter (7) through the

center hole in the main plate and thread into nut
and washer until 1– 2 threads are exposed on the Main Plate Mounting Bolts (All): 88.5 in-lbs (10.0
other side. Nm)

29. Holding nut (10) stationary with an open ended

wrench, turn the case splitting adapter (7)
clockwise until the engine cases begin to part.
STOP.

27. Main plate adjustment: Turn threaded spacers

in or out to raise, lower and level the main
plate.
IMPORTANT:
• Plate surface should be parallel to the 30. Using a soft-faced mallet, work around the seam of
surface of the engine crankcase. the engine cases tapping lightly to release the
• Plate height is correct when the plate is sealed bond.
resting on the washer and the case splitting
adapter contacts the transmission output
shaft.
• All threaded spacers must be in contact with
engine case prior to bolting on the plate
assembly.

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31. Alternately turn the case splitting tool in until 3. Lift the shift drum (2) out of the bearing.
resistance is felt, then work around the upper case
with a mallet until the cases are completely apart.

4. As an assembly, lift the input shaft (3), output

shaft (4), shift forks and shift fork rails (1) out of the
engine case.
Transmission Removal

CAUTION

Gloves should be worn at all times while working on

the transmission assembly to avoid personal injury.

1. Remove the shift ratchet assembly. See Shift

Ratchet Removal & Inspection, page 9.9.
2. Lift both of the shift fork rails (1) out of the
crankcase just enough so the ends clear the
crankcase bores. Rotate rails and forks away from
the shift drum.

10

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Transmission Inspection
Input Shaft

NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION

1 Gear, 2nd - Input -

2 Retaining Ring, External -

3 Shim - 25 x 34 x 0.5 -
4 Gear, 6th - Input 28.000 - 28.021 mm
5 Bushing I.D. - 25.02 - 25.04 mm / O.D. - 27.96 -27.98 mm
6 Shim - 25 x 34 x 2 -
7 Gear, 3rd & 4th - Input -

8 Retaining Ring, External -

9 Washer, Flat - 28 x 35 -
10 Gear, 5th - Input -

11 Bushing 28.015 - 28.035 mm

12 Shaft, Input & 1st Gear -

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Output Shaft

NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION

1 Shaft, Output -

2 Bushing I.D. - 30.02 - 30.04 mm / O.D. - 33.96-33.98

mm
3 Gear, 2nd - Output 34.000 - 34.025 mm
4 Washer, Toothed - 30 x 38 -
5 Retaining Ring, External -

6 Gear, 6th, Output -

7 Retaining Ring, External -

8 Washer, Toothed - 28 x 35 - 10
9 Gear, 3rd - Output 31.015 - 31.030 mm
10 Bushing, Splined O.D. - 30.975-31.005 mm
11 Washer, Thrust - 15 Tooth -
12 Washer, Lock - 15 Tooth -
13 Gear, 4th - Output 31.015 - 31.030 mm
14 Gear, 5th - Output -

15 Washer, Flat - 24 x 35 -

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NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION

16 Gear, 1st - Output 24.015 - 24.0.35 mm
17 Washer, Flat -

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NOTE: Refer to the Assembly View section in this 9. Temporarily install shift drum into bearing and
chapter for component locations and exploded rotate, checking for smooth bearing operation.
diagrams. See ASSEMBLY VIEWS, page 10.6.
Shift Drum
Refer to the Service Specifications section in this
chapter for complete transmission specifications. 10. Inspect shift drum grooves for wear. Pay close
See Service Specifications, page 10.3. attention to corners of grooves where forks change
direction.
Shafts 11. Inspect surface of shift drum star for excessive
wear or damage.
1. Measure outside diameter of shafts and bearing
areas for wear and concentricity. Look closely at 12. Inspect right side shift drum bearing.
splines for wear. Inspect ends of shafts for signs of 13. Temporarily install shift drum in right hand case
wear: bearing and inspect fit. Spin drum to check for
• Dull finish smooth bearing operation.

• Discoloration
Crankshaft Removal
• Rough or uneven surface 1. Separate RH crankcase from LH case. See
• Measurement outside of specification Crankcase Separation, page 10.21.
2. Lift crankshaft assembly (1) straight up until clear
Gears of right side engine case.
2. Visually inspect:
• Gear internal splines
• Gear teeth
• Gear dogs for rounding, cracks, chips
• Gear dog slots for rounding
• Bearing surfaces
• Shift fork grooves

Check each gear for damage, cracks, wear

(rounding of dogs or surfaces), or discoloration.
Shift Forks, Shift Fork Rails
3. Inspect all contact surfaces of each shift fork.
Replace a shift fork if any part is discolored
(overheated), unusually scored, warped, or worn NOTE: Connecting rod bearings and main
beyond service limit. bearings are easily damaged. Be careful not to
cause damage to these parts when servicing
4. Inspect each shift fork pin for wear or damage and items within the crankcase.
compare to specifications. 10
5. Inspect shift fork rails for wear, scoring, or runout.
6. Measure shift fork rail O. D. for wear in 3 or 4
places along the length. The rail O. D. should be
consistent over the entire length.
7. Slide rails into crankcase holes and check for a
good snug fit.
8. Visually inspect the shift drum bearing in the left
crankcase for wear or damage. The bearing must
be fully seated in the case and held in position by
the retaining plate. Replace the bearing if it is
loose in the bore, or if any side play is detected.

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Connecting Rod Side Clearance 2. Mark the outside of both connecting rods prior to
Inspection removal so they can be assembled in the same
direction in relation to the crankshaft.
1. Move connecting rods to one side of crankshaft.
Insert a feeler gauge (1) between one connecting
rod and the crankshaft. Compare measurement to
specification outlined in this chapter. See Service
Specifications, page 10.3.

3. Remove connecting rod bolts and connecting rod

bearing caps.
NOTE: It may be necessary to lightly tap the
caps with a plastic mallet to loosen them.
2. If clearance recorded exceeds service limit, the
crankshaft, connecting rod or both must be
inspected and worn parts replaced. See
Crankshaft Inspection, page 10.32. CAUTION
The mating surface of connecting rod and cap is
Connecting Rod Removal / Identification rough in appearance, which is a normal condition
due to the manufacturing process. If rod caps are
NOTE: The connecting rod caps are marked with installed incorrectly and tightened, the precision
paint from the factory, however it is recommended mating surfaces will be damaged. Replace the
that an additional reference mark be added for connecting rod assembly if mating surfaces are
clarity. Caps are matched to rods and MUST be damaged.
installed with the proper orientation left to right
and front to back. DO NOT strike or stamp the
connecting rod.

1. Use a permanent marker to mark orientation of

connecting rods and rod bearing caps. These
parts MUST be installed in their original
locations. EXAMPLE: Right connecting rod must
be assembled on the right side with the bearing
cap that was removed from it. The bearing cap and
connecting rod must be assembled in the same
direction as it was removed using the same bolt.

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Connecting Rod Inspection (Big end) 3. Apply engine oil to threads of rod bolts. Torque
bolts to specification.
IMPORTANT: Connecting rod bolts can only be
reused three times. Failure to replace bolts after
completing three torque sequences may result in
severe engine damage. Each time a bolt has been
torqued to specification, it should be marked with
a center punch.

EXAMPLE:
• 1st Torque: Manufacturer installation of
connecting rod bolts.
• 2nd Torque: Torque for inspection per this
procedure.
• 3rd Torque: Reinstallation following inspection.
Discard bolts the next time they are
removed.
1. Refer to Piston Pin / Pin Bore Inspection, page
8.10for connecting rod small end inspection.

CAUTION
Be sure to match connecting rod caps with their Connecting Rod Bolts:
respective rod and orient the cap properly before
installing the cap. Secure the big end of rods in a vise STEP 1: Tighten both bolts to 22 ft-lbs (30.0 Nm)
equipped with soft, protective jaws before torquing STEP 2: Tighten both bolts an additional 90° ± 5°
rod bolts.
4. Measure I. D. of connecting rod big end for size
and out of round and compare to specification. See
Service Specifications, page 10.3.

10

2. Remove bearings and install caps on connecting

rods. Be sure mating surfaces (1) of rod and cap 5. Visually inspect connecting rod upper and lower
are clean. ends for scoring, damage, or excessive wear.

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Connecting Rod Bearing Inspection 2. Measure the connecting rod big end bearing I. D.
1. Inspect bearing inserts (1) for unusual wear, with a dial bore gauge and record.
peeling, scoring, damage etc. Replace as a set if
damage is noted. Inspect bearing clearance and
refer to Bearing Selection Chart. See Connecting
Rod Bearing Selection, page 10.31.

3. Measure the connecting rod journal on crankshaft

and record.
4. Subtract the journal diameter from the connecting
rod bearing diameter to calculate oil clearance
and compare to specification. See Service
Connecting Rod Bearing Clearance Specifications, page 10.3.
Inspection 5. If service limits are exceeded, install new rod
1. Assemble the connecting rod cap with bearings bearings and recheck oil clearance.
and torque to specification. 6. If service limits are still exceeded, determine if
crankshaft or connecting rods need to be
replaced.

Connecting Rod Bolts:

STEP 1: Tighten both bolts to 22 ft-lbs (30.0 Nm)
STEP 2: Tighten both bolts an additional 90°

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Connecting Rod Bearing Selection
1. Two different dimension crankshafts were used. Identify the crankshaft by part number and use the
corresponding chart for bearing selection.

2. There are 3 sizes of connecting rod bearings available: Black, Orange and Blue (see chart below).
3. To determine which bearing to use, look at the color code on the left crankshaft counterweight “R” for Red or
“W” for White. The letter will be etched onto the outer surface of the counterweight.
4. The color code on the connecting rod is laser etched onto the big end side of the connecting rod. There will
be an “R” for Red or “W” for White.

10

5. Refer to the chart below to select the proper bearing insert.

FOR EXAMPLE: If the CONNECTING ROD grade is RED and the CRANKSHAFT stamp is W (white) (or not
stamped), use BLACK bearing inserts.

CONNECTING ROD BEARING SELECTION CHART FOR CRANKSHAFT PN 1204692

Connecting Rod Color Crankshaft Color Bearing Color (P/N Bearing Thickness
3514804-xxx)
WHITE Paint Mark (“W” RED (“R” Stamp) Blue ( - 027 )
Stamp) 1.409 - 1.415 mm

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CONNECTING ROD BEARING SELECTION CHART FOR CRANKSHAFT PN 1204692

WHITE Paint Mark (“W” WHITE (“W” Stamp Blue ( - 027 )
Stamp) or not marked)
RED Paint Mark (“R” Stamp) RED (“R” Stamp) Blue ( - 027 )
RED Paint Mark (“R” Stamp) WHITE (“W” Stamp Orange ( - 159 ) 1.413 - 1.419 mm
or not marked)

CONNECTING ROD BEARING SELECTION CHART FOR CRANKSHAFT PN 1205267

Connecting Rod Color Crankshaft Color Bearing Color (P/N Bearing Thickness
3514804-xxx)
WHITE Paint Mark (“W” RED (“R” Stamp) Blue ( - 027 )
Stamp) 1.409 - 1.415 mm

WHITE Paint Mark (“W” WHITE (“W” Stamp Orange ( - 159 )

Stamp) or not marked)
1.413 - 1.419 mm
RED Paint Mark (“R” Stamp) RED (“R” Stamp) Orange ( - 159 )
RED Paint Mark (“R” Stamp) WHITE (“W” Stamp Black (Std)( - 067) 1.417 - 1.423 mm
or not marked)

Crankshaft Inspection 3. Visually inspect all bearing journals for scoring,

Record all measurements and compare to damage or excessive wear.
specifications. Replace crankshaft if any measurement 4. Crankshaft and connecting rods are identified by
is worn beyond the service limit. See Service color. Be sure to compare measurements to
Specifications, page 10.3. specifications for the proper color (or non-
1. Measure the width of the rod bearing journal. marked) connecting rod or crankshaft.
Measure O. D. of crankshaft rod journal in four
places and compare to specifications.

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

2. Measure width of connecting rods at big end.

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Connecting Rod Installation 2. After cleaning passages, verify crankshaft journals
1. Make sure proper bearing clearance is achieved and oil passage openings are free of debris.
by using the correct colored bearing insert for a
given color combination of connecting rod and Main Bearing Inspection
crankshaft. 1. Inspect crankcase main bearing surfaces (1 & 2)
2. Clean all oil off connecting rod, connecting rod for wear, peeling, scoring, or damage.
cap and bearing inserts. 2. Inspect alignment of bearing lubrication hole in
3. Install bearing inserts into connecting rods and right crankcase half (1) and left case half (2). Holes
caps. First, install bearing tab into groove, then must be aligned with their respective oil passage
press the rest of the bearing into place. in crankcase.

NOTE: Procedure during disassembly called

for marking of connecting rods and caps.
Ensure that each part is installed in original
location including rod cap bolts.

4. Apply assembly lube to connecting rod bearings

and crank pin.
5. Install rods and caps onto the crankshaft,
observing the paint mark on the connecting rods.
The paint mark must face away from the center
of the crankshaft. Be sure the identifier marks
made previously are aligned.
6. Tighten rod cap bolts:

Main Bearing Oil Clearance Inspection

Connecting Rod Bolts: 1. Measure main bearing I.D. and concentricity with
a dial bore gauge for right and left side. Compare
STEP 1: Tighten both bolts to 22 ft-lbs (30.0 Nm) to specification. Subtract crankshaft main journal
STEP 2: Tighten both bolts an additional 90° diameter from main bearing diameter to calculate
oil clearance. See Service Specifications, page
7. Check that the connecting rods rotate smoothly 10.3.
and freely on crankshaft journal.

Crankshaft Cleaning
1. Pass cleaning solvent through the oil passages to
ensure that passages are clear.

10

2. If crankshaft dimensions are within tolerances and

oil clearances are incorrect, the crankcase set
must be replaced.
NOTE: Replace crankcase halves as a set.

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Left Crankcase Assembly Refer to crankcase assembly view for locations and
Prepare LEFT crankcase for assembly: torque specification. See Crankcase, page 10.6.

Refer to crankcase assembly view for locations and 1. Clean crankcase oil passages (1) thoroughly. Rinse
torque values. See Crankcase, page 10.6. and dry with compressed air.

1. Clean crankcase and oil passages (1) thoroughly.

Rinse and dry with compressed air.

2. Install new bearings in crankcase as required.

• Apply a film of lithium grease to outer race of
2. Install new ball bearings in crankcase as required. bearings to prevent galling upon installation.

• Apply a film of lithium grease to outer race of • Press on outer race of bearings using an arbor
bearings to prevent galling upon installation press and a suitable arbor that is slightly smaller
than bearing outside diameter.
• Press on outer race of bearings using an arbor
press and a suitable arbor that is slightly smaller • DO NOT press on inner race of ball bearings.
than bearing outside diameter 3. Install bearing retainers as required and torque to
• DO NOT press on inner race of ball bearings specification.
Torque Specification
3. Install bearing retainers as required and torque to 7.3 ft-lbs (10 Nm)
specification.
4. Install piston cooling jets (2) with a new o-ring and
4. Install the scavenge return tube (2) with a new o- torque to specification.
ring. Torque Specification
5. Install rear scavenge oil inlet screen assembly (3) 5.1 ft-lbs (7 Nm)
with a new o-ring. See Lubrication System, page 5. Install pressure lubrication pump oil pickup
4.7. screen (3) with a new o-ring and torque fastener to
6. Install front scavenge oil inlet screen assembly (4) specification.
Torque Specification
with a new o-ring .
7.3 ft-lbs (10 Nm)
Right Crankcase Assembly
Prepare RIGHT crankcase for assembly:

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Crankshaft Installation 5. Place crankshaft (3) into right crankcase half.

NOTE: Install left engine case onto an engine

stand.

1. Insert a punch or other suitable object into the

opening (1) to align the balance shaft split gear
teeth.

6. Align crankshaft and balance shaft timing marks

(4).

2. Rotate the balance shaft so the timing marks (1)

are facing the main bearing bore.

7. Remove the split alignment tool installed as part of

step 1.

Transmission Installation
1. Install balance shaft if previously removed. See
Balance Shaft Installation, page 10.17.
3. Apply assembly paste to main bearings.
10
2. If transmission shaft bearings were replaced, be
4. Hold crankshaft over right crankcase and position sure all bearing retainer plate screws are installed
rods so that left side rod is in cutout for rear and tightened to specification. See Crankcase,
cylinder and right side rod is in cutout for the front page 10.6.
cylinder.

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3. Working on a flat surface, assemble the input shaft Crankcase Assembly
(1) and output shaft (2) so the gears are properly 1. Clean crankcase mating surfaces to remove all
meshed. grease, oil, and old sealant.
2. Check to be sure all shafts are seated properly
(crankshaft, balance shaft, shift drum, shift forks,
input shaft, output shaft).
3. Check to be sure that alignment dowel pins and oil
pipes, etc. are in place.
4. Remove the drive sprocket spacer (1) and o-ring
(2) from the LH crankcase prior to installation.

4. Install shift rails (3) into shift forks and assemble to

input and output shafts.
5. Lubricate parts with engine oil. Apply assembly
lube to ends of transmission shafts.
6. Install input shaft (1) and output shaft (2), shift
forks and rails (3) into the right crankcase. Make
certain both shafts are fully seated and rotate
freely.
7. Rotate shift rails away from shift drum bore and 5. Apply a light even bead of LoctiteTM Ultra Black
install shift drum (4). 598 to entire case sealing surface.

8. Rotate shift drum to align proper grooves with

forks. 6. Spread sealant into a thin even layer on entire case
mating surface. Be sure all areas are covered. DO
9. Move shift fork pins into drum grooves and seat
NOT ALLOW SEALANT TO DRY. CONTINUE
rails.
ASSEMBLY UNTIL CASES ARE SEALED AND ALL
10. Install crankshaft. See Crankshaft Installation, BOLTS ARE TIGHT.
page 10.35.
11. Assemble crankcase. See Crankcase Assembly,
page 10.36.

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7. Lower the LH case onto the RH case and install 13. Install the gear position switch. See Sensors -
mainshaft / crankcase installer PV-54030 (3) and Powertrain Management, page 5.11.
engine case assembly cup PF-51663 onto the
14. Install the drive sprocket. See Drive Sprocket
transmission output shaft.
Installation, page 12.9.
15. Install the balance shaft driven gear and drive
gear. See Balance Shaft Installation, page 10.17.
16. Install the scavenge oil pump. See Scavenge Oil
Pump Installation, page 4.14
17. Install the pressure lubrication oil pump. See
Pressure Lubrication Oil Pump Installation , page
4.14
18. Install the starter drive. See Starter Drive
Installation, page 10.20.
19. Install the cam chains. See Cam Chain Installation,
page 7.15.
20. Install the flywheel. See Flywheel Installation,
page 9.21.
8. Pull crankcase together by tightening nut (5) and 21. Install the clutch assembly. See Clutch Installation,
holding tool (6) tapping on crankcase with a soft page 9.18.
mallet. 22. Install the primary cover. See Primary Drive
Cover Installation, page 9.7.
23. Install cylinders. See Cylinder Installation, page
8.12.
24. Install cylinder heads. See Cylinder Head
Installation, page 7.33.
25. Install the stator cover. See Stator Cover
Installation, page 9.19
26. Install engine in frame. See ENGINE
INSTALLATION, page 6.7.

NOTE: The cases will mate before the output

shaft is drawn fully into bearing. IMPORTANT!
Continue to turn nut and tap case until sealant 10
squeezes out along the entire perimeter and
resistance is felt when turning nut.

9. Remove the tools from the output shaft.

10. Install crankcase bolts and torque to specification.
See Crankcase Bolt Length And Torque Pattern,
page 10.9.
11. Install a new output seal in LH crankcase using
seal installer PF-51243.
12. Install the o-ring and drive sprocket spacer
removed in STEP 4 with tapered edge toward the
o-ring.

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Stake Nut Installation 4. Stake the stake nut as shown below using round
• A stake nut is located on the clutch side of the side of punch. Do not crack or tear staking lip. Do
transmission input shaft. not use a sharp chisel to stake the nut.

• Another stake nut is located on the crankshaft

drive gear end (2).

• It is important that they are torqued and staked

correctly for proper function
NOTE: Do not reuse or reinstall any
previously used stake nut. A new stake nut
needs to be installed every time the nut is
removed or loosened.

Use the following procedure to install the stake nuts

correctly:
1. Clean threads on shaft so there is no oil or
contaminants.
2. Thread NEW stake nut onto shaft finger tight.
3. Torque stake nut to specification.

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TROUBLESHOOTING
Troubleshooting

PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Transmission Will Not Broken Shift Cam Shift Cam Replace shift cam
Shift
Bent Shift Forks Shift Fork Replace shift fork(s)
Worn Gearshift Pawl Shift Cam Replace shift cam
Broken Gears Transmission Gears Replace necessary parts
Damaged/Broken Transmission, Shift Cam Replace necessary parts
Bearings Bearings
Worn Gear Shift Ratchet Shifter Ratchet Refer to chapter 9
Mechanism
Broken or out-of-place Shift Ratchet Spring Refer to chapter 9
spring on shift ratchet
Shift Detent Ratchet Stuck Shift Ratchet Repair as necessary
Seized Pivot Point, Bent External Shift Linkage Repair as necessary
External Shift Linkage
Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails
Fork Rails
Debris From Broken Parts Transmission Repair as necessary
Locking Transmission Components
Excessive Noise Related Worn Main Bearings Crankshaft and/or Repair as necessary
to Bottom End of Engine Crankshaft Bearings
Worn Connecting Rod Connecting Rod Bearings Repair as necessary
Bearings and/or Connecting Rod
and/or Rod Bearings
Worn Connecting Rod Connecting Rod, Repair as necessary
Small End Bushing Connecting Rod Bushing,
Piston Pin, Piston
Worn, seized, chipped or Transmission Gears Repair as necessary
broken gear teeth
Worn, seized, chipped or Transmission Bearings Repair as necessary 10
broken Transmission
Bearings
Originates from Primary Clutch, Oil Pump Drive Repair as necessary
Cover
Oil Pump Oil Pump, Oil Pump Drive Refer to chapter 4
Cam Drive Cam Chain, Cam Refer to chapter 7
Sprocket

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Transmission Hard to Shift Improper Clutch Clutch Refer to chapter 9
Operation
Incorrect Oil Viscosity Engine oil and filter Refer to chapter 3
Incorrect Clutch Clutch Adjustment Refer to chapter 3
Adjustment
Bent, Rubbing, Sticky, Shifter Ratchet Assembly Refer to chapter 9
Broken Shift Shaft
Sticking Pivot Point, Bent External Shift Linkage Repair or replace
External Shift Linkage components as necessary
Bent or Distorted Shift Shift Forks Replace bent shift fork
Forks
Damaged Shift Drum Shift Drum Replace damaged shift
Grooves drum
Shift Ratchet Bent / Stuck Shift Ratchet Repair as necessary
Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails
Fork Rails
Transmission Jumps Out Broken Shift Stop Pin Shift Stop Pin Replace stop pin
of Gear
Worn Shift Drum Pawls or Shift Drum or Shift Replace damaged shift
Shifter Ratchet Linkage drum or shifter ratchet
Broken Shift Ratchet Shift Ratchet Spring Replace spring
Spring
Damaged Shift Drum Shift Drum Replace shift drum
Grooves
Bent, Worn, Distorted Shift Forks Replace shift forks
Shift Forks
Bent or Distorted Shift Shift Fork Rails Replace shift fork rails
Fork Rails
Worn Engagement Dogs Transmission Gears Replace necessary parts
on Transmission Gears

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CHAPTER 11
FRONT WHEEL / SUSPENSION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.3
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.4
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.4
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.6
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.7
TRIPLE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.9
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
HANDLEBAR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
CLUTCH CABLE, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
FRONT WHEEL, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
FRONT AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
BRAKE DISC REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
FRONT WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
FRONT WHEEL BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
FRONT FORK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
TRIPLE CLAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.26
TRIPLE CLAMP INSTALLATION / STEERING HEAD BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 11.27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30

11

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GENERAL INFORMATION Special Tools
Service Notes TOOL DESCRIPTION PART NUMBER
Fork Spring Compressor PV-49463

WARNING Fork Spring Compressor

Adapter / Cartridge Tool PF-51664–2

Indian Motorcycles are produced using the Fork Oil Seal Driver PF-51610
designated tires listed as original equipment. This
includes field testing to ensure stability and superior Fork Seal Installation
PF-51611
handling. The use of tires other than original Tool
equipment may cause instability which could lead to Wheel / Stem Bearing
a crash, resulting in serious injury or death. Use only PF-51324
Removal / Installation Kit
the recommended tires inflated to the recommended
tire pressures based on load conditions as listed on Spanner Socket
(Steering Stem) PV-43508
the tire information label.

Tubeless tires are used on certain Indian Motorcycle

models. Operating the motorcycle with damaged Torque Specifications
rims creates a safety hazard including air pressure
loss, steering imbalance and/or reduced steering PART DESCRIPTION TORQUE
control. Do not attempt to repair or straighten SPECIFICATION
damaged rims.
ABS Pulse Ring / Brake Disc 22 ft-lbs (29.8 Nm)
Bolts

CAUTION Cartridge Screw, Fork 17 ft-lbs (23.0 Nm)

Clutch Lever Cap Screw 84 in-lbs (9.5 Nm)
Work performed to the front end of the motorcycle Fork Cap to Jamb Nut 11 ft-lbs (14.9 Nm)
usually involves supporting the machine with the
front end elevated. Take precautions so that the Fork Cap to Outer Tube 16 ft-lbs (21.6 Nm)
motorcycle is securely supported when the front tire
is off the ground. This reduces the possibility of Front Axle 52 ft-lbs (70.5 Nm)
personal injury or damage to the motorcycle.
Front Axle Pinch Bolts 18 ft-lbs (24.4 Nm)
Leaking front fork seals are a safety hazard and should Front Master Cylinder 84 in-lbs (9.5 Nm)
be replaced immediately if a leak is found. Fork oil
could contaminate front brake components which LH Switch Cube 31 in-lbs (3.5 Nm)
could reduce stopping ability of the motorcycle. RH Switch Cube 31 in-lbs (3.5 Nm)
Contaminated brake discs or pads greatly reduce
available stopping force & increase stopping distance. Riser Bolts 60 ft-lbs (81.3 Nm)
Brake discs can be cleaned using commercially
available brake cleaner. NEVER attempt to clean Riser Cap Bolts 22 ft-lbs (30 Nm)
contaminated brake pads. Replace pads as a set.
Steering Lock Bolts 18 ft-lbs (24.4 Nm)
• Refer to Chapter 2 for MAINTENANCE of front
end components. Steering Stem Adjuster Nut 29 ft-lbs (39.3 Nm)
• Refer to Chapter 13 for TIRE REMOVAL, Triple Clamp Nut, Top 72 ft-lbs (97.6 Nm)
REPAIR, & BALANCING
Triple Clamp Pinch Bolts (All) 18 ft-lbs (24.4 Nm)
• Refer to Chapter 14 for BRAKE SYSTEM
service and repairs.

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Service Specifications

ITEM STANDARD SERVICE

Axle Runout - .20 mm (.008")
Front Wheel Runout Axial .50 mm (.020") 2.0 mm (.080”)
(Cast and Spoked Type)
3.5" x 16" Radial .50 mm (.020") 2.0 mm (.080”)

Fork Tube Diameter 46 mm Not Applicable

Fork Tube Runout - .20 mm (.008")
Fork Oil Type Indian Motorcycle Fork Oil (PN: 2880015)
Fork Spring Pre-Load 1.3“ (34.5 mm) Not Applicable
56 - 114 lb/in (9.8 - 20.0
Fork Spring Rate Not Applicable
N/mm)
Fork Spring Free Length 457.9 mm (18.02 in) -
Oil level must be measured
Fork Oil Capacity (per leg,
and adjusted to 335cc (335 ml) Set Level
dry)
specification.

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ASSEMBLY VIEWS
Controls

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, LH Switch Cube 36 in-lbs (4 Nm) Tighten Top Two Screws First
2 Screw, Clutch Perch Clamp 145 in-lbs (16.38 Nm)
Bolt

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NUMBER PART TORQUE (IF APPLICABLE) NOTES

DESCRIPTION
3 Screw, RH Switch 36 in-lbs (4 Nm) Tighten Top Two -
Cube Screws First
4 Screw, Brake Lever 12 ft-lbs (16 Nm) -
Cap
5 Grip, Throttle - Ridge goes toward rider.

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Handlebar

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Bearing, Ball -

2 Nut, Steering Head -

3 Bolt, Upper Fork Clamp — M8 x 1.25 x 18 ft-lbs (24.4 Nm) See Tightening Procedure
30 (QTY.2) Outlined in this Chapter
4 Washer -
5 Nut, Top Triple Clamp 72 ft-lbs (97.6 Nm) See Tightening Procedure
Outlined in this Chapter
6 Bolt, Speedometer— M8 x 1.25 x 25 22 ft-lbs (29.8 Nm) Tighten Front Bolts First,
(QTY.4) then Rear

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Front Fork Assembly

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Assembly, Fork Leg -

2 Slide, Metal -
3 Washer -
4 Oil Seal -
5 Snap Ring -

6 Dust Seal -
7 Assembly, Cap 16 ft-lbs (21.6 Nm)
8 Spacer -

9 Washer -
10 Spring -

11 Assembly, Cylinder -

12 Oil Lock -
13 Fork Tube, Inner -
14 Bushing -

15 Packing -

16 Bolt 17 ft-lbs (23.0 Nm)

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Triple Clamp

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Nut, Top Triple Clamp 72 ft-lbs (97.6 Nm) See Tightening
Procedure Outlined in this Chapter
2 Washer -
3 Bolt, Upper Fork Clamp — M8 x 1.25 x 18 ft-lbs (24.4 Nm) See Tightening
30 (QTY.2) Procedure Outlined in this Chapter
4 Triple Clamp, Upper -

5 Nut, Steering Head See Tightening Procedure Outlined in this

Chapter
6 Bearing, Ball — 47 x 25 x 12 -

7 ASM, Lower Bracket -

8 Bearing, Sealed – 22 x 55 x 17 -

9 Steering Lock - 11
10 Bolt, Steering Lock — M6 x 1.00 x 10 77 in-lbs (8.7 Nm)
(QTY.2)
11 Bolt, Lower Fork Clamp — M8 x 1.25 x 18 ft-lbs (24.4 Nm) See Tightening
30 (QTY.4) Procedure Outlined in this Chapter

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Front Wheel

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Bearing Spacer, Outer -

2 Wheel Bearing -

3 Bearing Spacer, Inner -

4 Brake Disc -
5 Ring, Tone, ABS -

6 Screw, Pulse Wheel / Brake Disc — M8 x 25 (QTY.5) 22 ft-lbs (29.8 Nm)

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SERVICE PROCEDURES 6. Remove Throttle Grip (5).

Handlebar, Removal / Installation

WARNING

Clutch cable must be routed, installed, and

adjusted correctly to function properly. Note how
cable is routed and secured before removing the
cable. Permanent cable damage may result if the
inner cable is bent or twisted during installation.
If the cable is incorrectly routed, installed, or
adjusted, serious injury or death may occur.

CAUTION
CAUTION
Cover painted or chrome parts to prevent damage.
Use care to protect fuel tank and front fender. Tank Keep brake reservoir in an upright position to
removal is recommended. Secure, set aside, or prevent air from entering the system. Bleeding is
support parts as they are removed. required if air enters the system.

1. Place motorcycle in an upright position with the 7. Remove four speedometer screws (6).
front wheel clamped in a wheel vise
2. Remove left hand Switch Cube screws (1).
3. Remove Clutch Lever perch screws (2).

4. Remove Right hand Switch Cube screws (3). Re-

move Switch Cube. 11
5. Remove Master Cylinder screws (4). Place Brake
assembly in position that allows hose not to be
stressed.

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8. Press tab (7) down to remove the connector from Clutch Cable, Removal / Installation
speedometer. 1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
Clutch Cable Removal
2. Remove the cable routing clip (1) and the clutch ca-
ble jam nut (2).

9. Lift handlebars out of upper triple clamp.

NOTE: Make an index mark on the handlebar
along the parting line of the riser cap to ensure
proper handlebar position upon reassembly.

10. Installation is performed by reversing the removal 3. Protect the clutch release arm (3) with a shop towel.
procedure. Using an adjustable wrench, rotate the release arm
inward. Disconnect clutch cable from release arm.
11. Line up the handlebar index mark made in STEP 9
and torque speedometer, starting with the front
bolts, to specification.

Speedometer Bolts: 22 ft-lbs (29.8 Nm) Tighten

Front Bolts First, then Rear

4. Withdraw the clutch cable from the mounting boss

located on the primary cover.
5. At the handlebar, pull the clutch cable casing
straight out until clear of lever perch and rotate ca-
ble outward to align inner cable wire with slot in
lever.
6. Pull lever slightly until slotted opening in lever is
clear of perch and slide cable barrel end down and
out of lever.
7. Note routing of clutch cable through frame.
8. Remove the clutch cable.
1. Clutch Cable Installation

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CAUTION CAUTION

Do not kink, bend, or twist the inner cable or outer CALIFORNIA MODELS: Remove the charcoal canister
cable casing during installation prior to raising motorcycle wheels off the ground. As
the swingarm lowers it can contact the canister hose
2. Route clutch cable in the same manner as removed. fittings and damage them.
3. Apply multi-purpose grease to the lever end of the 1. Secure the motorcycle in an upright position with
cable and install it in the clutch lever at the
tie-down straps and a platform jack positioned
handlebar.
beneath the engine cases.
4. Install the casing in the lever perch at the
handlebar.
5. Install cable in the mounting boss located on the
primary cover.
6. At the release arm end of the cable, pull the inner
cable until fully extended. Be sure the upper end of
the cable casing is seated in the lever perch at han-
dlebar end.
7. Apply multi-purpose grease to the lower barrel
end of the cable.
8. Rotate the release arm inward (as in STEP 3) until
cable can be installed in release arm.
9. Adjust clutch cable free play.

Front Wheel, Removal / Installation NOTE: Do not operate the front brake lever
with the calipers or wheel removed.

WARNING Removal
2. Remove the front fender. See Front Fender
This procedure requires raising and supporting Removal, page 3.7.
the motorcycle so that the front wheel is off the
ground. Precautions should be taken to ensure 3. Loosen axle pinch bolts (1) on lower right fork leg.
the motorcycle is properly stabilized at all times.
Failure to properly support motorcycle may result
in personal injury or damage to the motorcycle.

CAUTION

Do not twist the brake hose or brake line. Do not

allow calipers to hang from the brake hose. Secure
calipers in such a way to avoid hose damage.
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4. Support wheel and remove axle (2). Spacers are Front Axle Inspection
loosely retained by the dust seals, but may fall out 1. Place axle in V-blocks and inspect runout.
after wheel has been removed. Compare to specifications in this chapter. See
Service Specifications, page 11.3.

Installation 2. Replace axle if it fails inspection. Do not attempt to

straighten a bent axle.
5. Install front wheel and spacers into fork.
6. Install the axle and torque to specification. Front Wheel Inspection
1. Install front wheel in truing stand.
NOTE: Bearings must be in good condition to
accurately measure runout.

Front Axle: 52 ft-lbs (70.5 Nm) 2. Set up a dial indicator to measure radial runout (up
and down) (A) and compare to specifications. See
7. Cycle the front suspension. Tighten axle pinch Service Specifications, page 11.3.
bolts to specification. 3. Position dial indicator to measure axial runout
(side to side) (B) and compare to specifications.
See Service Specifications, page 11.3.

Axle Pinch Bolts: 18 ft-lbs (24.4 Nm)

Tighten each screw once after initial torque

8. Install front fender. See Front Fender Installation,

page 3.8.

4. Visually inspect wheel for cracks.

5. Replace wheel if it fails visual or measured
inspection. Do not attempt to straighten cast or
wheels.

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Brake Disc Removal / Installation Front Wheel Bearing Inspection
1. Remove front wheel. See Front Wheel, Removal /
Installation, page 11.13. NOTE: Inspect bearings installed in the wheel. Do
not remove to inspect. Bearings cannot be
2. Position wheel with brake disc and ABS tone ring repacked. Replace both wheel bearings if one or
facing up. both fail inspection, or if either bearing was
3. Remove and discard brake disc / tone ring screws removed.
(1).
1. Visually inspect bearing seals (1) on each side for
4. Remove tone ring (2) and brake disc (3) from wear or damage.
wheel.

2. Check bearings by turning inner race by hand.

5. Installation is performed by reversing the
removal procedure. Use new brake disc bolts • Look for signs of discoloration, scoring, galling,
for installation or contamination from moisture or dirt. Replace
bearings if any of the above are present.
6. Torque new brake disc bolts to specification in a
star pattern. • Turn the inner race of the bearings. The
bearings should turn smoothly and quietly. The
inner race should be firm with minimal side to
side movement and no detectable up and down
movement.

Brake Disc Bolts: 19 ft-lbs (25.7 Nm) 3. Discard bearings that fail any of the above
inspections.

CAUTION
Do not reuse bearings after removing them from the
wheel. Removal damages the bearings internally.

4. Inspect bearing fit into wheel hub. The outer race

of the bearing must fit tightly into the bore. You
should not be able to move it (or remove it) by
hand. Replace the wheel if outer race of a new
11
bearing does not fit tightly in the bore.

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Front Wheel Bearing Replacement 13. Install the front wheel. See Front Wheel, Removal
/ Installation, page 11.13.

CAUTION Front Fork Removal

Do not reuse bearings that have been removed.

WARNING
NOTE: This procedure requires the Wheel
This procedure requires raising and supporting
Bearing Removal / Installation Kit (PF-51324).
the motorcycle so that the front wheel is off the
Refer to special tool manufacturer instructions for
ground. Precautions should be taken to ensure
proper use of tool.
the motorcycle is properly stabilized at all times.
Failure to properly support motorcycle may result
1. Remove front wheel. See Front Wheel, Removal /
Installation, page 11.13. in personal injury or damage to the motorcycle.

2. Remove brake discs. See Brake Disc Removal /

Installation, page 11.15.
CAUTION
3. Carefully remove both seals using a suitable seal
removal tool and discard. Be careful not to scratch
the seal bore. Do not twist the brake hose or brake line. Do not
allow calipers to hang from the brake hose. Secure
calipers in such a way to avoid hose damage.

CAUTION

CALIFORNIA MODELS: Remove the charcoal canister

prior to raising motorcycle wheels off the ground. As
the swingarm lowers, it can contact the canister hose
fittings and damage them.

1. Remove front fender. See Front Fender Removal,

page 3.7.

4. Refer to special tool manufacturer instructions to

remove bearing from LH side of hub.
5. Remove bearing.
6. Remove spacer.
7. Extract or drive bearing from RH side of hub.
8. Installation: Use the Wheel Bearing Removal /
Installation Kit PF-51324) to install new wheel
bearings. Refer to special tool manufacturer
instructions for proper use of tool.
9. Install new wheel bearing into the RH side of hub
followed by the inner bearing spacer.
10. Install new wheel bearing into the LH side of hub.
11. Install new seals and existing outer bearing
spacers into each side of the wheel hub.
12. Install the brake discs. See Brake Disc Removal /
Installation, page 11.15.

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2. Secure the motorcycle in an upright position with 6. Loosen top triple clamp pinch bolt (3).
tie-down straps and a platform jack positioned
beneath the engine cases.

7. Loosen lower triple clamp pinch bolts (4).

NOTE: Do not operate the front brake lever

with the calipers or wheel removed.

3. Remove front brake calipers and support them so

they do not hang by brake hoses. See Front
Caliper Service, page 14.25.
4. Remove front wheel. See Front Wheel, Removal /
Installation, page 11.13.
5. Remove turn signal assembly by removing bolt (1)
and nut (2).

8. Slide fork legs down and remove.

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Front Fork Disassembly 2. Place fork in soft jawed vise and loosen fork cap
approximately 1 turn. Do not remove the cap.
NOTE: The following procedure requires the use Remove fork from vise.
of Fork Spring Compressor (PV-49463) and Fork
Spring Compressor Adapter/Cartridge Tool (PF-
51664-2).

NOTE: Refer to appropriate Front Fork Exploded

View. Clean fork tubes before disassembly.

NOTE: Two types of fork caps have been used an

“early” and “late” design. The “early” design cap
is flat on top with M37x1.5 threads and the “late”
design cap has a raised circle in the center with
M35 x 1.5 threads. The caps and fork tubes are not
interchangeable between designs.

1. Secure Fork Spring Compressor (PV-49463) (1)

vertically in a vise with drive bolt UP.

WARNING

Wear eye / face protection. Be sure spring is

engaged properly with pegs of tool as you compress
the spring in the following steps.

3. Mount special socket adapter(PF-51664-1) (2) and

30mm socket in spring compressor (PV-49463).
Center socket adapter (PF-51664-1) in holding
fixture with all thumb screws (3).

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4. Place fork tube in spring compressor tool with 8. Remove Spacer (5) and Washer (6) from top of
hole in bottom of fork slider over peg on bottom of spring.
tool.

9. Remove Spring (7) from fork tube.

5. Place special tool (PV-49463) in soft jawed vise
with the drive bolt (4) facing up. Adjust length of
spring compressor by turning drive bolt (4) as
required until fork cap is captive in socket.

10. Pour fork oil out of tube assembly.

11. Remove fork cartridge by inserting Fork Cartridge
Tool (PF-51664-2) with a 3/8” extension into fork
6. Rotate fork tube until cap is unscrewed completely tube.
from fork tube.

11

7. Back off spring compressor and remove special

socket along with Cap assembly.

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12. Prevent Fork Cartridge Tool (PF-51664-2) from 15. Remove seal retaining ring. Use care not to scratch
turning and remove cylinder screw (9) from the surface of the inner fork tube.
bottom of fork. Using a pick tool, remove crush
washer (8).

16. Push inner and outer tube together, then pull apart
quickly to produce a slide hammer motion to
remove the inner tube.
13. Tip fork upside down and slide Cylinder
Assembly (10) out of fork tube along with Oil Lock 17. Remove Oil Seal.
(11).

18. Remove Washer.

14. Carefully lift dust seal out of outer fork tube with a
small flat screwdriver.

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19. Remove Slide (12). 3. Inspect slider (2) for dents or other indentations
due to rocks or other road debris or damage. If
damage is found on exterior of slider, insert fork
tube into slider and move the tube through the
complete travel range. Check for resistance or
binding in the damaged area. If binding or
resistance is evident, replace the slider.

20. Remove the lower bushing from the inner tube.

4. Inspect oil lock valve (3) for scoring, excessive or

abnormal wear.

Front Fork Inspection

1. Measure fork spring free length and compare to
specifications on .

5. Visually inspect the damper rod piston ring (4).

Replace component if scoring, deep scratches
2. Inspect fork stanchion tube (1) for scoring, heavy and/or excessive wear is noted.
scratches, dents due to rocks or other road debris, 11
or excessive wear. Replace tube (s) if deep
scratches, pitting, or dents are found.

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6. Place fork tube in V-blocks and measure runout. 2. Lubricate and install a new lower bushing on inner
Replace the tube if runout exceeds service limit fork tube.
listed on .

WARNING

Do not attempt to straighten bent fork tubes. Doing 3. Apply a light film of fork oil to outside edge and
so will weaken the tube and make the motorcycle inside seal lips of new oil seal.
unsafe to operate.
NOTE: Install oil seal with markings (5) facing
UP (toward top of tube and retaining ring).
Front Fork Assembly
NOTE: Clean all parts prior to assembly.

1. Lubricate and install new bushing (12) into fork

slider.

4. Install Fork Seal Installation Tool (PF-51611) on

fork tube.

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5. Lubricate the surface of the inner fork tube and 9. Wipe away any excess grease or oil. Install dust
slide backing washer and new oil seal onto fork seal (use opposite end of Fork Seal Tool (PF-
tube. 51610) until fully seated in outer tube.

6. Insert fork tube in fork leg.

Cylinder Installation
7. Use the Fork Seal Tool (PF-51610) (6) to install oil
10. Be sure screw threads in bottom of Cylinder
seal until seated. Be sure top edge of seal is past
Assembly are clean and not damaged.
(below) retaining ring groove.
11. Place Cylinder Assembly (10) along with Oil Lock
(11) into fork slider. Carefully align bottom of Oil
Lock with recess in bottom of fork.

8. Install a new retaining ring (7) fork tube.

11

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12. Prevent fork cartridge cylinder from turning by 18. Seal top of tube with your hand and push
inserting Fork Cartridge Tool (PF-51664-2) with a downward against air pressure. Hold for 10– 15
3/8” extension into fork tube. seconds. This will help force trapped air from
cartridge and tube.

13. Install a new cylinder screw (9) and a new crush 19. Mount fork assembly upright in a soft jawed vise
washer (8). by brake caliper mounts on slider.
20. Install Spring (7) into fork tube.

14. Torque cylinder screw to specification.

21. Place Washer (6) and Spacer (5) on top of spring.
Place Fork Cap on Spacer.

Cartridge Screw: 17 ft-lbs (23.0 Nm)

Oil Filling / Cartridge Air Bleeding

15. Set fork leg upright.
16. Lift tube to top of travel range.
17. Tip fork leg at an angle to reduce air bubbles.
Slowly add 335cc of Indian Motorcycle fork oil.

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22. Install fork spring socket adapter (PF-51664-2) in Front Fork Installation
compressor as outlined for disassembly.
23. Slowly compress fork tube assembly with drive nut NOTE: Clean the fork tubes and the clamping
surfaces of the triple clamps to remove any oil or
(4) until fork cap enters the outer tube, and
grease prior to installation.
threads start to make contact.
1. Install one fork tube assembly into lower triple
clamp.

24. Rotate outer tube to start cap. Use care to avoid

thread damage.
2. Continue to slide tube through lower triple clamp
and into upper triple clamp. Stop when the top of
the fork cap is flush with the top of the upper triple
clamp.

25. After cap thread is started, continue to turn tube

and adjust spring compressor pressure as
required until cap is fully seated against top of
outer tube.
26. Tighten fork cap to outer tube. Torque to 3. Torque the bottom bolt on the lower triple clamp
specification. (1).

11

Fork Cap to Outer Tube: 16 ft-lbs (21.6 Nm)

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4. Torque the top bolt on the lower triple clamp (2). Triple Clamp Removal

WARNING

This procedure requires raising and supporting

the motorcycle so that the front wheel is off the
ground. Precautions should be taken to ensure
the motorcycle is properly stabilized at all times.
Failure to properly support motorcycle may result
in personal injury or damage to the motorcycle.

CAUTION

5. REPEAT steps 3 – 4. Do not twist the brake hose or brake line. Do not
6. Torque the upper triple clamp bolt (3). allow calipers to hang from the brake hose. Secure
calipers in such a way to avoid hose damage.

CAUTION

CALIFORNIA MODELS: Remove the charcoal canister

prior to raising motorcycle wheels off the ground. As
the swingarm lowers it can contact the canister hose
fittings and damage them.

1. Secure the motorcycle in an upright position with

tie-down straps and a platform jack positioned
beneath the engine cases.

Lower Triple Clamp Bolts: 18 ft-lbs (24.4 Nm)

Upper Triple Clamp Bolt: 18 ft-lbs (24.4 Nm)

7. Repeat steps 1 through 6 for the other fork tube.

8. Install brake line guides (if removed).
9. Install front wheel. See Front Wheel, Removal /
Installation, page 11.13.
10. Install brake calipers. See Front Caliper Service,
page 14.25.
NOTE: Do not operate the front brake lever
11. Install front fender. See Front Fender Installation, with the calipers or wheel removed.
page 3.8.
2. Remove the front fender. See Front Fender
12. Inspect all bolts for proper torque. Inspect hoses Removal, page 3.7.
and wiring for proper routing.
13. Lower front end of motorcycle to the ground and
test front suspension / fork operation.

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3. Remove front wheel. See Front Wheel, Removal / 11. Remove stem adjuster nut (2) with a suitable
Installation, page 11.13. spanner socket.
4. Remove Speedometer assembly.
5. Remove Headlight assembly.
6. Remove the handlebar / riser assembly. See
Handlebar, Removal / Installation, page 11.11.
7. Remove fork tubes. See Front Fork Removal, page
11.16.
8. Remove brake line guides from upper and lower
triple clamp.
9. Remove center nut (1) and washer on upper triple
clamp.

NOTE: 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).
13. Inspect bearings and bearing races.

Triple Clamp Installation / Steering Head

Bearing Adjustment
1. Inspect both top and bottom bearing races for
10. Slide upper triple clamp off steering stem. pitting, dents, or worn surface. Replace bearings
and races as a set if they are worn or damaged.
2. Be sure lower stem bearing (1) is seated against
step on lower triple clamp. Apply all purpose
grease to bearing and install lower triple clamp /
stem to frame.

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3. Grease and install upper bearing (2) onto stem 10. Set upper triple clamp in place on stem. Install
and push it down until seated in upper bearing washer (4) and nut (5) and tighten top nut until it is
race. finger tight.

4. Screw adjuster nut (3) (shoulder side down) onto

the steering stem until it is finger tight. NOTE: Nut will be torqued after fork tubes are
installed.

11. Slide fork tubes through lower triple clamp and

into upper triple clamp. Align top edge of fork cap
with top edge of upper triple clamp and hold in
position.
12. Tighten top triple clamp pinch bolt enough to hold
tubes in place. Leave lower triple clamp pinch
bolts loose.
13. Torque the top steering stem nut to specification.

Top Steering Stem Nut: 72 ft-lbs (97.6 Nm)

5. Turn triple clamp assembly fully to the right.
6. Torque adjuster nut to specification using suitable
spanner wrench. NOTE: CHECK STEERING STEM BEARINGS at
this time. Pull firmly on fork tubes with a front-
to-rear motion. If movement can be felt in
steering bearings, disassemble and go back to
STEP 10. Tighten steering stem adjuster nut an
additional 5 degrees, and reassemble following
Steering Stem Bearing Adjuster Nut: 29 ft-lbs (39.3 STEPS 10– 15. Repeat this procedure until no
Nm) play can be felt.

14. Verify fork tube height in upper triple clamp. The

7. Place a mark on the frame in alignment with one of
top of the fork cap should be flush with the top of
the slots on the adjuster nut.
the upper triple clamp.
8. Turn lower triple clamp from lock to lock five
times and return to full right position.
9. Loosen adjuster nut 90 degrees (1/4 turn) so the
reference mark on frame is aligned with the next
one of the four slots on the stem nut.

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15. Torque the upper triple clamp pinch bolts (both
sides) to specification.

Upper Triple Clamp Pinch Bolts: 18 ft-lbs (24.4 Nm)

16. Torque bottom bolts on lower triple clamp to

specification.
17. Torque top bolts on lower triple clamp to
specification.

Lower Triple Clamp Pinch Bolts (ALL): 18 ft-lbs (24.4

Nm)

18. Repeat STEPS 15–17.

19. Install handlebar assembly. See Handlebar,
Removal / Installation, page 11.11.
20. Install front wheel. See Front Wheel, Removal /
Installation, page 11.13.
21. Verify all fasteners are installed and properly
torqued.

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TROUBLESHOOTING
Troubleshooting

PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED

Heavy Steering Steering Stem Nut Over Tightened Torque to specification
Damaged Steering Stem Bearings Replace
or Races
Bent Steering Stem Replace
Front Tire Damaged or Worn Replace
Low Tire Pressure Inflate to specification
Pulls to One Side or Wanders Damaged Steering Stem Bearings Replace
or Races
Steering Stem Nut Over Tightened Torque to specification
or Under Tightened
Low Tire Pressure Inflate to specification
Rear Wheel Not Aligned Correctly Align
Bent Front Axle Replace
Damaged or Excessively Worn Replace
Front Tire / Incorrect Tire
Damaged Wheel Bearings Replace
Damaged Swing Arm Bearings Replace
Loose Swing Arm Pivot Nut Torque to specification
Bent Frame or Swingarm Replace
Handlebars Oscillate (Wobble) Bent Front Axle Replace
Wheel Has Excessive Runout True (Spoked) / Replace (Cast)
Tire Mounted Incorrectly Check Mounting and Balance
Damaged Tire / Worn Tire Replace
Loose Steering Stem Nut Torque to specification
Incorrect Tire Replace
Incorrect Tire Pressure Correct
Noise Coming From Front Worn Fork Bushings Rebuild Forks
Suspension
Low Fork Fluid Determine Cause / Replace Fork
Oil
Loose Fasteners Torque to specification
Loose Steering Stem Bearings Determine Cause / Correct
Front Wheel Oscillates (Wobbles) Bent Front Rim Replace
Damaged Front Wheel Bearings Replace
Damaged or Incorrect Tire Replace

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PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED

Front Wheel Oscillates (Wobbles) Loose Axle Torque to specification
Fork Tube Height Unequal Install Correctly
Fork Oil Level Unequal Set Correctly
Fork Spring Free Length Different Replace
Between Right & Left
Wheel Assembly Out-of-Balance Balance
Low Tire Pressure Inflate to specification
Front Suspension Too Soft Weak Fork Springs Replace
Low Fork Oil Level Determine Cause/Replace Fork Oil
Wrong Weight Fork Oil Replace
Contaminated and/or Deteriorated Replace
Fork Oil
Low Tire Pressure Set Correctly
Front Suspension Too Hard Tire Pressure Too High Set Correctly
Bent Fork Tubes Replace
Wrong Weight Fork Oil Replace
Too Much Fork Oil Set Correctly
Plugged Oil Passages Rebuild Front Forks
Damaged Sliders Replace
Forks Binding Correct
Wheel Turns Hard Damaged Wheel Bearings Replace
Front Axle Bent Replace
Brake Dragging Repair as Necessary
(Hydraulic or Mechanical Problem)
Brake Dragging (Bent Disc) Replace
Improper Assembly After Repairs Correct as Necessary

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NOTES

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CHAPTER 12
REAR WHEEL / SUSPENSION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
DRIVE BELT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
DRIVE SPROCKET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
DRIVE SPROCKET COVER, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
DRIVE SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
DRIVE SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
DRIVE SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
DRIVEN SPROCKET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
DRIVEN SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
DRIVEN SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
DRIVEN SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
REAR WHEEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
REAR WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
REAR AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
REAR WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
WHEEL BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
BRAKE DISC REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
SHOCK ABSORBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
SHOCK ABSORBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
SHOCK ABSORBER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
SWINGARM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
SWINGARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
SWINGARM BUSHING / BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
SWINGARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22
TROUBLESHOOTING, REAR WHEEL / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22
TROUBLESHOOTING, FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23 12

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GENERAL INFORMATION Torque Specifications
Service Notes PART / FASTENER TORQUE
SPECIFICATION
Belt Guard, Lower 96 in-lbs (11.0 Nm)
WARNING Brake Disc 22 ft-lbs (29.8 Nm)
This motorcycle was produced with the designated Drive Sprocket Cover 84 in-lbs (9.5 Nm)
tires as original equipment. The testing to ensure
stability and superior handling was done using the Drive Sprocket Lock Plate 88.5 in-lbs (10.0 Nm)
OEM tires. Using non-OEM tires could result in poor
Drive Sprocket Nut 180 ft-lbs (244.0 Nm)
motorcycle stability and handling, which can lead to
a crash resulting in serious injury or death. Use only Gusset Plate 55 ft-lbs (75.0 Nm)
the recommended tires inflated to the recommended
tire pressures. P-Clamp Screws (Brake Line 84 in-lbs (9.5 Nm)
/ W.S.S.)
Tubeless tires are used on certain Indian Motorcycle Pushrod Bolt, Upper 55 ft-lbs (75.0 Nm)
models. Operating the motorcycle with damaged rims
creates a safety hazard including air pressure loss, Rear Axle Nut 65 ft-lbs (88.0 Nm)
steering imbalance and/or reduced steering control. Rear Caliper Mounting Bolts 31 ft-lbs (42.0 Nm)
Do not attempt to repair or straighten damaged cast or
spoked rims. Indian Motorcycle Chief Classic and Shock Absorber Bolts 55 ft-lbs (75.0 Nm)
Vintage models are equipped with spoked tube-type (Upper & Lower)
rims. Small imperfections in the alignment of these
rims can be corrected using an approved wheel truing Shock Air Line Jamb Nut 20 ft-lbs (27.0 Nm)
stand and spoke wrench (commercially available). (Chieftain)
Always use genuine Indian Motorcycle parts or
equivalent so that quality is not compromised. The use Swingarm Nut (LH) 65 ft-lbs (88.0 Nm)
of tire valves and valve cores other than original Swingarm Shaft, Initial 8 ft-lbs (11.0 Nm)
equipment replacement Indian Motorcycle parts could Torque (Before Outer Nut
cause tire deflation which may lead to loss of control, Installation)
resulting in injury or death. Do not allow any
motorcycle to leave your service area without tire Swingarm Shaft, Jamb Nut 75 ft-lbs (102.0 Nm)
valve caps securely installed.
Wheel Speed Sensor 96 in-lbs (11.0 Nm)
• The rear shock absorber is serviceable.
• Refer to Chapter 2 for maintenance of rear
wheel & suspension components, and
suspension ride height adjustment.

Special Tools

SPECIAL TOOL PART NUMBER

Swing-arm Bushing Tool PF-51237
Shock Spanner Wrench PV-46993
Bearing Removal / PU-51324
Installation Kit
Platform Jack Commercially Available

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Service Specifications

ITEM STANDARD SERVICE LIMIT

Axle Runout - .20 mm (.008")
Rear Wheel Runout: Axial .80 mm (.030 inch) 2.0 mm (.080”)
Classic / Vintage
Chieftain Radial .80 mm (.030 inch) 2.0 mm (.080”)
Rear Wheel Size / Type All Models 16” x 3.5” Cast –
Rear Wheel Travel All Models 3.0” (76.2 cm) –
Shock Spring Free
All Models 8.0” (203.2 cm) –
Length
Shock Spring Installed All Models
Perform Ride Height Adjustment –
Length (Standard)
Refer to Chapter 2 for Ride Height
Suspension Ride Height All Models –
Measurement procedure
Classic / Vintage 450 lbs / in –
Spring Rate
Chieftain 400 lbs / in –
Swing Arm Pivot Shaft Runout Not Applicable .20 mm (.008")
LH Ball Bearing Journal: 19.965–
Swing Arm Pivot Shaft O.D. 19.99 mm / RH Needle Bearing –
Journal: 24.95–25.00 mm
Swing Arm Needle Bearing Bore O.D. (RH) 31.946–31.972 mm –
Swing Arm Ball Bearing Bore O.D. (LH) 41.967–41.992 mm –
Wheel bearing O.D. (approx) 51.987–52.00 mm –
Wheel bearing I.D. (approx) 19.998–20.00 mm –

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ASSEMBLY VIEWS
Rear Suspension

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NUMBER PART DESCRIPTION TORQUE SPECIFICATION (IF
APPLICABLE)
1 Nut 85 ft-lbs (115.2 Nm)
2 Washer -
3 Needle Roller Bearing -
4 Seal -
5 Swing Arm Bushing -
6 Swing Arm Pivot -
7 Swing Arm Bushing (Ball bearing) -
8 Ball Bearing -
9 Retaining Ring -
10 Washer -
11 Screw -
12 Washer -
13 ASM, Shock -
14 Screw 65 ft-lbs (88 Nm)
15 Screw 65 ft-lbs (88 Nm)
16 Axle, Rear -
17 Plate, Indicator -
18 Nut -
19 Adjuster, Axle -
20 ASM, Swing Arm -
21 Nut 65 ft-lbs (88 Nm)
22 Ring, E-Clip -

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Rear Wheel

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw 22 ft-lbs (29.8 Nm)
2 Ring, ABS (INTL only) -
3 Spacer, Axle -
4 Seal, Bearing -
5 Bearing, Wheel -
6 Rotor, Brake -
7 Wheel, Rear -
8 Spacer, Bearing -
9 Damper -
10 Spacer, Bearing Outer -
11 Bearing -
12 Sprocket -
13 Spacer, Bearing, Sprocket -
14 Ring. Retaining -

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DRIVE BELT SERVICE
Drive Belt Inspection Drive Belt Installation
1. Inspect belt tension and adjust if necessary. See 1. Inspect sprockets and verify sprocket fasteners
Drive Belt Inspection, page 2.32. are tight.
2. If one or more component is damaged, replace 2. Install drive belt with the Indian Motorcycle script
belt and both sprockets as a set if the drive system situated so that it reads correctly when viewed
has been in service for 5000 miles or more (8000 from the LH side of the motorcycle.
Km).
3. Install the drive sprocket cover. See Drive
Sprocket Cover, Removal / Installation, page 12.8.
Drive Belt Removal
4. Install the swingarm assembly. See Swingarm
NOTE: If belt is to be reinstalled, mark direction Installation, page 12.20.
of rotation on the outer surface of belt. Reinstall 5. Install the rear wheel. See Rear Wheel Removal /
belt in same direction as it was removed. Installation, page 12.13.
6. Set drive belt alignment and tension. See Drive
Belt Adjustment, page 2.33.
WARNING

A mis-aligned rear axle can cause drive line noise

and damage the drive belt, which could cause belt
failure and loss of control of the motorcycle.

WARNING

Care should be taken to be sure the motorcycle will

not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls.

1. Loosen rear axle and axle adjusters. See Rear

Wheel Removal / Installation, page 12.13.
2. Remove left rear shock. Shock Absorber Removal,
page 12.16
3. Remove drive sprocket cover. See Drive Sprocket
Cover, Removal / Installation, page 12.8.
4. Remove belt from drive sprocket.

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DRIVE SPROCKET SERVICE
Drive Sprocket Cover, Removal / 4. Loosen both axle adjuster nuts evenly to move
Installation wheel forward until belt is loose.
1. Remove bolts (1) and drive sprocket cover (3). 5. Pull belt off drive sprocket.
6. Remove two locking plate screws (4) and locking
plate (3).

2. To install the drive sprocket cover, reverse the

removal procedure.
7. Remove drive sprocket (5) and drive sprocket re-
3. Torque drive sprocket cover bolts to specification. taining nut (6).

Drive Sprocket Cover Bolts (All): 85 in-lbs (9.6 Nm)

Drive Sprocket Removal

1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Remove the drive sprocket cover. See Drive
Sprocket Cover, Removal / Installation, page 12.8.
3. Loosen rear axle nut (1) so that wheel assembly can
be moved forward to slacken drive belt.
8. Remove O-ring (7) and spacer (8) and from output
shaft.

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Drive Sprocket Inspection 5. Sprockets and belt normally exhibit a polished
1. Visually inspect sprocket teeth (1) for excessive appearance due to normal operation. Belt
wear and damage. replacement is not required unless
uncharacteristic damage is noted, or if the mileage
service interval is reached. Belt or sprocket
damage is usually due to debris trapped between
belt and sprocket, or from improper maintenance
and adjustment.

Drive Sprocket Installation

NOTE: If replacing the output shaft seal, it will be
necessary to use the Output Shaft Seal Tool (PF-
51243) for proper installation.

1. Place new output shaft seal over the output shaft

and drive into position using the Output Shaft Seal
Tool (PF-51243).
2. Apply grease to a new O-ring (1) and install on
2. Inspect splines (2) for a tight fit on output shaft output shaft.
splines.
3. Install seal sleeve (2) with the chamfer on inside
diameter of sleeve facing in, toward O-ring.

3. Inspect the back surface of sprocket hub (3) where

it contacts the seal sleeve. Replace if worn or if
4. Clean shaft threads and sprocket nut to remove all
surface is rough.
previous thread locking agent.
4. Inspect the machined sealing surface of the spacer
5. Apply a light film of anti-seize compound to
sleeve (4). Replace the spacer sleeve if it is
splines of shaft. Place belt onto front sprocket,
grooved or otherwise damaged.
place sprocket over splines of output shaft.
6. Apply Loctite™ 262 to threads of shaft and nut.
7. Install drive sprocket nut and torque to
specification.
NOTE: Install Clutch Shaft Holding Tool (PF-
51232) on clutch shaft prior to tightening
sprocket nut.
12

Drive Sprocket Nut: 180 ft-lbs (244.0 Nm)

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8. Install lock plate (3) and tighten screws (4) until
lightly seated on plate.

NOTE: The lock plate can be installed in many

positions and either side of the plate can be
used. If the plate still does not align, tighten
sprocket nut slightly and try to fit the lock plate
again.

9. Rotate the plate CLOCKWISE until it stops and

hold it firmly against the nut.
10. Torque lock plate screws to specification.

Lock Plate Screws: 88.5 in-lbs (10.0 Nm)

11. Remove the clutch shaft holding tool and install the
clutch assembly. See Clutch Installation, page
9.18.
12. Install the drive sprocket cover. See Drive
Sprocket Cover, Removal / Installation, page 12.8.
13. Adjust belt tension and wheel alignment. See
Drive Belt Adjustment, page 2.33.

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DRIVEN SPROCKET SERVICE
Driven Sprocket Removal Driven Sprocket Inspection
1. Visually inspect sprocket teeth (1) for excessive
wear and damage from foreign material or road
CAUTION debris.

Protect brake disc surface while working on wheel.

1. Remove rear wheel. See Rear Wheel Removal /

Installation, page 12.13.
2. Remove the LH wheel spacer (1) from the driven
sprocket roller bearing.

2. Inspect the back side of the sprocket where it

engages the damper (2) for wear, galling or
roughness. Surface must be smooth, with no burrs
or surface irregularities.

3. Lift the driven sprocket assembly (2) off of the

drive damper (3).

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3. Visually inspect the cushion drive damper (3) for Driven Sprocket Installation
cracks or deformation. Replace damper if damage 1. Install cushion damper (3) into wheel hub.
is found.
2. Install sprocket assembly (2) onto wheel hub
making sure the cushion damper is properly
engaged.

NOTE: If the drive system has been in service

for 5000 miles or more, replace both front and
rear sprockets along with the belt if any one 3. Install the LH wheel spacer (1) into the sprocket
item is damaged or worn beyond a normal roller bearing.
polished appearance.

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REAR WHEEL SERVICE
Rear Wheel Removal / Installation 4. Remove two caliper mounting bolts (1) and
remove caliper.

WARNING

Rear wheel removal involves supporting the machine

with the rear end elevated. Take precautions so that
the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death
can occur if the motorcycle tips or falls.

WARNING

Make sure the exhaust system has cooled to room

temperature before elevating the motorcycle. The
drive belt may be damaged if it comes into contact
with HOT exhaust components. CAUTION
Do not hang rear brake caliper from the brake line.
Do not twist the brake line or damage may result.
WARNING
NOTE: Do not apply rear brake pedal after the
If working on a motorcycle equipped with a charcoal brake caliper has been removed.
canister (EVAP), remove the canister prior to
elevating the rear of the motorcycle to prevent 5. Remove rear ABS wheel speed sensor mounting
damage to the canister hose fittings. bolt (2) and sensor (3), if applicable.

1. Place the motorcycle in an upright position on a lift

table with the front wheel clamped in a wheel vise.
2. Remove saddlebags, if equipped.
3. Position a platform jack beneath the engine cases
and raise until the rear tire is barely in contact with
the ground.

NOTE: Move sensor aside so that it is not

damaged.

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6. Loosen right and left axle adjusters (4). 11. Installation is performed by reversing the
removal procedure.
12. Torque fasteners to specification.

Axle Nut: 65 ft-lbs (88.0 Nm)

Wheel Speed Sensor Bolt: 96 in-lbs (10.8 Nm)
Rear Caliper Mounting Bolts: 31 ft-lbs (42.0 Nm)

Set drive belt tension and alignment. See Drive

Belt Tension, page 2.32 and Drive Belt Adjust-
ment, page 2.33.
7. Remove clip (5), rear axle nut (6) and washer (7)
from side of swingarm. Rear Axle Inspection
1. Install rear axle in V-blocks and measure runout
and compare to service limit. See Service
Specifications, page 12.3.
2. Axle diameter should be measured on bearing
surfaces.

8. Remove washer (7) and axle (8) from swingarm.

Rear Wheel Inspection

NOTE: Wheel bearings must be in good condition.

1. Set up a dial indicator to measure axial and radial

runout of the wheel and compare to service limit.
See Visual Inspection & Runout, page 13.9.
2. Visually inspect wheel for cracks or other damage.
3. Replace wheel if it fails visual or measured
inspection.
9. Push wheel forward and slide drive belt to the
LEFT side off of the rear sprocket.
10. Remove rear wheel assembly by sliding it to the
rear of the motorcycle.

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Rear Wheel Bearing Inspection 4. Carefully pry seal (1) out of RH side of hub.

NOTE: If possible, also inspect wheel bearings

before removing the wheel from the vehicle. Do
not remove bearings from wheel to inspect.
Bearings cannot be repacked. Replace both
bearings if one or both fail inspection, or if either
bearing was removed.

1. Visually inspect integral bearing seal for damage.

2. Inspect bearing fit in wheel hub. The outer race of
the bearing must fit tightly into the bore. You
should not be able to move outer race by hand.
3. Slide axle into wheel and check for smooth
rotation and tight fit.
NOTE: Due to extremely close tolerances, the
bearings must be inspected visually, and by 5. Refer to special tool manufacturer instructions to
feel. Look for signs of discoloration, scoring, remove bearing from brake disc side of hub.
galling, or contamination from moisture or 6. Remove bearing.
dirt. Replace bearings if any of the above are
present. Turn the inner race of the bearings. 7. Remove spacer.
The bearings should turn smoothly and quietly. 8. Extract or drive bearing from sprocket side.
The inner race should be firm with minimal
side to side movement and no detectable up 9. Installation: Use the Wheel Bearing Removal /
and down movement. Installation Kit PF-51324) to install new wheel
bearings. Refer to special tool manufacturer
instructions for proper use of tool.
Wheel Bearing Replacement 10. Install new seal into the RH side of hub.
11. Install the brake disc. See Brake Disc Removal /
CAUTION Installation, page 12.16.
12. Install driven sprocket. See Driven Sprocket
Installation, page 12.12.
Do not reuse bearings that have been removed.
13. Install the rear wheel. See Rear Wheel Removal /
Installation, page 12.13.
NOTE: This procedure requires the Wheel
Bearing Removal / Installation Kit (PF-51324).
Refer to special tool manufacturer instructions for
proper use of tool.

1. Remove rear wheel. See Rear Wheel Removal /

Installation, page 12.13.
2. Remove driven sprocket. See Driven Sprocket
Removal, page 12.11.
3. Remove brake disc. See Brake Disc Removal /
Installation, page 12.16.

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Brake Disc Removal / Installation Shock Absorber Removal
1. Remove the rear wheel. See Rear Wheel Removal
/ Installation, page 12.13.
2. Remove the driven sprocket and cushion damper. WARNING
See Driven Sprocket Removal, page 12.11.
Shock absorber removal involves supporting the
3. Position wheel with brake disc facing up. machine with the rear end elevated. Take
4. Remove and discard ABS tone ring / brake disc precautions so that the motorcycle is securely
screws (1). supported when the rear tire is off the ground. Severe
personal injury or death can occur if the motorcycle
5. Remove the ABS tone ring (2) and brake disc (3). tips or falls.

1. With the rear wheel properly supported, remove

the lower shock fastener (1) and upper shock
fastener (2) and remove shock absorber.

6. Installation is performed by reversing the

removal procedure.
7. Torque brake disc bolts to specification in a star
pattern. Ensure rotation arrows on rotor are noted
and followed.
Shock Absorber Inspection
1. Measure spring installed height and record so ride
height adjustment can be returned to rider’s
preference.
Brake Disc Bolts: 22 ft-lbs (30 Nm)

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2. Loosen spring collars (1) and (2) completely to 6. With shock upright, move damper rod through
relieve spring tension. entire travel range. Damper rod should move
smoothly with consistent damping through the
entire travel range, and return to the fully
extended position when released.
7. Inspect shock spring for cracks or distortion.
Measure free length and compare to specification.
See Service Specifications, page 12.3.

Shock Absorber Installation

1. Lift shock into position and install top shock
washer (1) bolt (2) finger tight.

3. Slide spring (3) off of shock.

2. Install the lower shock bolt (3) finger tight.

4. Thoroughly clean the shock spring.

5. Inspect eyelets (4 & 5) for cracks, damage or loose
fitting eyelet. Replace shock if either eyelet is
cracked.

3. Torque upper and lower shock bolts to

specification.

Shock Bolts: 65 ft-lbs (88.1 Nm)

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SWINGARM SERVICE
Swingarm Removal 3. Position a platform jack beneath the engine cases
and raise until it contacts the engine.

WARNING

Swingarm removal involves supporting the machine

with the rear end elevated. Take precautions so that
the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death
can occur if the motorcycle tips or falls.

WARNING

Make sure the exhaust system has cooled to room

temperature before elevating the motorcycle. The
4. Remove rear wheel assembly. See Rear Wheel
drive belt may be damaged if it comes into contact
Removal / Installation, page 12.13.
with HOT exhaust components.
5. Remove rear shocks. Shock Absorber Removal,
page 12.16
6. Remove the rear brake hose rear p-clamp bolt (1)
WARNING located on the left inner surface of the swingarm.

If working on a motorcycle equipped with a charcoal

canister (EVAP), remove the canister prior to
elevating the rear of the motorcycle to prevent
damage to the canister hose fittings.

1. Place the motorcycle in an upright position on a lift

table with the front wheel clamped in a wheel vise.

2. Remove exhaust assembly. See Exhaust Service,

page 5.14

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7. Remove upper belt guard bolt (2) from front and 10. Thread the swingarm shaft (6) and remove washer
two bolts from the back side of guard. (7) from the left side of the frame.

8. Remove lower belt guide bolts (3). 11. Support and remove the swingarm assembly
towards the rear of the motorcycle.

Swingarm Bushing / Bearing

Replacement
REMOVAL
1. Remove swingarm assembly from motorcycle. See
Swingarm Removal, page 12.18.
2. Remove shock absorber assembly from swingarm.
See Shock Absorber Removal, page 12.16.
3. Remove the internal snap-ring (1) followed by the
ball bearings (2) from the LH side of the swingarm.

9. Remove swingarm nut (4) and washer (5) from the

right side of the swingarm pivot shaft.

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4. Working from the RH side of the swingarm, gently 4. Install washer (7) on swingarm shaft. Slide the
pry the seals (3) out of the bearing bore. swingarm shaft (6) into the left side of the frame.

5. Remove needle roller bearing (4). 5. Install the swingarm shaft washer (5) and nut (4) on-
to the end of the swingarm shaft. Torque nut to
6. Inspect bearing bores for any galling or damage.
specification.
INSTALLATION
1. Working on the LH side of the swingarm, press or
drive new bearings (2) into the bearing bore using
a suitable bearing driver.
2. Install internal snap-ring (1).
3. Using the bearing driver drive a new needle bear-
ing (4) into the RH side of the swingarm until fully
seated.
4. Press new outer seals (3) into the bearing bore until
seated.
5. Install shock absorber assembly. See Shock Ab-
sorber Installation, page 12.17.
6. Install swingarm assembly. See Swingarm Installa-
tion, page 12.20. 6. Install upper belt guard and torque screw (5) two
screws on the back side of guard to specification.
Swingarm Installation
Drive belt must be installed on the drive sprocket
prior to installing the swingarm.
1. Clean inside of the swingarm shaft bores in both
sides of the frame midcastings.
2. Grease swingarm pivot shaft.
3. Lift the swingarm into position in the frame.

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7. Install lower belt guard and torque screws (6) to 11. Make sure that the following applies:
specification.
• The rear wheel turns freely, without any
interference between the belt guard, the tire,
and the swingarm.
• Brake line is properly routed and secured.
• The left and right axle adjusters are aligned
properly (wheel is in alignment).
• The rear brake functions properly.
• All fasteners have been tightened correctly.
• There is adequate clearance between swingarm
and exhaust mufflers and mounting.
• The swingarm is not loose, it doesn’t wobble
from side to side, and it doesn’t move up and
down more than 1/32 of an inch when pushed
and pulled firmly.
12. Install the seat. See Seat Removal / Installation,
page 3.7.
13. If equipped, install the charcoal canister. See
Belt Guard Screws: 8 ft-lbs (11 Nm)
Evaporative Emission Control System (CA Models),
page 2.25.
8. Install rear shocks. Shock Absorber Installation,
page 12.17 14. Test ride motorcycle to be sure rear suspension op-
erates smoothly without binding or abnormal
9. Install the rear brake hose rear p-clamp bolt (1) lo- noises.
cated on the left inner surface of the swingarm.
15. Adjust ride height. See Rear Shock Preload Inspec-
tion, page 2.38.

10. Install the rear wheel. See Rear Wheel Removal /

Installation, page 12.13.

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TROUBLESHOOTING
Troubleshooting, Rear Wheel / Suspension

PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED

Rear Wheel Feels “Loose” or Loose fasteners Torque to specification
Wobbles
Distorted (bent) rear wheel Replace wheel

Worn or damaged wheel bearings Replace wheel bearings

Worn or damaged swing arm bushings. Replace swing arm bushings

Damaged or incorrect rear tire Replace rear tire

Unbalanced rear wheel assembly Balance tire/wheel

Low tire pressure Inflate to specification

Loose swing arm, axle or suspension fasteners Torque to specification

Pushrod or shock bearing failure Replace pushrod or shock bearings

Rear Suspension Too Hard Incorrect preload adjustment Adjust to rider & load

Damaged shock absorber Replace / Rebuild shock

Damaged or corroded suspension mount Correct as necessary

bushing

Damaged or corroded swingarm bushings Replace

High tire pressure Deflate to specification

Drive belt adjustment too tight Adjust drive belt tension

Rear Suspension Too Soft Incorrect preload adjustment Adjust to rider & load

Damaged shock absorber Rebuild or replace shock

Weak shock spring Replace shock spring

Excessive load placed on motorcycle Reduce load weight

Low tire pressure Inflate to specification

Rear Suspension Noisy Loose fasteners Torque to specification

Worn wheel bearings Replace

Worn swing arm bushings Replace

Damaged shock absorber Replace as necessary

Worn pushrod or shock bearings Replace pushrod or shock bearings

Wheel Drags (Turns Hard) Incorrect drive belt adjustment Adjust drive belt tension

Brake problem Diagnose and Service

Loose fasteners Torque to specification

Bent rear axle Replace

Damaged wheel bearings Replace

Tire contact with object or chassis Determine point of contact and correct

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Troubleshooting, Final Drive

PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED

Belt Shows Excessive Wear Out-of-Alignment Align rear wheel
On One Side
Belt Squeal Out-of-Alignment Align rear wheel
Belt Whine / Noise Out-of-Alignment Align rear wheel
Belt Damage Inspect Belt
Incorrect Belt Tension Adjust Tension
Broken Sprocket Teeth Foreign material damage / Loose drive Replace parts or repair as necessary
belt or sprocket
Broken or Torn Cogs on Belt Foreign material damage / Loose drive Replace parts as necessary
belt or sprocket
Belt Jumps Sprocket Teeth Worn, damaged or out of adjustment Replace parts as necessary
belt or sprockets
Belt Loose Adjust Belt
Excessive Wear, Binding Belt Tight Adjust Belt
Suspension
Broken Belt Belt weakened by foreign material Replace Belt, Replace Sprockets
damage. Belt run excessively tight or
loose.

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NOTES

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CHAPTER 13
TIRES
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2 13
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.3
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
OZONE CRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
FRONT TIRE CUPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
TIRE SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TIRE CHANGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TIRE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.6
TIRE BALANCING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.8
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.9
VISUAL INSPECTION & RUNOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.9
TIRE REPAIR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.9
VALVE STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
VALVE STEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
VALVE STEM INSTALLATION - RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
VALVE STEM INSTALLATION - METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11

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GENERAL INFORMATION
Service Notes
WARNING

Do not attempt to repair tires that have:

WARNING
• Punctures with a diameter of greater than 6mm
If a consumer wishes to replace the Original (0.240").
Equipment Manufacturer (OEM) tires with another • Cuts with a length of greater than 6mm (0.240").
brand of tire, Indian Motorcycle recommends
contacting the tech-line department of the tire • Any punctures or cuts on the sidewall of the tire.
manufacturer being considered to ensure
• Tread depth of less than 1.6mm (.063") for the
compatibility. Indian Motorcycle makes no other
front tire.
recommendation other than the OEM tires. Tires
other than OEM may or may not adversely affect the • Tread depth of less than 1.6mm (.063") for the
handling characteristics of the motorcycle or may not rear tire.
have adequate clearance between tire and various
parts of the motorcycle. • Ply separation.
• Tread separation.
• Severe tread cupping.
• Cuts, gouges or scratches on the sealing surface
WARNING of the bead.
Indian Motorcycles are produced using the • Flat spots on the tread.
designated tires listed as original equipment. This • Bubbles, separation or any unusual damage to
includes field testing to ensure stability and superior the inner liner of the tire.
handling. The use of tires other than original
equipment may cause instability which can lead to a • Chemical sealants or balance additives added
crash resulting in serious injury or death. Use only to the tire.
the recommended tires inflated to the recommended
tire pressures. Operating the motorcycle with
damaged rims creates a safety hazard including air
pressure loss, steering imbalance and/or reduced
steering control. Do not attempt to repair or WARNING
straighten damaged rims.
All repairs must be made from inside the tire.
No form of temporary repair should ever be
attempted. Secondary damage caused by a
penetrating object may not be detected and tire or
tube deflation may occur at a later date.
It is dangerous to ride with a worn tire. When a
tire reaches the minimum tread depth listed
below, replace the tire immediately.

CAUTION

Two of the biggest factors contributing to premature

tire wear are overloading and under-inflation. Do not
deviate from the specifications for loading or
inflation.

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Service Specifications
Refer to Chapter 11 (Front Wheel and Suspension) for front wheel specifications.
Refer to Chapter 12 (Rear Wheel and Suspension) for rear wheel specifications.
Tire Specifications
POSITION TIRE TYPE / SIZE TIRE PRESSURE
13
Front Kenda Kruz K673F - 130/90-16 72H 36 PSI (248 kPa)
Rear Kenda Kruz K673 - 150/80-16 71H 40 PSI (276 kPa)

Minimum Tread Depth

FRONT TIRE REAR TIRE
1/16 in (1.6 mm) 1/16 in (1.6 mm)

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TIRE INSPECTION
Tire Wear Patterns Front Tire Cupping
Front of tread block worn more than rear of tread
Tire Wear Patterns block:
SYMPTOM CAUSE • The cupping of front tires is somewhat normal.
Riding on Crowned • Rear tires are subjected to forces in both
Wear on Left Side
Roads directions. The forces of braking and
acceleration result in even tire wear.
Edges Worn Underinflation or
Excessive Loads • Front tires are subjected only to the forces of
braking. When the brakes are applied, tire
Excess Wear in the Over-inflation or Tire deflection is increased and wear occurs in only
Middle of Tire Abuse one direction.
Underinflation, • Incorrect tire pressure is the number one cause
Cracks in Tread Grooves Excessive Loads, of excessive tire cupping. Too little tire pressure
Suspension Bottoming causes the tire to over-deflect which increases
the amount of scrubbing and causes more tire
Tread Block Cupping cupping.
(Usually Front Tire -See Normal Braking Wear
Below) • Binding or improperly assembled front forks can
also contribute to excessive tire cupping. If the
front forks do not react as they should the tire
Ozone Cracking acts as the sole suspension component and
tread deflection increases.
Ozone cracking usually shows up on the sidewalls of
tires and is caused by sunlight, electric motor
emissions, smog, or other environmental factors.
Ozone cracking does not pose a problem unless the
cracks reach the cords. If this occurs, moisture may
penetrate the carcass of the tire causing cord
separation. Tires showing signs of severe ozone
cracking (cords visible at the bottom of the cracks)
must be replaced.

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TIRE SERVICE
Tire Changing Tire Removal
There are three generally acceptable methods to
NOTE: This procedure is written assuming that a
dismount and mount a motorcycle tire to its rim. For
pneumatic, electric, or manually operated rim-
each of the three methods, there are countless
variations.
clamp type tire machine is being used. 13
The three general methods are: 1. Remove wheel / tire assembly from motorcycle.
See Chapter 11 for front wheel removal and
• Pneumatic or electrically operated tire machine Chapter 12 for rear wheel removal.
• Manually operated tire machine 2. Remove valve core (1) from valve stem and let all
• Manual manipulation of tire irons air escape.

Indian Motorcycle permits and recommends all three

of the general methods, but realizes that careless or
improper work habits can damage both the tire and
rim no matter which method is used. With any of the
methods, care must still be taken to avoid damaging
the rim, tire, inner tube (if applicable), brake disk, or
sprocket.
The pneumatic or electrically operated tire machine is
preferred because it is the most efficient method to
dismount and mount tires.
The manually operated tire machine is the next
preferred method. It can be just as efficient as a power
assisted tire machine but with some of the machines it
may be necessary to remove the belt driven sprocket
in order to gain sufficient clearance for tire removal. 3. Mount the wheel assembly onto a tire bead
breaker and break the bead starting at the valve
Manual manipulation is the least preferred method stem and continue around the circumference of the
since it will generally not deliver the same efficiency rim as necessary.
as the other methods and greater care needs to be
taken when performed. Care must be taken when 4. Flip the wheel assembly over and repeat STEP 3 on
using tire irons to not damage or stress the tire bead, the other side.
Also, the opposite bead needs to be in drop center of
wheel during mounting and dismounting of the tire. CAUTION
Be very careful not to damage the rim, tire, inner tube,
brake disk, or sprocket regardless of which method is IMPORTANT: Take great care not to bend or
used. otherwise damage the brake disc and/or belt driven
sprocket. If the bead breaker being used interferes
with either the brake disk and/or belt driven
sprocket, remove the disc or sprocket as required.

5. NOTE: Refer to manufacturer’s instructions

for proper tire changer operation.
Mount the tire and wheel assembly on the tire
machine per the manufacturers instructions.

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TIRES
6. Carefully work around the circumference of the Tire Installation
upper bead (2) with the tire lever until it is
completely off of the rim. NOTE: This procedure is written assuming that a
pneumatic, electric, or manually operated rim-
clamp type tire machine is being used.

NOTE: 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. Reliance upon sealants can
result in sudden tire failure and accident.
Directional Arrows
Tires (1) have directional arrows that must be
observed when installing tires to rims.

7. Lift the lower tire bead up until the tire lever can
be positioned and the tire completely removed.
8. Work around the circumference of the rim until the
tire can be lifted free of the rim.

The wheel assemblies must be free of foreign

debris that would affect balancing.
Carefully inspect the wheel bearings, seals and
axle for damage or corrosion.

1. Lubricate both tire beads with rubber lubricant.

WARNING

Never apply grease, oil, gasoline, spray type

lubricants or anything other than rubber lubricant or
a neutral soap and water solution to the tire bead.
Doing so can damage the tire.

2. NOTE: Refer to manufacturer’s instructions

for proper tire changer operation.
Mount the tire and wheel assembly on the tire
machine per the manufacturers instructions.
3. Orient tire correctly as to the directional arrows.

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 TIRES
4. Push tire on to rim until one bead is installed. It 13. Inflate tire observing the precautions listed below.
shouldn’t be necessary to use tire irons to put one
Tire Inflation & Precautions
side of the tire onto the rim. Remember to keep
bead(s) in the drop center of the wheel whenever • Wear approved eye protection
possible.
• Lubricate the tire beads with a tire mounting
lubricant before inflation.
13
• Lock assembly on mounting machine or place in
safety cage before inflating to seat beads
• Use extension gauge and hose with slip-on air
chuck.
• Stand back with no part of your body within the
perimeter of the assembled tire and rim.
• Inflate with core in valve stem
• Never inflate above 42 psi to seat beads
• If beads do not seat by 42 psi. Deflate and
repeat procedures. Never use a volatile
substance or rubber “donut” to aid bead
seating.
NOTE: Confirm tire is positioned correctly by
14. Inspect the line molded onto the tire side walls. It
observing directional arrows.
must be the same distance from the rim all the way
5. Lubricate the tire bead. around the tire. If the distance varies it indicates
that tire is not seated properly.
6. With your hands, push as much of the remaining
tire bead as possible into the rim, pinching both 15. If tire is not seated correctly, deflate and unseat
upper and lower beads into the drop center. the tire, lubricate the tire beads and repeat
inflation procedure.
7. When no more of tire can be installed by hand,
press down on portion of tire in front of you with 16. Install wheel assembly onto balance stand and
your knee to keep the top bead in the drop center. spin. Observe the wheel assembly while it is
spinning to make sure the tire is seated properly.
8. Install the tire lever and work around the
remaining circumference of the wheel until the 17. Adjust tire pressures to specifications.
bead is fully installed onto the rim.
NOTE: Be sure both beads are forced as far as
possible into the drop center of the rim.

9. Install valve core if it was removed.

10. Line up balance dot.
11. Confirm that the directional arrows are pointing in
the correct direction.
12. Bounce tire on the floor several times while
rotating tire. This will expand tire bead outward
slightly which will make tire inflation easier.

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TIRES
18. Balance tire / wheel assembly. 3. Spin the wheel assembly. Allow it to stop on its
own and mark the highest (lightest) part of the
wheel.
WARNING 4. Repeat the spinning process to verify the heaviest
part of the wheel.
FOR REPAIRED TIRES: Speed should not exceed 5. Place balance weights at the lightest portion of
50 MPH for the first 24 hours after repair and wheel in small increments.
repaired tire should never be used over 80 MPH.
Inspect inflation pressure after tire cools for at least 6. After each addition of weight, spin the wheel
three hours following run-in. assembly and allow it to stop by itself.
7. When correct amount of weight has been added to
FOR NEW TIRES: Replacement of OEM tires or wheel, it will no longer stop in the same location
replacement with differently constructed tires will and the wheel assembly is balanced.
not immediately produce improved reactions the
same as the original tires when new. When new tires
are installed, they should not be subjected to CAUTION
maximum power or hard cornering until a reasonable
“scrub” period of approximately 100 miles has been Do not add more than 85 grams (3.0 oz.) of weight to
covered. This will permit the rider to become the front or rear wheel.
accustomed to “feel” of new tires or tire
combination, and achieve optimum road grip. If more than the recommended weight is
necessary to balance the wheel, dismount the tire
Inspect and adjust tire inflation pressure after tire and rotate it 90o without regard to the yellow
cools down for at least three hours following “run- balance dot, and re-balance the wheel / tire.
in”. Adhesive Weight P/N 1521682
8. Install wheel / tire assembly onto motorcycle. See
Chapter 11 for front wheel installation and
Tire Balancing Chapter 12 for rear wheel installation.

WARNING

It is essential that the wheel assembly be balanced

before use and rebalanced each time the tire is
removed. Wheel balance affects stability, handling
and overall safety of the motorcycle.

The use of liquid balancer/sealer is not

recommended.
This procedure will outline balancing wheel assembly
in a gravity balance stand. If a pendulum or spin type
balancer is being used, reference the manufacturer’s
instructions that came with the equipment.
1. Mount wheel assembly in a commercially
available balance stand.
2. Remove all balance weights. Clean tire and rim
thoroughly.
NOTE: While it is possible to balance a wheel
assembly with axle and grease-free wheel
bearings as the pivot point, it is not
recommended. Use an inspection stand that
has knife edge bearings and its own axle.

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 TIRES
WHEEL INSPECTION
Visual Inspection & Runout Tire Repair Precautions
1. Clean the rim of all rubber particles and
corrosion.
2. Inspect wheel for cracks and/or distortion. WARNING
13
3. Inspect bead seating area for scratches, distortion,
or damage that could prevent proper sealing. Only permanent plug-patch repairs of small tread
area punctures from inside the dismounted tire are
4. Measure wheel for radial runout (1). recommended. Never perform an exterior repair and
5. Measure wheel for axial runout (2). never use an inner tube as a substitute for a proper
repair. Speed should not exceed 50 MPH for the first
24 hours after repair and the repaired tire should
never be used over 80 MPH. Inspect inflation
pressure after tire cools for at least three hours
following initial operation.

NOTE: Measure runout on tire bead sealing

surface of wheel. Be sure surface is clean.

6. Compare measurements of axial and radial runout

to specifications. See Service Specifications, page
13.3. Replace wheel if any measurement exceeds
Service Limit.
7. Clean the sealing surfaces of the rim thoroughly.
Use a soft brush (nylon) soap and water if
necessary.

WARNING

Do not scratch or damage sealing surfaces of rim.

Loss of air pressure can cause a loss of control and an
accident, resulting in serious injury or death.

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TIRES
VALVE STEM
Valve Stem Inspection 3. Clean gasket or o-ring sealing surface of rim.
1. Remove the valve stem cap and spray the valve 4. Place new valve stem (with seal washer or O-ring
stem down with a mild soap and water solution. installed) through hole in rim and position it so the
2. Observe the area around the base of the valve stem is perpendicular from wheel center and,
stem and valve core area. If any bubbles form over valve opening facing away from surface
a 1–2 minute period, the valve stem or inner tube containing direction indicator.
should be replaced.
3. Inspect valve stem for cracks or visible damage
and replace if necessary.
NOTE: Valve stem replacement is
recommended when tire is being replaced.

Valve Stem Installation - Rubber

1. Remove tire from wheel and cut valve stem with a
diagonal cutter to remove.
2. Clean tire valve hole and sealing area thoroughly.
3. Lubricate tire valve and hole with P-80 rubber
lubricant or equivalent.
4. Place tire valve into hole and screw a tire valve 5. Hold stem and tighten nut to specification.
installation tool (commercially available) onto
valve.
5. Place a small wood block against the rim to
improve leverage point and keep the pulling angle
as straight as possible. Valve Stem Nut: 44 in-lbs (5.0 Nm)
6. Pull the valve until fully seated and remove tool.
6. Install tire. See Tire Installation, page 13.6.
Valve Stem Installation - Metal
IMPORTANT: The Scout model uses directional
tires and wheels. Pay close attention to markings
to ensure proper tire and valve stem orientation.

1. Remove tire from wheel. See Tire Removal, page

13.5.
2. Remove valve stem (1), o-ring (2), nut (3) and
valve stem (4).

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TROUBLESHOOTING
Troubleshooting

PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED

Rear Wheel (Wobbles) Bent rim Replace 13
Worn or damaged wheel bearings Replace as a set
Worn or damaged swing arm Replace as a set
bushings.
Damaged or incorrect tire Replace rear tire
Wheel assembly out-of-balance Balance wheel
Low tire pressure Inflate to specification
Loose swing arm, axle or Torque to specification
suspension fasteners.
Handlebars Oscillate (Wobble) Bent front axle Replace
Worn or damaged wheel bearings Replace as a set
Tire mounted incorrectly Inspect and re-mount tire
Damaged tire Replace
Loose steering stem nut Adjust to specification
Incorrect tire Replace
Incorrect tire pressure Inflate to specification
Front Wheel Oscillates (Wobbles) Bent rim Replace
Worn or damaged wheel bearings Replace as a set
Damaged or incorrect tire Replace
Loose axle or axle pinch bolts Torque to specification
Right and left fork not installed at Repair
same height
Fork oil level incorrect Fill to specification
Fork spring free length different Replace spring that does not meet
between right & left specification
Wheel assembly out-of-balance Balance wheel

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NOTES

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 BRAKES

CHAPTER 14
BRAKES
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.3
14
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.4
FRONT BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.4
REAR BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.5
BRAKE LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.6
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.8
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
ABS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
ANTI-LOCK BRAKES SYSTEM (ABS) SERVICE (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
ABS SYSTEM SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
ABS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
ABS SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
ABS OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
ABS SYSTEM SERVICE (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
WHEEL SPEED SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
WHEEL SPEED SENSOR AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
ABS MODULE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
ABS BRAKE SYSTEM BLEEDING (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
BRAKE FLUID REPLACEMENT & BLEEDING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
ABS BRAKE VACUUM BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
ABS FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
ABS REAR BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
ABS FRONT BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
BRAKE LEVER RESERVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
FRONT BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
REAR BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
FRONT MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
FRONT CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26
REAR MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
REAR CALIPER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.29
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30

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BRAKES
GENERAL INFORMATION
WARNING
Service Notes
The brake system uses ethylene-glycol based fluid
Use only genuine Indian Motorcycle replacement
(DOT 4). Do not use or mix with different types of
parts when servicing the brake system. Clean all
fluid such as silicone-based (DOT 5) or any
system components prior to disassembly, including
petroleum-based fluid.
the fluid reservoir cover (s) to reduce the chance of
debris entering the system during repair or
Do not let water or moisture enter the master
maintenance work. Start with a clean work area away
cylinder when refilling. Water significantly lowers the
from dust, water or other contamination. Cleanliness is
boiling point of the fluid and can result in poor
very important for proper brake system maintenance
braking.
and repair. Follow procedure outlined in this manual
carefully, including fastener torques and the
Do not use brake fluid taken from old, used or
application of special lubricant in required areas.
unsealed containers. Never reuse brake fluid.
Special lubricants are included with service kits.
Keep brake fluid containers completely sealed and
out of reach of children.
WARNING
Brake hoses should be replaced whenever the
Contaminated brake discs or pads greatly reduce the exterior shows signs of deterioration or damage.
amount of stopping force available & increase Brake hoses should be replaced every four (4) years
stopping distance. Brake discs can be cleaned using regardless of their exterior condition.
a commercially available brake disc cleaner. Follow
the manufacturer instructions printed on the Bleed the brake system any time it is disassembled
container. NEVER attempt to clean contaminated or when the brake action is spongy.
brake pads. Always replace pads as a set.
Always inspect the operation of the brakes before
riding the motorcycle.

Replace sealing washers whenever brake lines are

removed.

Always remove the master cylinder fluid reservoir

cover and inspect the fluid level when brake pads are
replaced.

NOTICE: Brake fluid and some types of brake

cleaners will damage paint, plastics and some rubber
compounds. Cover or remove plastic and painted
parts before working on the brake system. If brake
fluid is spilled on cosmetic surfaces, immediately
rinse the area with a mild solution of soap and water
until all traces of brake fluid are removed. Make sure
the master cylinder reservoir being worked on is level
and clean before removing the cap.

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 BRAKES
Special Tools Service Specifications

TOOL DESCRIPTION PART NUMBER STAN-

ITEM SERVICE LIMIT
DARD
ABS Tool (Lever Reserve) PV-50104
Replace every 24
Vacuum Brake Bleeder Commercially Available Specified Brake months or 10,000 miles
DOT 4
Fluid (16,000 km)

Torque Specifications Brake Disc

5 mm 4.5 mm (.177") (Min)
Thickness, Front

PART / FASTENER
TORQUE Brake Disc
5mm 4.5 mm (.177") (Min)
14
SPECIFICATION Thickness, Rear
Banjo Bolt, Front (Caliper, M/ 16 ft-lbs (22 Nm) Brake Disc
C) - .30 mm (.012") (Max)
Runout
Banjo Bolt, Rear (Caliper, M/ 16 ft-lbs (22 Nm) Brake Pad Wear When wear limit
C) Limit (Front & - groove is no longer
Rear) visible
Bleeder Screw (All) 60 in-lbs (5.4 Nm)
Brake Pedal Free No
Brake Disc, Front 22 ft-lbs (30 Nm) Ad-
Play (Pedal -
Clearance) just-
Brake Lever Clamp 8 ft-lbs (11 Nm)
ment
Caliper Body, Front 35 ft-lbs (27.0 Nm) No
Brake Lever Ad-
Brake Caliper Mounting 31 ± 4 ft-lbs (42 ± 6 -
Freeplay (Front) just-
Fasteners Nm)
ment
Caliper Slide Bolt, Rear 20 ft-lbs (27.0 Nm)
Caliper Stud, Front 20 ft-lbs (27.0 Nm)
Master Cylinder Cover, Front 13 in-lbs (1.5 Nm)
Master Cylinder Cover, Rear 13 in-lbs (1.5 Nm)
Pad Retaining Pin 10 ft-lbs (13.5 Nm)
Wheel Speed Sensor (Both) 7 ft-lbs (9.5 Nm)

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BRAKES
ASSEMBLY VIEWS
Front Brake System

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Bolt, Front Disc — M8 x 25 22 ft-lbs (30 Nm)
2 Screw, ABS Sensor — M6 x 15 7 ft-lbs (9.5 Nm)
3 Screw, Caliper — M1 x 25 31 ft-lbs (42 Nm)
4 Bolt, Banjo — 10 x 1.25 16 ft-lbs (22 Nm)
5 Snap Ring, External -

6 Bolt, Banjo — 10 x 1.25 16 ft-lbs (22 Nm)

7 Rubber Seal -
8 Pivot Pin, Brake Lever 8 ft-lbs (11 Nm)
9 Rubber Diaphragm -

10 Cover, Front Master Cylinder -

11 Screw, Front Master Cylinder Cover 13 in-lbs (1.5 Nm)

12 Screw, Brake Lever Clamp 8 ft-lbs (11 Nm)

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Rear Brake System

14

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Valve, Bleeder 60 in-lbs (6.8 Nm)
2 Bolt, Caliper — 10 x 25 31 ft-lbs (42 Nm)
3 Bolt, Banjo — 10 x 1.25 16 ft-lbs (22 Nm)
4 Rubber Seal -
5 Bolt, Banjo — 10 x 1.25 16 ft-lbs (22 Nm)
6 Rubber Seal -
7 Rubber Diaphragm -

8 Cover, Rear Master Cylinder -

9 Screw, Rear Master Cylinder 13 in-lbs (1.5 Nm)

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Brake Line Routing

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Brake Line, Rear (Rear Caliper to Master Cylinder) -

2 Brake Line, Front (Front Caliper to Handlebar)

3 Screw, P-Clamp — M6 x 1.0 x 12 84 in-lbs (9.5 Nm)
4 Screw, Bracket — M6 x 1.0 x 35 60 in-lbs (6.8 Nm)
5 Screw, P-Clamp — M8 x 1.25 x 40 18 ft-lbs (24 Nm)

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ABS Models (INT’L)

14

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Brake Line, Rear (Rear Caliper to ABS Module) -

2 Brake Line, Rear (Rear Master Cylinder to ABS Module) -

3 Brake Line, Front (Front Caliper to ABS Module) -

4 Brake Line, Front (Handlebar to ABS Module) -

5 Screw, P-Clamp — M6 x 1.0 x 12 84 in-lbs (9.5 Nm)

6 Screw, Bracket — M6 x 1.0 x 35 60 in-lbs (6.8 Nm)
7 Screw, P-Clamp — M8 x 1.25 x 40 18 ft-lbs (24 Nm)

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Rear Master Cylinder

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Rear Master Cylinder Cover 13 in-lbs (1.5 Nm)
2 Cover, Rear Master Cylinder -
3 Rubber Diaphragm -
4 Reservoir, Rear Master Cylinder -
5 O-Ring, Sight Glass -
6 Sight Glass -
7 Spring -
8 P Cup -
9 S Cup -
10 Pushrod -
11 Piston -
12 Piston Washer -
13 Piston Snap Ring -
14 Dust Boot -
15 Pushrod Nut -
16 Clevis Nut 8 ft-lbs (11 Nm)
17 Clevis -

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Front Brake Caliper

14

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Brake Pads -
2 Lower Slide Pin 18 ft-lbs (24.4 Nm)
3 Bracket -
4 Lower Dust Boot -
5 Upper Dust Boot -

6 Piston -
7 Piston Seal -
8 Pad Spring -

9 Caliper Body -

10 Pad Retaining Pin 120 in-lbs (13.5 Nm)

11 Screw, Bleeder 48 in-lbs (5.4 Nm)
12 Upper Slide Pin 10 ft-lbs (13.5 Nm)

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Rear Brake Caliper

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Brake Pads -
2 Mount Bracket -
3 Guide Pin -
4 Piston -
5 Dust Seal -
6 Screw, Bleeder 48 in-lbs (5.4 Nm)
7 Pad Retaining Pin 10 ft-lbs (13.5 Nm)
8 Caliper Body -

9 Pad Wear Clip -

10 Dust Seal -
11 Guide Pin -
12 Pad Spring -

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ABS Module

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ANTI-LOCK BRAKES SYSTEM (ABS) SERVICE (INT’L)
ABS System Safety Precautions ABS General Information
Before working on an Indian Motorcycle equipped The Anti-Lock Brake System is a safety feature
with anti-lock brakes, review and understand all designed to prevent wheel lock-up and improve
general brake system, brake fluid, and ABS specific control of the motorcycle during extreme braking
precautions and system information. Do not attempt events, including:
maintenance or repair of the anti-lock brake system
without the proper tools. • Panic braking
• Slick surface braking (such as wet road
surfaces)
WARNING • Surface transitions (from asphalt to oily asphalt
or cobblestone, etc.)
Proper brake system bleeding is extremely
important to ensure adequate lever reserve in the Here are a few general points to note about ABS:
system. Always perform the Brake Lever Reserve test
described in this manual after bleeding the anti-lock • The anti-lock brake system cannot be turned
brake system. OFF.
• The ABS indicator lamp (located on the
• Operating with non-recommended tires or Instrument Cluster) always illuminates when the
improper tire pressure may reduce the key is in the ON position and remains on until
effectiveness of the anti-lock brake system. the anti-lock system activates, which occurs
• Always install the recommended size and type when vehicle speed exceeds 6 mph (10 kph).
of tires specified for the vehicle. • If the lamp is not illuminated when the key is
• Always maintain the recommended tire ON, connect Digital Wrench and perform an ABS
pressure. System 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 brakes will not activate, but the conventional
(16,000 km) or 2 years, whichever comes first. brake system will continue to operate normally.

• The anti-lock brake system will not prevent • If the lamp continues to illuminate after the
wheel lock-up, loss of traction, or loss of control vehicle speed exceeds 6 mph (10 kph), the
under all conditions. Always adhere to all safe system is not functioning. Connect Digital
motorcycle riding practices as recommended. Wrench and perform an ABS System inspection
to determine the cause.
• It is not unusual to leave tire marks on the road
surface during a hard braking event. • When the anti-lock brakes engage during a
braking event, the rider will feel pulsing at the
• The anti-lock braking system does not brake lever or pedal. Continue to apply steady
compensate for or reduce the risk associated pressure to the brakes for the best stopping
with: performance.
• excessive speed • The wheel speed sensor-to-pulse ring air gap is
• reduced traction on rough, uneven or loose adjustable. Shims can be added or removed to
surfaces bring the air-gap into specification. See
adjustment procedure outlined in this chapter.
• poor judgement
• The ABS system can be reprogrammed.
• improper operation
• The ABS light is controlled via CAN BUS.
• Wheel speed sensors provide feedback for anti-
lock brake operation.
• If fuse is open or removed, the ABS light will
remain ON after 6 mph (10 kph). ABS will not be
active. Normal (conventional) braking will be
available provided the system components
(master cylinder, lines, calipers, etc.) are in
working order.

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ABS System Components ABS Overview Of Operation
The following parts function in the same manner as the The ABS system is active and available when vehicle
same component in a non-ABS system, although parts speed exceeds 6 mph (10 kph).
are not necessarily interchangeable. Always refer to The system uses two independent Hall-Effect Wheel
the appropriate ABS parts information when replacing Speed Sensors. One sensor is mounted to the front
a component or component parts. caliper and one is mounted to the rear brake caliper
bracket. Two Pulse Rings are also used, one mounted
• Front Brake Calipers
to the left front brake disc hub and one to the rear
• Rear Brake Caliper brake disc hub, which rotate with the wheels. When
the vehicle is in motion, the multiple reluctor
• Front Master Cylinder segments on each pulse ring pass by the center pole 14
• Rear Master Cylinder of the respective wheel speed sensor, generating an
electrical pulse signal in the sensor which is sent to
• Brake Light Switch the ABS Module which is located in front of the rear
• Brake Lines wheel.
The ABS Module interprets wheel speed signal pulses
In addition to the brake system components listed to determine speed, rate-of-change, and front / rear
above, the following are exclusive to ABS equipped wheel speed differential to determine if wheel lock-up
vehicles: is about to occur. When wheel lock-up is imminent
during a braking event, the ABS Module controls the
• Wheel Speed Sensors (Front located on front
operation of solenoids and a pressure pump (located
caliper; Rear mounted on rear caliper bracket)
inside the ABS Module) to regulate the amount of line
• Wheel Speed Sensor Pulse Rings (Front and pressure and cycles (length of time) applied to the
Rear mounted to wheel with 5 disc bolts) caliper pistons and brake pads. This pressure / time
modulation can often be felt at the brake lever or the
• ABS Module Assembly brake pedal during an ABS braking event and is a
• ABS Related Wiring normal condition. Note that the brake fluid is not
diverted inside the module and does not “flow” in the
• ABS Indicator Lamp system any more than occurs in a conventional (non-
ABS) brake system.
If the surface coefficient changes (such as moving from
wet pavement to dry pavement) the ABS system will
recalculate (in a matter of milliseconds) and adjust
pressure output to caliper(s) as required.
In the event of a system fault, the ECM turns on the
ABS indicator lamp (via the CAN BUS) and leaves it on
even after vehicle speed exceeds 6 mph (10 kph)
activation speed.
If a system fault occurs, the light will remain on (and
ABS will not be active) until the ignition key is turned
to OFF position and back to ON.
The ABS Module Assembly is serviceable only as an
assembly. The module itself is not rebuildable.
Disconnect negative (-) battery cable from battery
before servicing ABS brake lines or system
components.

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ABS SYSTEM SERVICE (INT’L)
Wheel Speed Sensor Replacement
Removal - Front Removal - Rear
1. Remove bolt (1) securing the Wheel Speed Sensor 7. Remove bolt (2) securing the Wheel Speed Sensor
to bracket. to the bracket.

2. Withdraw speed sensor and remove any existing 8. Withdraw speed sensor and remove any existing
shims. shims.
3. Noting their position, clip cable ties securing the 9. Noting their position, clip the cable ties securing
harness to the motorcycle. the speed sensor harness to the rear brake line.
4. Locate connector inside the headlight and 10. Locate connector below the ABS module and
disconnect the wheel speed sensor. above the voltage regulator. Disconnect the wheel
speed sensor.
Installation - Front
Installation - Rear
5. Reverse procedure to install.
11. Reverse procedure to install.
6. Verify speed sensor air gap is within specification.
Perform adjustment procedure if necessary. See 12. Verify speed sensor air gap is within specification.
Wheel Speed Sensor Air Gap Adjustment, page Perform adjustment procedure if necessary. See
14.15. Wheel Speed Sensor Air Gap Adjustment, page
14.15.

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Wheel Speed Sensor Air Gap Adjustment 5. Based on air gap measurement, add or remove
shims to achieve the specified air gap.
NOTE: Wheel Speed Sensor air gap is adjusted by
adding and removing shims. Shims are added to
increase gap and removed to decrease gap. No
more than 3 shims (per Wheel Speed Sensor)
should be used at one time.

1. Using a suitable feeler gauge, measure the air gap

between the ABS Pulse Ring and the Wheel Speed
Sensor.
14

WSS Shim Thickness: 0.019 in (0.5 mm)

2. If the Wheel Speed Sensor air gap is out of
specification, proceed to step 3. 6. Reinstall Wheel Speed Sensor and torque to
specification.

Wheel Speed Sensor Air Gap (Max)

0.079 in (2.00 mm) Wheel Speed Sensor: 7 ft-lbs (9.5 Nm)

3. Remove Wheel Speed Sensor from bracket.

4. Withdraw the speed sensor and remove any
existing shims.

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ABS Module Replacement 7. Remove the fastener (2) securing the side ABS
Module mount.
NOTE: Do not disassemble the ABS module. The
ABS module is serviceable only as a sealed (pre-
bled) assembly. If ABS module has failed
internally, replace complete assembly.

WARNING

The hydraulic brake system MUST be completely

bled following removal or replacement of the ABS
module. Follow the brake bleeding procedure
outlined in this chapter after ABS module service.

Removal 8. Disconnect the electrical connectors from the ABS

1. Disconnect the negative battery cable. Module.

2. Position motorcycle in an upright position with the 9. Disconnect hydraulic lines (3) from ABS module
front wheel clamped in a wheel vise. and cap off lines to prevent contamination.

3. California Models ONLY: Remove the

evaporative emissions charcoal canister, if
equipped. Refer to , page 1.11.
4. Remove the swingarm assembly. Refer to , page
12.18 procedure.
5. Remove the voltage regulator. Refer to Regulator
/ Rectifier, page 15.9 procedure.
6. Remove the fastener (1) securing the bottom ABS
Module mount.

10. Remove ABS module.

Installation
11. Reverse procedure to install.
12. Bleed brake system as outlined in this chapter.
13. Attach Digital Wrench and check for ABS trouble
codes.

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ABS BRAKE SYSTEM BLEEDING (INT’L)
Brake Fluid Replacement & Bleeding
Precautions WARNING

An unsafe condition exists when air is trapped in the

hydraulic brake system. Air in the brake hydraulic
WARNING system acts like a soft spring and absorbs a large
percentage of the pressure developed by the master
Contaminated brake discs or brake pads greatly cylinder. Without this pressure, the braking system
reduce braking performance and increase stopping cannot develop full braking force to allow for safe,
distance. Do not attempt to clean contaminated pads. controlled stops. It is extremely important to bleed 14
Replace them. Clean the brake disc with brake the brakes properly after any brake system work has
cleaner. been performed or when inspection reveals spongy
brakes.

Keep these points in mind when bleeding

WARNING hydraulic brakes:
• The master cylinder reservoirs have limited
This brake system requires ethylene-glycol based capacities. It is easy to empty them during the
fluid (DOT 4). Do not use or mix different types of bleeding procedure. This introduces air into the
fluid such as silicone-based or petroleum-based. system which you are trying to purge. Watch the
reservoir closely and add fluid when necessary
to keep the level above the LOW mark and
prevent air from re-entering the system.
WARNING • Apply only light to moderate pressure to the
lever or pedal when bleeding the brake system.
Do not use brake fluid taken from old, used or Extreme pressure or rapid movement will cause
unsealed containers. Never reuse brake fluid. Brake a surge of fluid through the small orifices of the
fluid can accumulate moisture, reducing it’s brake system when the bleeder screw is opened
performance. and could introduce air into the system by
means of cavitation.
• Small amounts of air can become trapped in the
banjo bolt fittings at the master cylinder(s) and
WARNING junction points of brake lines. These fittings can
be purged of air by following a standard
Brake fluid is poisonous. Keep brake fluid tightly bleeding procedure at these fittings (instead of
sealed and out of reach of children. the bleed screw on caliper) if necessary to
speed the bleeding process. This is usually only
needed if system was completely drained of
fluid. Bleed each line connection, starting with
the fitting closest to the master cylinder,
WARNING working toward the caliper, and ending with the
bleed screw.
A soft, spongy feeling in the brake lever and/or • Always torque banjo bolts and other brake
brake pedal could indicate a hazardous condition in system fasteners and components to specified
the brake system. Do not operate the motorcycle torque.
until the failure in the brake system is corrected.
• Always install NEW genuine Indian Motorcycle
replacement parts and rubber parts upon
assembly. Apply special lubricant where
indicated (included in service kits).

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ABS Brake Vacuum Bleeder ABS Rear Brake Bleeding
A vacuum bleeder is recommended for ABS system
bleeding and can also be used to bleed conventional NOTE: The use of a vacuum bleeder is
recommended. DO NOT allow fluid level in
(non-ABS) brake systems. One style of bleeder is
reservoir to drop below the LOW mark at any time
shown below.
during the bleeding procedure.
Repeat entire bleed procedure at least once.

1. Remove rubber cap from rear caliper bleed screw

(1) and place a box end wrench on the screw.
2. Attach a tight-fitting clear hose from the vacuum
bleeder to the bleed screw and apply vacuum.

ABS Fluid Change

Review Brake Fluid Replacement and Bleeding
Precautions before working with brake fluid.
NOTE: When bleeding or flushing the system, 3. Fill rear brake fluid reservoir and leave cover off
monitor fluid level in master cylinder reservoir so fluid can be added as it is drawn through the
constantly. DO NOT allow fluid level to fall below system.
the LOW level.
4. Open bleed screw about 1/4 turn.

Use only DOT 4 brake fluid from a sealed container. 5. Pump brake pedal repeatedly with smooth full
strokes while adding brake fluid to the reservoir as
NOTE: EMPTY LINES - If system is dry or very required. For best results pump the pedal at a
low on fluid due to parts replacement or fairly rapid rate but avoid pumping too fast or fluid
disassembly, fill reservoir and pump lever or may become aerated. After about 2 cups of fluid
pedal slowly through stroke range until air have been run through the system, the bleeder
bubbles no longer rise through the fluid into the hose should have clear, bubble-free fluid running
reservoir. through it.
FLUSHING THE SYSTEM - Brake systems should 6. Close bleeder screw and fill the brake fluid
be flushed every 2 years or more often if the fluid reservoir.
is discolored. To flush the system, follow normal
brake bleeding process, and pump fluid through 7. Repeat the entire bleeding process to be sure all air
the system until fluid moving through the bleeder is purged from the system.
hose is clear. Do not allow reservoir level to fall 8. Torque all bleed screws to specification and install
below the LOW level or complete system bleeding the rubber caps.
will be required.

Caliper Bleeder Screws: 48 in-lbs (5.4 Nm)

9. After completing the bleeding procedure a second

time, inspect brake fluid level and add if
necessary.

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10. Clean the reservoir cover, diaphragm, and 3. Remove rubber cap from bleeder screw (3) on
reservoir sealing surface. If diaphragm is front caliper and place a box end wrench on the
extended, return it to normal (flat) position. Install screw.
diaphragm and cover.
11. If pedal is not firm, repeat bleeding procedure and
insect brake system.

ABS Front Brake Bleeding

1. Pull brake lever forward to ensure smooth lever
operation. Loosen pivot screw (1) if necessary.
14

4. Attach tight fitting clear hose from vacuum

bleeder to bleed screw and apply vacuum.
5. Hold lever to handlebar or hold firm pressure on
lever, then open bleed screw about 1/4 turn.
6. Pump brake lever repeatedly with smooth full
strokes while adding brake fluid to the reservoir as
required. For best results pump the lever at a fairly
2. Remove front brake fluid reservoir cover (2) and rapid rate but avoid pumping too fast or fluid may
leave it off so fluid can be added as it is drawn become aerated. Eventually, the bleeder hose
through the system. should have clear, bubble-free fluid running
through it. Close the bleeder screw.
7. Fill fluid reservoir and install diaphragm and
cover. Torque cover screws to specification.

Front Master Cylinder Cover: 13 in-lbs (1.5 Nm)

8. Perform Brake Lever Reserve Inspection. See Rear

Master Cylinder Installation, page .

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Brake Lever Reserve Inspection
This procedure requires use of the Brake Lever Re-
serve Tool (PV-50104).
1. Turn handlebars fully LEFT.
2. Place grommet of Brake Lever Reserve Inspection
Tool PV-50104 on ball end of front brake lever.
3. Connect a scale (commercially available) with a
minimum of 25 kg / 50 lb capacity to end of tool.
4. Keep tool centered so it does not touch hand grip.
Pull on scale to specified force.

Brake Lever Reserve Force: 42 lbs (19 kg)

5. Have an assistant verify brake lever does not

contact hand grip. Clearance must exist at
specified pull force as shown.
6. If lever makes contact with hand grip or bar end,
bleed the front brake system.
7. See troubleshooting if bleeding problems persist.

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BRAKE SYSTEM SERVICE
Front Brake Pad Replacement 10. Slowly pump lever to set brake pads against disc.
Lever should be firm, not spongy. If lever is
NOTE: Always replace brake pads as a set and spongy, inspect pad installation, bleed brake lines
always replace pads in both front calipers at the and inspect brake disc.
same time.
11. Install reservoir cover and torque to specification.
1. Remove the set screw, and then remove brake pad
pin (1).

14
Master Cylinder Reservoir Cover: 13 in-lbs (1.5 Nm)

12. Operate brake lever several times until lever is

firm and pressure can be felt.

WARNING

After pad installation or any brake system repair,

safely elevate wheel, apply and release brake pedal
or lever 2-3 times and release. Verify wheel turns
freely without drag. If brake drag is evident, do not
2. Push each pad back by hand to gain clearance for operate the motorcycle. Inspect vehicle to determine
new pads. cause and then repair as necessary.
NOTE: Brake fluid will be forced back into the
reservoir when pads are pushed back. Remove
reservoir cover and monitor fluid level, or Rear Brake Pad Replacement
attach a hose to the brake bleeder screw and
open the bleed screw while pushing the pads NOTE: Always replace brake pads as a set.
and pistons back.
Always replace brake pads as a set.
3. Remove each pad.
1. Remove the rear brake caliper mounting pins (1)
4. Wipe brake disc clean with a shop towel sprayed and remove the caliper.
with brake cleaner (commercially available).
5. Inspect caliper piston seals for any sign of fluid
leakage.
6. Install new brake pads with friction material
toward disc.
7. Insert pin through caliper and through outer pad.
Lay spring in place over pads and press on center
while sliding pin through spring and then through
inner pad.
8. Torque pad retaining pin to specification.

Pad Retaining Pin: 120 in-lbs (13.5 Nm)

9. Inspect brake fluid in reservoir and set to proper

level.

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2. Push each pad back by hand to gain clearance for 8. Bleed brake system if necessary.
new pads.
NOTE: Brake fluid will be forced back into the
reservoir when pads are pushed back. Remove WARNING
reservoir cover and monitor fluid level, or
attach a hose to the brake bleeder screw and After pad installation or any brake system repair,
open the bleed screw while pushing the pads safely elevate wheel, apply and release brake pedal
and pistons back. or lever 2-3 times and release. Verify wheel turns
freely without drag. If rear brake drag is evident,
3. Remove the set screws (2) and pad retaining pins inspect pedal clearance. Do not operate the
(3). Slide the mount bracket (4) back into the motorcycle if drag is still evident after clearance
caliper, and slide the pads (5) off the end of the adjustment. Inspect vehicle to determine cause and
guide pins (6). Do NOT remove the guide pins for repair as necessary.
pad removal. Note orientation of retaining spring.

Brake Disc Inspection

1. Visually inspect disc for cracks or damage.
2. Measure brake disc thickness in several locations
around disc with a micrometer, and along wear
surface and compare to specifications. See , page
14.3.

4. Install new brake pads with friction material

toward disc.
5. Using the guide pins, install caliper back onto
bracket with mounting fasteners. Install set screws
and pad pins. Torque fasteners to specification.

NOTE: Replace the brake disc if any

measurement is worn beyond the service limit.
Brake Caliper Mounting Fasteners: 31 ± 4 ft-lbs (42 ±
6 Nm) 3. With disc mounted to wheel, inspect for brake disc
runout / warpage with a dial indicator and
6. Inspect fluid level in the reservoir and adjust as compare to specifications. See , page 14.3.
necessary.
NOTE: Runout should be measured 2-4mm in
7. Pump brake pedal slowly several times to set new from outside edge of disc.
pads against disc, until lever is firm and pressure
can be felt. 4. Replace brake disc if dial indicator reading
displays excessive brake disc runout and other
possible causes have been eliminated.

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Front Master Cylinder Service 5. Remove reservoir cover (3) and diaphragm (4).

CAUTION

Brake fluid and brake cleaners could damage paint,

plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on
the brake system. If brake fluid is spilled on cosmetic
surfaces, immediately rinse the area with a mild
solution of soap and water until all traces of brake
fluid are removed. Be sure master cylinder reservoir
14
is level before removing cover.

NOTE: Replace all rubber parts upon assembly.

6. Remove the nut (5) and pivot pin (6) and pull lever
1. Clean the master cylinder. Attach a drain hose to assembly out of master cylinder.
caliper bleed screw and place the end in a
suitable container. Drain brake fluid from the front
brake system by slowly pumping brake lever.
2. Remove the RH side mirror from the lever perch.
3. Remove banjo bolt (1) and brake line from master
cylinder.

7. Remove dust boot (7) and snap ring (8) out of

master cylinder.

4. Remove screws (2), clamp, and master cylinder

from the handlebar.

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8. Slide piston (9) out with spring. Note spring 15. Carefully install spring / piston assembly into
orientation for assembly of new spring (new master cylinder bore. Work the front piston seal
parts). carefully past the chamfer and into bore. Use care
not to damage or fold the seal when working it
past the chamfer.
16. Continue to install the piston until the rear seal is
past the chamfer. Push and hold the piston in far
enough to allow the retaining ring to be installed.
17. Be sure retaining ring is fully seated in the groove.
18. Clean the bore from the retaining ring outward, so
the outer edge of the new dust boot adheres
properly and will not dislodge from the bore.
19. Install new boot, seating the outer edge fully in the
bore and engage outer lip of boot in piston
groove.
20. Apply non-petroleum grease from kit to brake
9. Clean master cylinder with isopropyl alcohol and
lever contact surface.
dry with compressed air. DO NOT soak in alcohol
for more than 30 seconds. DO NOT aim 21. Install master cylinder on handlebar. Torque
pressurized air directly at the level sight glass. clamp screws to specification.
10. Inspect cylinder bore and chamfer of bore for
corrosion, scratches, scoring, or pitting. Replace
master cylinder if any of these conditions are
evident.
11. Measure the diameter of the bore. Replace master Master Cylinder Clamp Screws: 8 ft-lbs (11 Nm)
cylinder if worn beyond the service limit.

Master Cylinder Bore Diameter Service Limit:

0.504 in (12.8 mm)

12. Clean the compensating port and supply port with

compressed air to be sure they are clean and
unobstructed.
13. Apply a light film of special lubricant from piston
kit to each piston seal cup.
14. Assemble the piston / spring assembly as shown.
Large diameter of beveled edge on piston cups
face toward spring.

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Front Caliper Service 3. Cover the brake hose connection on the caliper
and clean the outer surfaces of caliper assembly
with brake cleaner (commercially available) or
CAUTION isopropyl alcohol. Dry with compressed air.
4. Remove pad retaining pin (3) and brake pads.
Brake fluid and brake cleaners will damage paint,
plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on
the brake system. If brake fluid is spilled on cosmetic
surfaces, immediately rinse the area with a mild
solution of soap and water until all traces of brake
fluid are removed. Make sure the master cylinder
14
reservoir being worked on is level before removing
the cap.

NOTE: Replace all rubber parts upon assembly.

Keep parts in order for assembly. The top and
bottom pistons in the caliper are not the same size.

1. Remove banjo bolt (1), sealing washers, and brake

hose from caliper assembly and allow it to drain NOTE: Pads contaminated with oil or grease
into a container. Cover the end of brake line to must be replaced as a set.
prevent debris from entering.
5. Keep parts in order for assembly in the same bore.
Top and bottom pistons (in each caliper half) have
different diameters.
6. Remove each piston with a caliper piston pliers. If
a caliper piston pliers is not available, wrap the
caliper in a shop towel and apply short bursts of
compressed air through the brake line hole and
through the transfer passage to force the pistons
out of the bore.
7. Remove dust seals and piston seals. Use care not
to damage the seal bores.
8. Clean all parts thoroughly with isopropyl alcohol.
Be sure the seal bores are clean, removing all
traces of dirt or dried brake fluid.
2. Remove front caliper mounting studs (2) and
remove the caliper. 9. Clean piston seal and dust seal bores to remove
residue that could cause the pistons to stick,
resulting in brake drag.
10. Inspect each piston bore for corrosion, scratches,
scoring, or pitting. Replace caliper if any of these
conditions are evident.
11. Measure the diameter of each caliper bore.
Replace caliper if any is worn beyond the service
limit.

Front Caliper Bore Diameter

SERVICE LIMITS
Std Bore XX in (XX mm)

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12. Measure the outside diameter of each piston in two Front Caliper Installation
spots 90° apart, 5mm from outer edge. Repeat 1. Clean mounting surfaces of caliper and fork leg.
measurement 5mm from inner edge. Replace
piston if worn beyond service limit at any 2. Apply brake cleaner or isopropyl alcohol to a
measuring point. clean shop towel and wipe brake discs clean.
3. Separate brake pads and install caliper assembly
Front Caliper Piston Outside Diameter over brake disc.
SERVICE LIMITS
Std Size: 1.18 in (30.0 mm) 4. Install caliper mounting studs and torque to
specification.

NOTE: Install all new rubber parts during

assembly. Do not reuse old seals or boots.

13. Apply special lubricant from service kit to new

piston seals and dust seals. Caliper Mounting Studs: 31 ft-lbs (42 Nm)
14. Apply non-petroleum grease (included in kit) to
outer surface of all pistons. 5. Connect brake hose to caliper with banjo bolt and
new sealing washers. Torque to specification.
15. Install piston seals and dust seals in caliper body.
16. Install pistons in their respective bores.
17. Install brake pads. Torque retaining pin and set
screw to specification.
Banjo Bolt (Brake Line): 16 ft-lbs (22 Nm)

6. Fill and bleed the front brake hydraulic system.

See ABS Front Brake Bleeding, page 14.19.
Brake Pad Retaining Pin: 10 ft-lbs (13.5 Nm)
WARNING

After pad installation or any brake system repair,

safely elevate the wheel, apply and release the brake
pedal or lever 2-3 times and release. Verify the wheel
turns freely without drag. If brake drag is evident, do
not operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.

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Rear Master Cylinder Service 3. Remove mounting fasteners (3) from master
cylinder to footpeg. Remove the master cylinder.

CAUTION

Brake fluid and brake cleaners will damage paint,

plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on
the brake system. If brake fluid is spilled on cosmetic
surfaces, immediately rinse the area with a mild
solution of soap and water until all traces of brake
fluid are removed. Make sure the master cylinder
14
reservoir being worked on is level before removing
the cap. Replace all rubber parts upon assembly.

NOTE: Replace all rubber parts upon assembly.

4. Remove clevis, clevis nut, pushrod nut, and dust
1. Remove brake line banjo bolt (1), sealing washers boot.
and brake line. Allow fluid to drain into a
container.

5. Remove internal snap ring followed by piston,

pushrod, cups, and spring.
2. Remove screw (2) retaining the clevis to the 6. Inspect cylinder bore and chamfer on the front of
footpeg. the bore for corrosion, scratches, scoring, or
pitting. Replace master cylinder if any of these
conditions are evident.
7. Measure the diameter of the bore. Replace master
cylinder if worn beyond the service limit.

Master Cylinder Bore Diameter Service Limit:

0.504 in (12.8 mm)

8. Clean compensating port and supply port with

compressed air to be sure they are clean and
unobstructed.
9. Clean all parts with clean Indian Motorcycle DOT
4 brake fluid or isopropyl alcohol.
10. Replace ALL RUBBER PARTS with new.
11. Carefully assemble and install the internal master
cylinder components in order.

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12. Install the master cylinder and torque the jamb 6. Remove caliper piston.
nut. mounting fasteners, and brake line banjo bolt
7. Remove dust seals and piston seals. Use care not
to specification.
to damage the seal bores.
8. Clean caliper thoroughly with isopropyl alcohol.
Dry with compressed air. Clean seal grooves
thoroughly. Any residue left behind in the grooves
could cause caliper pistons to stick and result in
Rear Master Cylinder Jamb Nut: 12 ft-lbs (16 Nm) brake drag.
Master Cylinder Mounting Fasteners: 8 ft-lbs (11 9. Inspect bore and surface of piston for corrosion,
Nm) scratches, scoring, or pitting. Replace caliper
Brake Line Banjo Bolt: 16 ft-lbs (22 Nm) assembly if any of these conditions are evident.
10. Measure diameter of each bore and piston.
Replace caliper assembly or parts if worn beyond
Rear Caliper Service service limit.
1. Remove the brake pressure switch from the banjo Rear Caliper Bore Diameter
bolt. SERVICE LIMITS
2. Remove banjo bolt (1) and sealing washers from Std Bore XX in (XX mm)
rear caliper and allow fluid to drain into a
container.
Rear Caliper Piston Outside Diameter
SERVICE LIMITS
Std Size: 1.18 in (30.0 mm)

11. Install all new rubber parts during assembly. Do

not reuse old seals or boots. Apply special
lubricant from service kit to new piston seals and
dust seals.
12. Apply special assembly oil to outer surface of all
pistons.
13. Install piston seals and dust seals in caliper body.
14. Install pistons in their respective bore.
15. Replace caliper pin boot on bracket and on
3. Remove caliper bolts (2) and lower caliper off of
caliper. Apply special lubricant from service kit to
mounting bracket.
boots and both pins.
16. Assemble bracket to caliper. Remove excess
lubricant.
17. Install spring plate and outer brake pad. Start pad
pin through outer pad.
18. Install inner pad with insulator and backing plate.
19. Torque brake pad retaining pin to specification.

Brake Pad Retaining Pin: 10 ft-lbs (13.5 Nm)

4. Remove the rear brake pads. Refer to “Rear
Brake Pad Replacement”, page 14.21 20. Be sure end tabs of pads are both fully engaged in
procedure. the heel plate on bracket.

5. Slide caliper bracket off pins and remove spring

plate.

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21. Install caliper to bracket and torque caliper bolts
to specification.

Caliper Bolts: 31 ft-lbs (42.0 Nm)

22. Install brake line with new sealing washers and

torque banjo bolt to specification.
14

Banjo Bolt (Rear Caliper): 16 ft-lbs (22 Nm)

23. Bleed brake system. See ABS Rear Brake

Bleeding, page 14.18.

Rear Caliper Installation

1. Install caliper to rear mounting bracket and torque
to specification.

Caliper Bolts: 31 ft-lbs (42.0 Nm)

2. Install brake hose, and brake switch with new

sealing washers.

Brake Switch (Rear Caliper): 16 ft-lbs (22 Nm)

3. Fill and bleed the rear hydraulic brake system.

See ABS Rear Brake Bleeding, page 14.18.

WARNING

After pad installation or any brake system repair,

safely elevate the wheel, apply and release the brake
pedal or lever 2-3 times and release. Verify the wheel
turns freely without drag. If brake drag is evident, do
not operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.

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TROUBLESHOOTING
Troubleshooting

PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED

Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component
Erratic Braking Fluid Leakage (Internal of Master Cylinder) Replace Master Cylinder
Action Worn Pads Replace Brake Pads
Oil Contamination of Brake Pads and/or Brake Pads Must Be Replaced. Disc May Be
Disc Cleaned.
Air In System Bleed Air From System
Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
Excessive Brake Disc Runout Level.
Worn or Damaged Wheel Bearings Replace Brake Disc.
Loose Front Axle Nut or Clamps or Loose Rear Replace Wheel Bearings.
Axle Torque Correctly
Caliper Mount Surface Uneven Or Misaligned; Inspect / Repair
Missing or Damaged Fasteners Replace Line(s)
Clogged or Restricted Hydraulic Line Replace Bracket
Caliper Bracket Misaligned, Bent or Distorted Install New Screws. Torque to
Loose Brake Disc Specification
Brake Pads Glazed Replace Pads. Avoid Needless Heavy
Braking for 100-200 miles (Burnish New
Brake Pads).
Poor Brakes or Air In System Bleed Air From System
No Brakes When Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
First Applied. Brake Disc is Bent or Warped Level.
Brake Lever Caliper Misalignment Replace Brake Disc
Pressure Present External Leak Determine Cause and Correct
If Lever Is Internal Leak (master cylinder) Repair or Replace Damaged Component
“Pumped”. Faulty Brake Hose Repair or Replace Master Cylinder
Inspect for Bulges / Replace
Brake Pedal or Brake Disc Bent or Warped Replace Brake Disc
Brake Lever Mounting Surface of Brake Disc Uneven / Disc Repair or Replace as Necessary
Pulsates Loose Repair or Replace as Necessary
Caliper Mount Surface Uneven Or Misaligned;
Missing or Damaged Fasteners
Excessive Lever Air in System Bleed Air From System
or Pedal Travel / Loose Mounting Hardware Repair as Necessary
Spongy Brake Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
Feel. Incorrect Brake Fluid Used Level.
See “Weak / Erratic Brakes” and Poor Brakes” Flush System and Replace With Correct
possible causes above. Fluid
Fluid Leakage Loose Banjo Fittings Tighten to Specified Torque
Damaged Banjo Fitting Sealing Washers Replace
Cracked / Damaged Hose Replace
Worn Master Cylinder Piston, Caliper Piston(s) Repair / Replace Master Cylinder or
or Seals Wheel Caliper.
Diaphragm (master Cylinder reservoir) Inspect / Replace Cover, Cap, Diaphragm
Leaking or Reservoir as Required
Fluid level too high (new brake pads installed Correct fluid level
without removing added fluid)

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PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED

Brakes Drag Reservoir Over Filled Adjust Level As Necessary
Excessively or Brake Pedal Or Lever Not Returning Inspect Linkage, Pivots and Mechanism
Self-Apply Completely To Rest Position For Cause Of Binding Or Restricted
(Brakes Inadequate Freeplay Movement;
Overheat) Compensating Port Plugged Measure Pedal Clearance / Adjust
Internal Corrosion of Components (Master Repair or Replace Master Cylinder
Cylinder / Caliper) Replace Damaged Component
Rear Caliper: Corrosion of Sliding Parts, Bent Repair or Replace As Necessary
or Damaged Parts Flush System, Install Correct Fluid
Contaminated Brake Fluid
Caliper Pistons Sticking
Repair / Replace Caliper (Corrosion /
Buildup of Residue In Caliper Piston Seal
14
Rider Error (Operator Riding Brakes) Grooves)
Educate Operator
Brake Squeal/ If noise is minor and inconsistent, some brake Apply non oil-based solvent to a clean
Squeak squeak / squeal is characteristic of disc brakes shop towel and wipe dust / dirt from
and usually caused by dust / dirt on pads and / brake disc.
or brake disc. Repair as Necessary. Inspect Pad
Pad Not Secure in Caliper Installation
Aftermarket (not genuine Indian Motorcycle) Install Genuine Indian Motorcycle Parts
Parts Replace
Worn or Damaged Wheel Bearing(s) Replace
Worn Pads / Disc

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NOTES

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CHAPTER 15
STARTING / CHARGING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
STARTER MOTOR / SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.8 15
REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
BATTERY BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
BATTERY BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
BATTERY CHARGING - NEW BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
BATTERY CHARGING - IN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
STARTER MOTOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
STARTING SYSTEM DIAGNOSTIC TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
STARTER CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
TROUBLESHOOTING FLOW CHART 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
TROUBLESHOOTING FLOW CHART 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
TROUBLESHOOTING FLOW CHART 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
STARTING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
STARTER SOLENOID GROUND CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
GEAR POSITION SWITCH NEUTRAL INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
CLUTCH SWITCH CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.19
CLUTCH SWITCH REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
STARTER SOLENOID POSITIVE CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
STARTER CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.21
STARTER MOTOR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.21
STARTER CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.22
CHARGING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.22
TROUBLESHOOTING, CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.22
CURRENT DRAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
REGULATED VOLTAGE / AMPERAGE OUTPUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
STATOR AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25
STATOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.26

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STARTING / CHARGING
STATOR WINDINGS TO GROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.26
STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
RECTIFIER / REGULATOR CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
DIODE LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29
REGULATOR / RECTIFIER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29

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 STARTING / CHARGING
GENERAL INFORMATION Battery Label

Service Notes
All electrical system and component service can be
performed with the engine in the frame.
IMPORTANT: CAUTIONS TO OBSERVE DURING
ELECTRICAL SYSTEM SERVICE
• Always turn off ignition switch before
disconnecting any electrical component.
• Always verify that bullet-type connectors are
free of corrosion, contamination or breaks
when troubleshooting electrical problems.
• Verify that bullet-type connectors are firmly
seated. Listen and/or feel for a click when 15
connecting them.
• Ensure to release the lock on lock-type
couplers before disconnecting them to avoid
damaging the connector.
• Pulling on the wires when disconnecting
couplers can introduce problems. Hold the
connectors themselves when disconnecting
them, not their associated wires.
• Inspect each male and female terminal of
multi-pin connectors for corrosion,
contamination, loose or bent pins.

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STARTING / CHARGING

CAUTION
WARNING

Battery electrolyte is poisonous. It contains sulfuric Even with a good battery, battery voltage can
acid. Serious burns can result from contact with skin, recover after charging, but under excessive loads the
eyes or clothing. Antidote: battery voltage will drop quickly and eventually
“die”. Often the charging system is suspect when it is
• External: Flush with water. not the cause of the problem. Always inspect for
excessive loads if the battery continues to lose its
• Internal: Drink large quantities of water or
charge. Items such as incorrect wattage bulbs,
milk. Follow with milk of magnesia, beaten egg,
sticking brake light switch(s), continuous low rpm
or vegetable oil. Call physician immediately.
operation or leaving the lights on without the engine
• Eyes: Flush with water for 15 minutes. Call running for long periods of time can drain a battery
physician immediately. even if the charging system is operating correctly.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always CAUTION
shield eyes when working near batteries.

KEEP BATTERIES AND BATTERY ACID OUT OF WIRE ROUTING

REACH OF CHILDREN. Make sure that all wires are routed correctly away
from moving parts, hot exhaust, or sharp edges.
The charging system used on the motorcycle is
calibrated for the maintenance free battery that is
installed as original equipment. Do not replace with a
conventional lead-acid battery. Before CAUTION
troubleshooting the charging system, inspect the
battery thoroughly. A discharged, poorly charged or
faulty battery will make the readings obtained FUSES
during charging system troubleshooting erroneous
or difficult to interpret. Fuses are in place to protect circuit wiring and
components. Always determine the cause of an open
A battery will self-discharge when the motorcycle is fuse before installing a new fuse.
not in use. Make sure to properly store the battery as
outlined later in this section. Do not increase the value of the fuse to correct the
Maximum voltage and service life is only achieved problem.
when the battery is properly serviced initially. Make
sure to follow instructions outlined later in this Do not use wire, tin foil or other substitutes for fuses.
section.
Overcharging can be caused by a faulty battery
(shorted cell). Test system with a known good CAUTION
battery when diagnosing an overcharge condition.
New batteries must be properly maintained as ELECTRONIC COMPONENTS
outlined in this section to ensure proper service life.
Semiconductor parts used in electronic components
will not withstand careless handling.

Do not drop or strike parts that contain

semiconductors such as the ECM or rectifier/
regulator. Dropping electronic components can
cause damage to the component.

Follow instructions supplied in this chapter, including

chapter 5 (Fuel Injection) and chapter 17 (Ignition
System), very carefully when working on electronic
components. Failure to follow instructions may cause
irreparable damage to the part being inspected.

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Special Tools TORQUE
PART DESCRIPTION
SPECIFICATION
TOOL DESCRIPTION PART NUMBER
Battery Terminal Bolts 36 in-lbs (4.1 Nm)
Battery Tester PU-50296
Coolant Reservoir Heat 96 in-lbs (10.8 Nm)
Electrical Tester Kit PV-43526 Shield Bolt
Relay Bypass PU-49466 Regulator/Rectifier to 84 in-lbs (9.5 Nm)
Bracket Nuts
Smartlink Module Kit PU-47471
Regulator/Rectifier 19.0 ft-lbs (25.7 Nm)
USB to Serial Adapter PU-50621 Bracket to Frame Bolts
Starter Terminal Nut 60 in-lbs (6.8 Nm)
Torque Specifications Starter to Engine Mount 88.5 in-lbs (10 Nm)
Screws
PART DESCRIPTION
TORQUE
Stator Cover Screws 15 ft-lbs (20.0 Nm)
15
SPECIFICATION
Battery Box Mount Screw 96 in-lbs (10.8 Nm) Stator Mounting Screws 88.5 in-lbs (10 Nm)
to Cover
Battery Hold Down 36 in-lbs (4.1 Nm)
Screw Stator Wire Clip Screws 70.8 in-lbs (8.0 Nm)

Service Specifications

ELECTRICAL SPECIFICATIONS

ITEM SPECIFICATIONS
Electrical (General) Ignition System Distributor-less Transistorized Dual Coil Type
Ignition
Starting System Electric
Charging System Permanent Magnet / 3 Phase / Full Wave
Rectification
Regulator/Rectifier Solid State Three Phase Voltage Regulator/Rectifier
Lighting System 12 V DC

CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Alternator No Load AC Output @ 800 - 1000 RPM (Engine cool) 14A (168 Watts) @ Idle
Alternator No Load AC Output @ 2000 RPM (Engine cool) 29A (348) @ 2000 RPM
Stator Coil Resistance (@ 21oC / 70oF) (Black to each other black)
(Disconnect regulator - see test.) 146 milliohms ±20%

Stator Coil Resistance To Ground (Each black wire) Infinity (no continuity)
Regulator/Rectifier Regulated Voltage 14.3 - 14.7 V DC
Alternator Output (Amps / Watts) 32A (460 Watts) @ 6000 RPM
Type Leoch:
Battery Voltage 12 Volts DC
Nominal Capacity @ 10 Hr Rate 12 AH

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ITEM SPECIFICATIONS
Recommended Battery
Charging Current STD: 1.20 A for 5 to 10 hrs

Cold Cranking Amp Rating 210

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STARTING SYSTEM SPECIFICATIONS

ITEM SPECIFICATION
Battery Voltage, No Load Above 12.5 V DC
Resistance: Between Any Two Commutator Bars Continuity (0 Ohms)
Resistance: Commutator to Armature Shaft Infinity (OL on Fluke™ 73)
Resistance: Battery Input Terminal to Insulated Brush Continuity (0 Ohms)
Resistance: Bat. Input Terminal to Starter Motor Case Infinity (OL on Fluke™ 73)
Starter Motor Operating Amp Draw 140 - 160 Amps
Starter Motor No Load Amp Draw (Bench Test) 30 - 37 Amps after initial surge
Starter Torque Limit Clutch Break-Away Torque 50 - 60 ft-lbs (70 - 80 Nm) when new
15
ASSEMBLY VIEWS
Starter Motor / Solenoid

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Starter Motor -
2 Nut, Terminal (B+) - M6 (QTY.1) 60 in-lbs (6.8 Nm)
3 Terminal Cover -
4 Bolt, Starter Motor - M6 x 1.0 x 25 (QTY.2) 88.5 in-lbs (10.0 Nm)
5 Cable, Solenoid to Starter Motor (B+) -

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

6 Battery -

7 Starter Solenoid -

Stator

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Stator -
2 Bolt, Stator - M6 x 1.0 x 35 (QTY.3) 88.5 in-lbs (10.0 Nm)
3 Clip, Stator Wire -

4 Screw, Stator Clip - M5 x 0.8 x 10 70.8 in-lbs (8.0 Mm)

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Regulator / Rectifier

15

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Nuts, Hex 84 in-lbs (9.5 Nm)
2 Regulator / Rectifier, Voltage -

3 Connector, Electrical Regulator / Rectifier -

4 Bracket, Regulator / Rectifier -

5 Bolt, Regulator Bracket - M8 x 1.25 x 35(QTY.4) 19.0 ft-lbs (25.7 Nm)

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Battery

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Battery Hold Down - M10 x 1.25 x 25 (QTY.1) 36 in-lbs (4.1 Nm)
2 Bracket, Battery Hold Down -

3 Battery -

4 Screw, Battery Box - M8 x 1.25 x 12 (QTY.1) 96 in-lbs (10.8 Nm)

5 Screw, Shoulder - M6 x 1.0 x 10 (QTY.4) 96 in-lbs (10.8 Nm)
6 Battery Box -

7 Reservoir, Engine Coolant 84 in-lbs (9.5 Nm)

8 Shield, Heat Coolant Reservoir -
9 Bolt, Heat Shield - M6 x 1.0 x 12 (QTY.1) 96 in-lbs (10.8 Nm)
10 Nuts, Self Threading -

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BATTERY SERVICE Battery Installation
Battery Removal NOTE: Be sure cable ends and battery terminals
1. Remove the seat. See Seat Removal / Installation, are clean. Apply a light film of di-electric grease to
page 3.7. terminal bolt threads.

2. Rotate the fuse panel out of the way to access the 1. Carefully install battery with negative terminal
battery. toward front of vehicle.
3. Remove the battery hold down bolt (Item 1). 2. Connect positive cable (2) to the battery and
torque to specification.
3. Connect ground (negative) cable (1) to battery
and torque to specification.

15
Battery Terminal Fasteners: 36 in-lbs (4.1 Nm)

4. Apply dielectric grease over terminal areas for

corrosion protection.
5. Install seat. See Seat Removal / Installation, page
3.7.

Battery Box Removal

4. Remove negative (-) battery terminal bolt and
cable first. 1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
5. Remove positive (+) battery terminal bolt and
cable last (2). 2. Remove the seat. See Seat Removal / Installation,
page 3.7.
6. Lift battery straight up and out of the battery box.
3. Remove battery. See Battery Removal, page 15.11.
4. Lift starter solenoid and coolant filler from bracket.
5. Remove rear battery box screws (1).

NOTE: It may be necessary to push the main

harness away from the battery, toward the RH
side of the frame in order to remove the
battery. 6. Remove front battery box screws (2).

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7. Lift battery box (3) to disconnect the load module 3. Install the battery box fasteners (2), (1) and torque
connectors (4). . to specifications.

8. Remove battery box.

Battery Box Installation

1. Connect the Load / Tip Over Module connectors
Battery Box Screws: 84 in-lbs (9.5 Nm)
(4).
4. Install the starter solenoid.
5. Install the coolant reservoir filler.
6. Install battery. See Battery Installation, page
15.11.
7. Install seat assembly. See Seat Removal /
Installation, page 3.7

Battery Charging - New Battery

1. Charge the battery at 1.2 amps for 5 to 10 hours.
use a straight rate charger (not load sensing or
battery tender type) for the initial charge of a new
battery.

CAUTION
2. Lower the battery box / ECM assembly (3) into
position so the screw holes are lined up. Do not attempt to quick charge the battery at any
time.

2. Remove battery from charger and let it sit for 30

minutes or longer.
NOTE: Measure voltage with a digital
multimeter. If lower than 12.5VDC, battery
must be recharged again in accordance with
step 1 and 2 above.

3. After charging battery and letting it sit for 30

minutes or more, check battery voltage again. If
battery voltage is still below 12.5 V DC, replace
the battery.

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Battery Charging - In Service 5. Install battery. See Battery Installation, page
1. Measure battery voltage with a digital multimeter. 15.11.
The reading should be above 12.50 V DC. If 6. Once connections are secured, apply a thin film of
battery voltage is lower than 12.50 V DC battery di-electric grease to terminals.
must be charged according to the instructions
given below. 7. Install seat. See Seat Removal / Installation, page
3.7.

CAUTION Battery Testing

Do not remove caps on battery while recharging. Do
not attempt to inspect or add fluid to a maintenance The recommended battery tester for all Indian
free battery. Motorcycle batteries is special tool PU-50296. See
Special Tools Index, page 1.14.
2. Charge battery at 1.2 amps for 5 to 10 hours. Conductance describes the ability of a battery to
NOTE: Specification: 1.2 A for 5-10 hours
conduct current. A conductance tester functions by
sending a low frequency AC signal through the battery
15
and a portion of the current response is captured, from
3. Remove battery from charger and let it sit for 30
this output a conductance measurement is calculated.
minutes or longer.
Conductance testing is more accurate than voltage,
4. Measure battery voltage with a digital multimeter. specific gravity, or load testing.
If battery voltage is lower than 12.50 V DC battery
must be recharged again in accordance with step
1 and 2 above.
5. After charging battery and letting it sit for 30
minutes or more, check the battery voltage again.
If battery voltage is still below 12.50 V DC, replace
battery.
NOTE: When motorcycle is not used for one (1)
month or more, remove battery and store it in a
cool, dry area. Inspect voltage monthly and
charge according to above instructions if
necessary.

Battery Inspection
1. Remove battery. See Battery Removal, page 15.11.
2. Inspect battery tray and hold-down bracket for
damage. Be sure all foam strips are in place on
battery box.
3. Inspect for cracked or broken battery case.

CAUTION
Do not remove the battery cap assembly in an
attempt to inspect fluid level, specific gravity or
attempt to add fluid to battery. After initial servicing,
battery should remain sealed.

4. Inspect terminals for corrosion. If corrosion is

found, remove battery and clean terminals with a
solution of baking soda and water. Finish process
by cleaning terminals (both battery and battery
cables) with a wire brush.

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STARTER MOTOR SERVICE
Safety Information

WARNING

Always disconnect the battery (negative terminal first) before servicing the starter motor.

• Inspect the condition of the battery before troubleshooting the starter system. Also inspect main engine
ground and battery cable connections.

Starting System Diagnostic Table

SYMPTOM POSSIBLE CAUSE RECOMMENDATION

Starter motor does not turn with Gear Position Switch or circuit Test Gear Position Switch.
transmission in neutral. Turns with malfunction.
clutch pulled in.
Starter motor does not turn with Clutch Switch or Side Stand switch Test Switches.
transmission in gear and clutch circuit malfunction.
lever pulled in. Turns with
transmission in neutral.
Starter motor will not turn. Low battery voltage. Poor cable See Troubleshooting Flow Chart 1
connections. Main ground loose.
Starter motor turns slowly. Engine Low battery. Faulty starter motor or See Troubleshooting Flow Chart 2
may or may not start. drive mechanism. Engine
mechanical problem.
Starter motor turns, but engine Starter torque limit clutch slipping. See Troubleshooting Flow Chart 3
does not turn.
Starter motor turns at normal Ignition Problem Chapter 16
speed, but engine does not start. Engine Problem Chapter 7-10
Fuel Delivery Problem Chapter 5

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Starter Circuit Diagram

15

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Troubleshooting Flow Chart 1

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Troubleshooting Flow Chart 2
NOTE: These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an
inductive ammeter clamp and a DMM.

15

Troubleshooting Flow Chart 3 STARTING SYSTEM TESTS

SYMPTOM POSSIBLE CAUSE Battery Load Test
Starter clutch 1. Load test battery using a commercially available
Starter motor turns, but malfunction. battery load tester. Follow the battery load tester
engine does not turn. manufacturer instructions.
Starter torque limit
The starter motor can be clutch slipping. NOTE: Although not as conclusive, the
heard spinning. following test can be used to direct
Starter gears damage. troubleshooting efforts if a battery load tester
is not readily available.

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2. Charge battery until open circuit voltage is above 4. Working on the vehicle side of the harness, test
12.5 Volts (). continuity between terminal 2 (black wire) and
chassis ground.
3. Install battery and connect battery cables.
4. Connect digital multimeter to battery and keep it
connected for duration of test.
5. Turn ignition key on and move head light high
beam switch to High Beam for 1 minute (without
the engine running).
6. Measure battery voltage.
7. If battery voltage has dropped below 10.5 V DC,
re-charge and re-test battery or replace it.

Starter Solenoid Ground Circuit Test

WARNING

Ensure that the motorcycle is secure and that the Resistance should be ≤ 0.5 Ω
transmission is in neutral for the following test.

1. Shift transmission to Neutral. Gear Position Switch Neutral Indicator

2. Locate the starter solenoid (1) and disconnect the Test
start solenoid connector (2). Symptoms of a faulty Gear Position Switch may
include:
• Starter motor does not operate when
transmission is in neutral,

but...
• Starter motor does operate when clutch is pulled
in.
1. Place the ignition switch in the RUN position to
power up the electrical system.
2. Place engine stop switch in the RUN position.
3. Shift transmission into Neutral.
4. Observe neutral indicator light.

3. Set the multi meter to read resistance and insert

meter leads into the appropriate jacks.

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5. If indicator is not lit with transmission in neutral: • Test the gear position switch resistance between
the switch connector terminal 1 and chassis
• Place the RUN/STOP switch in the STOP position ground.
and turn motorcycle power off.
• Roll the motorcycle forward and back enough to
verify that it is in neutral.
• Locate the gear position switch (1) wire
connector (2) located near the engine at the rear
of the cases above the voltage regulator.

15

• Compare reading to the resistance specification.

Gear Position Switch Neutral Resistance

Specification: 1Ω±0.5Ω

6. If resistance reading is not within specified

parameters, replace neutral switch or repair
wiring as necessary.
7. If neutral indicator switch is working correctly and
neutral indicator did not light with the transmission
in neutral; inspect neutral lamp and circuit wiring
for a open/short circuit.

Clutch Switch Circuit Test

The symptom of a faulty clutch switch circuit is:
• Starter motor will not operate with transmission
in gear and clutch lever pulled in. Starter
operates with transmission in neutral. Use an
ohmmeter to determine if continuity is present
when the switch is closed (lever pulled in).

• Set the multimeter to test resistance and insert 1. Transmission can be in neutral or in any gear.
meter leads into the appropriate jacks. 2. Disconnect the clutch switch connectors.
3. Set multimeter to measure resistance and insert
meter leads into appropriate jacks.
4. Connect red (+) lead of multi meter to either of the
clutch switch terminals and the black meter lead to
the other clutch switch terminal.
5. Operate clutch lever while observing meter
display.
6. Pull clutch lever to the handlebar. Meter should
display continuity or very low resistance (less than
1 ohm) when the clutch switch closes.

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7. Release clutch lever, meter should display OL CAUTION
(open line).
8. If clutch switch does not test as described inspect The clutch switch has a locating pin on the bottom
clutch switch, clutch switch wiring or mounting of side which slide into the clutch lever perch. Use
switch to clutch lever for fault. caution when removing the clutch switch so the
locating pin does not break off.
9. If switch is mounted correctly and physically
operates but does not open and close electrically,
replace switch. Gently pull the clutch switch out of the lever perch
until the locating pin is free.
Clutch Switch Removal / Installation 4. Installation is performed by reversing the
1. Remove clutch lever. removal procedure.

Starter Solenoid Positive Circuit Test

WARNING

Secure motorcycle on the side stand and place

transmission in neutral for the following test.

1. Place the transmission in neutral.

2. Remove the positive cable (1) from starter motor.

2. Disconnect the electrical connectors at the clutch

switch and slide the switch out from the lever side.

3. Set multi meter to DC Volts and insert meter leads

in the appropriate jacks.
4. Connect the red meter lead (+) to the positive
starter cable eyelet and the black (-) meter lead to
chassis ground.
3. 5. Place key switch in RUN position to power up the
electrical system and place the STOP/RUN switch
in the RUN position.
6. Press starter button. The meter should display
battery voltage. If voltage is more than .2 volts
below battery voltage, inspect the power supply
circuit.

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Starter Current Draw Test 7. Turn the ignition switch ON to power up the
electrical system and observe ammeter. It should
NOTE: This procedure requires the use of an register negative amps. If it does not, turn the
inductive ammeter to read current draw and a volt ammeter probe around.
meter to monitor battery voltage during the test.
8. Place the engine STOP/RUN switch is in the RUN
position, transmission is in neutral, clutch lever
pulled in and that the ignition system is disabled.

WARNING 9. Press starter switch and crank starter for about 5

seconds and observe both meters and the
tachometer.
Do not allow any part of the jumper cable clamp
to touch the chassis or any other ground. 10. The battery voltage should remain above 9.6 volts.
11. The amperage draw of the starter should not
exceed 160 amps.
CAUTION Starter current draw @ 77°F (25°C): ≤160 Amps 15
Disable the ignition system so that the engine will not
start during this test.
Starter Motor, Removal / Installation
• Remove ignition coils and spark plugs.
• Install test spark plugs into plug caps.
• Ground spark plugs against engine. WARNING

Ensure that the ignition switch is turned off.

1. Remove seat. See Seat Removal / Installation, Remove the negative cable at the battery before
page 3.7. removing the starter motor.
2. Inspect the battery. Charge or replace battery as
necessary before proceeding. 1. Disconnect the negative battery cable. See
Battery Removal, page 15.11.
3. Place transmission in neutral.
2. Remove the radiator assembly. See Radiator
4. Position an inductive ammeter clamp on battery Removal / Installation, page 4.21.
positive cable.
3. Disconnect the positive terminal from the starter
5. Set the multi meter to Volts DC scale and connect motor.
red lead of meter to positive post of battery.
4. Remove the two bolts (1) from the rear of the
6. Connect black lead of meter to negative post of starter motor (2) and slide assembly to the RH side
battery. of the motorcycle to release from engine case.

5. Remove starter motor.

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6. To install the starter motor, reverse the CHARGING SYSTEM SERVICE
removal procedure.
7. Torque the starter mounting bolts to specification.

Starter Mounting Bolts: 88.5 in-lbs (10.0 Nm)

8. NOTE: Hold the lower terminal nut with an

open ended wrench while tightening the upper
nut to avoid damage.
Torque the starter motor positive terminal nut to
specification.

Starter Motor Positive Terminal Nut: 35 in-lbs (4.0

Nm)

Starter Clutch Removal

1. See STARTER DRIVE SERVICE, page 10.19.

Troubleshooting, Charging System

NOTICE: The battery must be fully charged and in good condition to obtain accurate readings. Battery charging
current is automatically reduced by the regulator / rectifier if the regulator / rectifier unit reaches a critical
temperature (overheated). The system should be cool when testing DC charging output or when testing the
regulator / rectifier to ensure accurate readings. Refer to test procedure for individual charging system
components for more information.

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15

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Current Drain Inspection Regulated Voltage / Amperage Output
Inspection
IMPORTANT: Current drain should only be
measured after all systems have timed out and NOTE: This procedure requires the use of an
gone to sleep. Leave power OFF and do not disturb inductive ammeter to read current draw and a volt
for approximately 12 MINUTES for an accurate meter to monitor battery voltage during the test.
reading.
1. Remove seat. See Seat Removal / Installation,
Current drain is suspect if battery discharges when page 3.7.
motorcycle is not in operation (short periods of
storage). 2. Place the inductive ammeter over the positive (+)
battery cable.
1. Remove seat. See Seat Removal / Installation,
page 3.7. 3. Set multi meter to V DC scale.
2. Disconnect ground cable (-) from battery. 4. Connect voltmeter red (+) lead to battery red (+)
lead and black (-) voltmeter lead to battery black
3. Set multimeter to read milliamps (mA) and insert (-) lead.
meter leads into appropriate jacks. Connect red
meter lead to ground cable eyelet and connect
black meter lead to battery negative (-) terminal.

5. Start engine and warm to operating temperature.

6. At 1000 RPM or slightly above; the ammeter
should reach the “break-even” point (no
NOTE: Do not operate electric starter or meter amperage leaving the battery) and the voltmeter
fuse will be damaged. should be rising toward 14 VDC.
4. With ignition switch off, and after 12 minutes Specification: Break-even point for charging
have passed, read current drain. System: 1500 RPM
5. If current drain exceeds specifications inspect
wiring and components for short to ground. 7. Increase engine RPM to 2500. The ammeter should
rise a slight amount, then stabilize. Volt meter
Parasitic Draw Specification (after 12 minutes should read above 14 V DC.
with power OFF): 4.5 mA MAX

6. Locate the faulty component or wiring by

disconnecting accessories, wiring connections,
and fuses one-at-a-time while observing current
drain. When current drain falls within
specifications, focus efforts on the last circuit or
component that was disconnected.

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8. Use results obtained from preceding tests and the
following descriptions to determine if charging WARNING
system is functioning properly.
CHARGING SYSTEM OPERATING CARBON MONOXIDE: Never run an engine in an
CORRECTLY: Ammeter goes up a small amount, enclosed area. Exhaust contains poisonous carbon
then stabilizes slightly above +0 amps. Volt meter monoxide gas that can cause loss of consciousness
rises toward 14.8 ± V DC, drops off a little and and may lead to death. If you must run the engine to
starts to stabilize. do some repairs, do so in an open area or with an
exhaust evacuation system operating.
LOW BATTERY: Amperage continues to rise,
voltage levels off as battery is absorbing voltage.
Charging system may be okay. Need to charge
battery fully or use a good battery and repeat test. CAUTION
Meters will indicate similar reading to the
overcharging chart.
VOLTAGE / ARCING: Use caution not to touch any of
CHARGING SYSTEM UNDERCHARGING: Ammeter the connections or allow the exposed terminals to 15
drops to 0 or remains below 0 (negative reading) come close to any other part of the vehicle or other
at all rpm, volt meter remains the same or goes objects, as an arc may occur.
down. Go to voltage drop inspection.
CHARGING SYSTEM OVERCHARGING: Ammeter 1. Disconnect the 3-pin stator connector.
rises well above 0 and remains there or continues 2. Set multi meter to measure AC Volts.
to rise. Volt meter goes well above 14.8 V DC and
may continue to rise. 3. Connect one lead of the multi meter to pin A (1)
and one lead to pin B (2) on the 3-pin stator
EXCESSIVE LOAD: Current levels off or starts to connector.
drop, voltage continues to rise. Load may be
excessive (accessories or shorted components).
Determine if excessive loads are present.
Disconnect accessories and re-test.
9. Turn ignition key off.
10. Remove inductive ammeter clamp.
11. Install seat. See Seat Removal / Installation, page
3.7.

Stator AC Voltage Output Test

NOTE: Set multimeter to VAC (alternating
current). Engine cold. Regulator / Rectifier
disconnected (2-pin and 3-pin connector). Engine
must be running. Be sure to heed the following
Warnings and Cautions.

CAUTION

WARNING VOLTAGE / ARCING

Use caution not to touch any of the connections or
allow the exposed terminals to come close to any
HOT COMPONENTS: The engine and exhaust
other part of the vehicle or other objects, as an arc
system become very hot during operation and
may occur.
remain hot for a period of time after the engine is
shut off. Wear insulated protection for hands and
arms or wait until the engine and exhaust system 4. Start the engine and let it run at idle. Observe the
have cooled sufficiently before working on the multi meter reading.
machine. 5. The meter should indicate a minimum reading of
24 VAC at idle.
6. Repeat test for pins A (1) & C (3).

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7. Repeat test for pins B (2) & C (3). 3. Connect one meter lead into pin A (1) and the
other lead into pin B (2) on the stator connector
No load AC Volts @ 800 RPM: Approx 24 VAC and read resistance value.

NOTE: The test results in Steps 6, 7, and 8 can

read more than 24 VAC, but it is important that
the reading for each pair of wires is
approximately equal.

8. Increase RPM to 2000. Repeat Steps 4-8.

9. At 2000 RPM the reading should be at least 34
VAC.
NOTE: The test results obtained in step 10 can
read more than 34 VAC, but it is important that
they are all approximately equal.

No load AC Volts @ 2000 RPM: Approx 34 VAC

Stator Resistance: Less than 1 Ohm

Stator Resistance Test
4. Repeat test for pins A (1) & C (3).
5. Repeat test for pins B (2) & C (3).
CAUTION
6. If resistance values do not match specification,
inspect stator and replace as necessary.
The engine must not be running while performing the
following resistance test.
Stator Windings To Ground Inspection

NOTE: Set multimeter to measure resistance.

Engine OFF and cold. Regulator Rectifier 3– pin CAUTION
connector unplugged.

1. Disconnect the 3 pin connector (1) from stator. The engine must not be running while performing the
following resistance test.

2. Set the multi meter to measure resistance (Ω) and

insert the meter leads in to the appropriate jacks.

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NOTE: Set multi meter to measure resistance. 3. Using a terminal tool or pick tool, remove the three
Engine OFF and cold. Regulator Rectifier 3-pin electrical terminals from the stator connector.
connector unplugged.

1. Disconnect the 3 pin connector (1) from stator.

15

4. Remove the three bolts (1) from stator wire guide

(2).

2. Connect one multi meter lead to pin A (1) and

place the other lead of the multi meter in contact
with a good engine ground, observe resistance to
ground reading.

5. Remove three stator bolts (3).

6. Push the rubber harness seal (6) through to the
inside of the stator cover (5) and remove stator
assembly (4).

Stator to Ground (-) Continuity Specifications:

Open Circuit (OL)

3. Repeat test for other two stator leads (2 & 3) to

ground.
4. There should be no connection from stator
windings to ground.

Stator Removal
1. Remove stator cover. See Stator Cover Removal,
page 9.19.
2. Disconnect the stator connector from the regulator.

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Stator Installation 4. Install the stator wire clip (5) and fasteners (6).
The electrical connector must be removed from the Torque stator wire guide fasteners to specification.
stator assembly before it can be installed in the motor-
cycle. See Stator Removal, page 15.27 for information
on connector removal.
1. Feed the stator wires through the hole in the stator
cover and push the rubber harness seal (1) Stator Wire Clip Screws: 70.8 in-lbs (8.0 Nm)
through until fully seated.
2. Position the stator (2) inside the stator cover (3). 5. Press the three wire terminals into the connector
housing until there is an audible “click” and the
wires cannot be backed out.
NOTE: Wires can be installed into any position
on the electrical connector. Charging
performance will not be affected.

6. Plug the stator connector into the regulator /

rectifier.
7. Install the stator cover. See Stator Cover
Installation, page 9.19

Flywheel Removal
See Flywheel Removal, page 9.20.

Rectifier / Regulator Connector

3. Install the stator screws (4) and torque to Inspection
specification. 1. Remove the regulator / rectifier assembly. See
Rectifier / Regulator Replacement, page 15.29.
2. Disconnect both 2-pin and 3-pin connectors (1).

3. Inspect male and female pins in the 3-pin

Stator Screws: 88.5 in-lbs (10.0 Nm) connector and the 2-pin connector carefully.
Check for corrosion, loose pins, poor connections,
or evidence of overheating or other damage.
4. If the wiring and connectors are undamaged and
appear to be clean and tight, inspect the battery,
stator, and related wiring. Test the regulator /
rectifier for diode leakage.

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Diode Leakage Test 2. Remove the two nuts (2) securing the regulator /
rectifier to the bracket.
NOTE: Engine must be OFF. Perform this test at 3. INSTALLATION is performed by reversing the
the regulator / rectifier 2-Pin connector. Testing at
removal procedure.
any other point (between battery and battery cable
for example) could include leakage not 4. Torque the regulator / rectifier nuts to
attributable to the Regulator / Rectifier unit. specification.

1. Disconnect the 2-pin connector at voltage

regulator / rectifier unit.
2. Install a jumper across the connectors as shown for
the Bk wire to provide a complete ground path.
Regulator / Rectifier Nuts: 84 in-lbs (9.5 Nm)
3. Connect meter as shown, with red (+) meter lead
to the RD / BK wire on harness side, and the black
meter lead to the RD / BK wire on the regulator /
rectifier side. 15

4. Compare leakage to specification below.

Specification:
Leakage: Less than 1.0 mA

Regulator / Rectifier Replacement

1. Disconnect the electrical connectors from the
regulator / rectifier (1).

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NOTES

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CHAPTER 16
IGNITION SYSTEM
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.3
BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.3
TEST LEAD ADAPTER KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.3
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.4
IGNITION SYSTEM TEST FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.4
BATTERY VOLTAGE INSPECTION: TEST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5
SPARK INSPECTION: TEST 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5 16
IGNITION COIL POWER & GROUND SIGNAL TEST 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5
IGNITION COIL RESISTANCE: TEST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.6
CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.6
IGNITION COIL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.6

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IGNITION SYSTEM
GENERAL INFORMATION CAUTION
Service Notes
Using incorrect heat range spark plugs can damage
There are many hazards present when working on or the engine. Always follow the manufacturer’s
around the ignition system. Read and pay close recommendations for spark plug heat range.
attention to the following warnings and cautions when
working on any component in this section.
GENERAL PRECAUTIONS
• This ignition system is controlled electronically
WARNING and no provisions are available to inspect or
change ignition timing. A timing light is still
Never run an engine in an enclosed area. Exhaust valuable as a diagnostic tool.
contains poisonous carbon monoxide gas that can • Poor connections are the most common cause of
cause loss of consciousness and may lead to death. If ignition problems. Inspect all connections and
you must run the engine to do some repairs, do so in replace the spark plugs before doing extensive
an open area or with an exhaust evacuation system ignition system troubleshooting.
operating.
• Make sure the battery is fully charged and that
the charging system is operating correctly.
• A signal from the Crankshaft Position Sensor
WARNING must be present at the ECM for spark to occur.

The engine and exhaust system become very hot

during operation and remain hot for a period of time Special Tools
after the engine is shut off. Wear insulated protection
for hands and arms or wait until the engine and SPECIAL TOOL PART NUMBER
exhaust system have cooled before working on the Electrical Tester Kit PV-43526
machine.
Digital Multimeter Commercially Available

Inductive Timing Light Commercially Available

CAUTION
Torque Specifications
Some procedures call for the engine to be run in
order to warm the engine to operating temperature. PART / FASTENER TORQUE
If this is done the exhaust pipes can “blue” if a SPECIFICATION
cooling air stream is not provided by means of a shop
fan directed the exhaust system. Spark Plug 7.4 ft-lbs (10 Nm)

Coil to Valve Cover 7.4 ft-lbs (10 Nm)

CAUTION
Service Specifications
Parts containing semi-conductors can be easily ITEM SPECIFICATIONS
damaged if handled carelessly. Do not drop or
Spark Plug NGK DCPR8E
subject the electronic components to shock loads.
Spark Plug Gap .034 in (.9 mm)

Ignition Switch/ Primary 0.6 - 0.8 Ohms ± 20%

Cables
CAUTION Resistance Secondary N/A
Values
Follow the instructions closely when troubleshooting 860 Ohms ± 10% @ 68°F
Crank Position Sensor Resistance (20°C)
items in this section. Some electrical components can
be damaged if they are connected or disconnected * Spark plug end caps are not removable
while the ignition is powered ON and current is
present.

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TROUBLESHOOTING
Basics Test Lead Adapter Kit
Before troubleshooting the ignition system, ensure that 1. Tests in this section may include the testing of
the engine STOP/RUN switch is in the RUN position, voltage and / or resistance at the connectors for
the battery is fully charged, and system related fuses various sensor and system components. Use the
are not open (blown). Check visually for corroded, appropriate test adapter lead when performing
loose, or broken connections in critical areas (e. g. these tests at connector pin(s).
sensor connector). Check for loose wire pins in the 2. Forcing an incorrect or oversized probe into a
individual sensor connectors and at the ECM connector may cause inaccurate test results (due
(mounted on right side of the battery box). to lack of a solid mechanical connection to the
Don’t forget the spark plugs! terminal). It can also damage the connector being
probed or the connector housing, creating another
The Ignition System Troubleshooting flow chart (and problem which greatly complicates the diagnostic
the accompanying text) is designed to help you process. Extreme care must be taken not to
troubleshoot ignition system problems. It will not lead introduce problems while probing a connector.
you to faulty or fouled spark plugs. Always inspect
spark plug condition first (and replace if necessary) Electrical Tester Kit: PV-43526
when troubleshooting ignition system problems.
CAUTION
Be sure that the spark plugs are the correct heat range
and are the correct size specification.
16
Once the ECM connector has been disconnected, do
not touch the pins on the ECM. Static electricity from
your body can damage the ECM. Do not attempt to
WARNING perform tests on the ECM.

Extremely high voltage is present in the ignition

system. Do not touch the ignition coils or spark plugs
during test procedures.

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ECM Connector Map
See ECM Connector MAP, page 5.31.

Ignition System Test Flowchart

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 IGNITION SYSTEM
Battery Voltage Inspection: Test 1 5. Shift transmission into neutral and pull in clutch
1. Remove the seat. See Seat Removal / Installation, lever.
page 3.7. 6. Depress starter button and observe timing light.
2. Set multimeter to measure DC Volts. 7. Determine if timing light flashes without
3. Inspect battery voltage. interruption for both cylinders.
8. Consistent flashes indicate that some secondary
voltage is present. The likelihood of an ignition
related problem is reduced but not eliminated.
Keep the following points in mind:
• There is a threshold voltage and amperage
requirement for timing lights below which they
will not trigger and therefore, not flash.
• Fouled spark plugs may drop secondary voltage
so low that a timing light will not trigger and
therefore, not flash.
• With no current flowing (open secondary side of
the ignition coil) the timing light will not flash.
• A faulty high tension circuit or poor connection 16
is one example of an open secondary.
9. Replace spark plugs, connect plug wires and re-
test.
10. If timing light does not flash consistently for one or
both cylinders, test ignition coil (Test 3).

Ignition Coil Power & Ground Signal Test

3
Power To Ignition Coil
Battery voltage must be present at the ignition coil (Pin
B) when the power button is switched on and the
electrical system powered up.
4. If the battery voltage is below 12.5 V DC charge or 1. Disconnect the electrical connector from the
replace the battery with a fully charged battery. ignition coil. See Ignition Coil Removal /
Installation, page 16.6.
NOTE: When operating the starter with a low
battery, the voltage available for the ignition 2. Set the multimeter to measure VDC and insert the
coils can drop below the minimum required to meter leads into the appropriate jacks.
produce spark.
3. Connect the black lead to ground (on the engine).
4. Connect a small thin test adapter lead to terminal
Spark Inspection: Test 2 1 of the ignition coil primary connector and the
1. Remove ignition coil(s). See Ignition Coil Removal red meter lead to the test adapter.
/ Installation, page 16.6. 5. Turn ignition key ON to power up the motorcycle
2. Install secondary ignition cable test adapter electrical system and place the STOP/RUN switch
(commercially available) between coil (s) and in the RUN position.
spark plug(s). 6. Battery voltage should appear on terminal 1 of the
3. Connect timing light to secondary ignition cable coil connector (RD wire).
test adapter.
4. Turn ignition key ON to power up the motorcycle
and place the STOP/RUN switch in the RUN
position.

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IGNITION SYSTEM
7. With transmission in Neutral, crank the engine. 3. Measure resistance between terminal 1 and
Battery voltage should again be present on center terminal 3 on the coil. Compare to specification.
wire.
Ignition Coil Ground Signal
The following steps will test the ECM (Ground)
Signal To Ignition Coil
ECM ground signal must be present at terminal 3
of the ignition coil primary harness connector. The
signal will appear as a pulse on the meter between
Ground (-) and Open (OL).
8. Set the multimeter to measure resistance (Ω).
9. Place a small thin test adapter into terminal 3 of
the ignition coil connector (the WH wire) and
connect one meter lead to the test adapter..
10. Ground the other lead to the engine.
11. Place transmission in Neutral.
12. Turn the ignition key ON to power up the
motorcycle electrical system and place the STOP/
RUN switch in the RUN position.
13. Crank the engine with the electric starter and
watch the display on the multi meter. The meter
display should pulse evenly while engine is Primary Coil Resistance: 0.6 - 0.8 Ω
cranking, indicating a ground signal is present.
14. Repeat the test on the other outside wire in the
connector. Crankshaft Position Sensor (CPS)
• If no pulse is present, test the Crankshaft
Resistance Inspection:
Position Sensor. See CPS Test / Replace, page 5.45.
• If the signal is present on one wire and not the
other, test related wiring and connections. Ignition Coil Removal / Installation
• If both signals are present and there was battery 1. Place the IGNITION and RUN / STOP switch in the
voltage on the RD wire (center terminal) but still OFF position.
no spark, test the ignition coil windings. (Test 5). 2. Remove the seat. See Seat Removal / Installation,
page 3.7.

Ignition Coil Resistance: Test 4 3. Remove the fuel tank. See Fuel Tank Removal,
page 5.21.
Ignition Coil Primary Winding
4. Remove air box. See Air Box Removal, page 5.18.
1. Remove ignition coil. See Ignition Coil Removal /
Installation, page 16.6
2. Set the multi meter to measure resistance (Ω) and
insert the meter leads into the appropriate jacks.

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 IGNITION SYSTEM
5. Remove the ignition coil fastener (1).

6. Remove the ignition coil electrical connector (3)

and lift the ignition coil (2) out of the cylinder
head. 16
7. INSTALLATION of the ignition coil is
performed by reversing the removal
procedure. Torque fasteners to specification.

Coil to Valve Cover Fastener: 7.4 ft-lbs (10 Nm)

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NOTES

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CHAPTER 17
CHASSIS ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.2
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.2
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.3
HEAD LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.3
TAIL LIGHT / LICENSE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.4
FUSE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.5
FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.6
FUSE BOX LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.6
FUSE APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.7
LOAD / TIP OVER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.9
LOAD / TIP OVER MODULE CONNECTOR MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.9
LOAD/TIP OVER MODULE, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
HEADLIGHT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
HEAD LIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
17
HORN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
HORN REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
TAIL LIGHT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
LED TAIL / BRAKE LIGHT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
TAIL / BRAKE / LICENSE PLATE LIGHT, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
TURN SIGNAL / HAZARD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
TURN SIGNAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
FRONT TURN SIGNAL, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
REAR TURN SIGNAL, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
SPEEDOMETER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15
INSTRUMENT CLUSTER, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
BRAKE LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
SIDE STAND SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
BREAKOUT WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
ANIMATED WIRING DIAGRAM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
STARTING CIRCUIT, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
IGNITION SYSTEM, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
THROTTLE CONTROL, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22
MAIN WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.23
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.23

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GENERAL INFORMATION Torque Specifications
Service Notes PART DESCRIPTION TORQUE
Keep the following notes in mind when diagnosing an SPECIFICATION
electrical problem: Head Light Retaining 36 in-lbs (4 Nm)
Ring
• Refer to wiring diagram for stator and electrical
component resistance specifications. Head Light Mount Pivot 35 ft-lbs (47 Nm)
• When measuring resistance of a component that Bolt (Adjuster)
has a resistance value under 10 Ohms, Head Light to Lower 18 ft-lbs (24 Nm)
remember to subtract meter lead resistance Triple Mount Screw
from the reading. Connect the leads together
and record the resistance. The resistance of the Horn Bracket Bolt 96 in-lbs (10.8 Nm)
component is equal to tested value minus the
lead resistance. Ignition Side Cover Bolts 96 in-lbs (10 Nm)
• Become familiar with the operation of your Instrument Cluster 22 ft-lbs (29.8 Nm)
meter. Be sure leads are in the proper jack for Mount Screws
the test being performed (i. e. 10 A jack for
current readings). Refer to the Owner’s Manual License Plate Bracket to 36 in-lbs (4 Nm)
included with your meter for more information. Fender Nut

• Pay attention to the prefix on the multi-meter Load / Tipover Module 84 in-lbs (9.5 Nm)
reading (K, M, etc.) and the position of the Mounting Screws
decimal point. Tail Light to Fender 84 in-lbs (9.5)
• For resistance readings, isolate the component Screw
to be tested. Disconnect it from the wiring Turn Signal Bolt, Rear 18 ft-lbs (24.4 Nm)
harness or power supply.
Turn Signal, Front 36 in-lbs (4.1 Nm)

Special Tools

TOOL DESCRIPTION PART NUMBER

Battery Tester PV-50296
Electrical Tester Kit PV-43526
Smartlink Module Kit PU-47471
USB to Serial Adapter PU-50621

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ASSEMBLY VIEWS
Head Light

17

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Screw, Retaining Ring 36 in-lbs (4 Nm)
2 Retaining Ring -

3 Head Light -

4 Nut -
5 Screw, Adjuster 35 ft-lbs (47 Nm)
6 Headlight Bucket -

7 Screw 18 ft-lbs (24 Nm)

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Tail Light / License Plate Light

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Taillight -

2 Lamp, License Plate -

3 Washer (QTY. 2) -

4 Nut (QTY. 5) 36 in - lbs (4 Nm)

5 Washer (QTY. 3) -

6 Bracket, License Plate -

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Fuse Box

17

NUMBER PART TORQUE (IF

DESCRIPTION APPLICABLE)
1 Tab, Fuse Box -
Mounting
2 Cover, Fuse Box -
3 Latch, Fuse Box -
Cover

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FUSE BOX • The main fuse box (Item 2) is located beneath
the seat.
Fuse Box Location
There are two fuse locations utilized on the 2015 Indian
Scout.
• The main fuse holder (Item 1) is located on the
rear of the battery box.

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Fuse Application Chart

17

PIN CIRCUIT DESCRIPTION FROM TO

A1 Not Used - -
A2 Headlight Relay Output Fuse Box LH Control
A3 Headlight Relay Coil Power Fuse Box Splice (IGNSW)
A4 Fuel Pump / Ignition Coil Relay Output Fuse Box Splice (FPPWR)
A5 Fuel Pump Relay Coil Power Fuse Box Splice (ENGPWR)
A6 Engine Relay Output Power Fuse Box Splice (ENGPWR)
A7 Engine Relay Coil Power Fuse Box Splice (ENGBRK)
A8 Cooling Fan Relay Output Fuse Box Cooling Fan
A9 Fan Relay Coil Power Fuse Box Splice (IGNSW)
B1 Not Used - -
B2 Headlight Relay Control ECM 1 Fuse Box
B3 Headlight Circuit Breaker Output Fuse Box C8 Fuse Box B3
B4 Fuel Pump Relay Control ECM 1 Fuse Box B4
B5 Fuel Pump / Coil Fuse Output Fuse Box C4 Fuse Box B5
B6 Engine Relay Control ECM1 Fuse Box B6
B7 Engine Relay Power Input Fuse Box B7 Splice (ENGBRK)

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PIN CIRCUIT DESCRIPTION FROM TO

B8 Cooling Fan Relay Control ECM 1 Fuse Box B8
B9 Cooling Fan Circuit Breaker Power Fuse Box D6 Fuse Box B9
C1 Not Used - -
C2 Starter Relay Output Power Fuse Box C2 Start Solenoid
C3 Starter Relay Coil Power Fuse Box C3 Splice (IGNSW)
C4 Fuel Pump / Coil Fuse Output Fuse Box Bus 1B Fuse Box C4
(Main Fuse)
C5 Fuel Pump / Coil Fuse Input Main Fuse Fuse Box C5
C6 Engine Breaker Output Fuse Box C6 Splice (ENGBRK1)
C7 Engine Breaker Input Fuse Box C7 Splice (MFUSE)
C8 Headlight Circuit Breaker Output Fuse Box C8 Fuse Box B3
C9 Fusebox Bus D Input Fuse Box C9 Splice (MFUSE)
D1 Not Used - -
D2 Starter Solenoid Relay Control ECM 1 (E141) D2
D3 Starter Relay Input Power D3 Splice (ENGBRK)
D4 Fuel Sender Resistor Output Fuse Box D4 Splice (FUELSEND)
D5 Fuel Sender Resistor Power Fuse Box D5 Splice (ACCR)
D6 Cooling Fan Circuit Breaker Output Fuse Box D6 Fuse Box B9
D7 Cooling Fan Circuit Breaker Input Splice (MFUSE) Fuse Box D7
D8 Ignition Breaker Output Fuse Box D8 Splice (IGNBRK)
D9 Fuse Box BUS D Input Fuse Box D9 Splice (MFUSE)

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LOAD / TIP OVER MODULE
Load / Tip Over Module Connector Map

17

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Load/Tip Over Module, Removal / HEADLIGHT SERVICE
Installation
Head Light Bulb Replacement
CAUTION IMPORTANT: Avoid touching a halogen bulb with
bare fingers. Oil from your skin leaves a residue,
causing a hot spot that will shorten the life of the
The negative battery cable MUST be disconnected bulb. If a bulb is touched, clean it thoroughly with
before the Load / Tip Over Module can be removed. denatured alcohol.

1. Remove headlight retaining screw (1).

1. Remove seat. See Seat Removal / Installation, 2. Lift headlight upward to remove from base.
page 3.7.
2. Remove the battery box.
3. Disconnect the three electrical multi-plugs (1)
from the load / tip over module.
4. INSTALLATION is performed by reversing the
removal procedure.
5. Torque load /tipover module mounting screws to
specification.

Load / Tip Over Module Mounting Screws: 84 in - lbs

(9.5 Nm)

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3. Disconnect wire harness (2) and move rubber 6. INSTALLATION is performed by reversing the
grommet (3) to allow access to headlight bulb. removal procedure.

Headlight Retaining Screw: 32 in-lbs (3.6 Nm)

4. Squeeze bulb retainer and move pins out of way of

bulb.

17

5. Remove Bulb (4).

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HORN SERVICE TAIL LIGHT SERVICE
Horn Removal / Installation LED Tail / Brake Light Operation
1. Remove screw (1) securing the horn to the frame The multiple LED tail / brake lamp functions much like
bracket. a conventional incandescent tail / brake lamp. LED
2. Disconnect the horn electrical connector (2). lights require a regulated current supply to prevent
damage, so a current regulation circuit is incorporated
inside the tail lamp unit. Direct 12 volt battery power
can be applied directly to the brake or tail lamp wire
for testing purposes, but polarity MUST be observed
or the LEDs will be permanently damaged.
Tail / Brake Light Power Supply:
When the motorcycle is powered ON, battery voltage
is delivered to the TAIL / BRAKE LEDs on the BN / PINK
wire from the Headlight Relay. Current through each
TAIL LED (WHITE wire) is limited (inside tail lamp
unit) to approximately 250 mA.

Tail / Brake Light Ground Signal:

The front and rear brake light switches provide a path
to ground through the Load / Over Module to the ECM
3. Remove the horn. via BLACK / YELLOW wire (rear brake switch) and
4. Installation is performed by reversing the YELLOW / VIOLET wire (front brake switch). When the
removal procedure. ECM receives a grounding signal from either of the
brake switches, ground is provided to the tail / brake
5. Torque fasteners to specification. light LED, thus illuminating the light.

When the motorcycle is powered ON, the ECM

provides a ground path to the tail light LED, thus
illuminating the light.
Horn to frame bracket: 96 in-lbs (10.8 Nm)
Tail / Brake / License Plate Light,
Removal / Installation
NOTE: The tail and brake lights are LEDs and
cannot be replaced individually. If the lights fail to
function when activated, and all circuit tests
indicate correct power and ground distribution,
the tail /brake light must be replaced as an
assembly. The license plate light can be replaced
individually.

Tail / Brake Light Removal

1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.

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2. Working from beneath the rear fender, access the 6. Remove the license plate light (4) from the license
three tail light nuts (1) and remove along with plate bracket.
washers.

7. Installation is performed by reversing the

3. Lift the tail light assembly (2) off of the rear fender removal procedure. Torque all fasteners to
and disconnect the electrical connectors noting specification.
their position for reassembly.

17
Tail Light to Mount: 84 in-lbs (9.5 Nm)

License Plate Light to Mount: 15 in-lbs (1.7 Nm)

4. Remove the tail light assembly.

License Plate Light Removal License Plate Bracket to Tail Light: 84 in-lbs (9.5 Nm)
5. Remove nuts (3) and washers.

Tail Light Asm to Fender: 84 in-lbs (9.5 Nm)

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TURN SIGNAL / HAZARD SERVICE 2. Remove bolt (1).

Turn Signal Operation

The turn signal / hazard light system does not utilize a
conventional “flasher module”, but instead receives a
grounding signal from the ECM. Power to the turn
signals is provided via the IGNITION CIRCUIT
BREAKER located in the main fuse box. Turn Signal
INPUTS & OUTPUTS can be located in the ECM
Connector Map and Fuse Application Chart.
See ECM Connector MAP, page 5.31.
See Fuse Application Chart, page 17.7.
NOTE:

Front Turn Signal, Removal / Installation 3. Unplug turn signal connector and withdraw the
turn signal from the tail light assembly.
NOTE: 4. Installation is performed by reversing the
removal procedure. Torque all fasteners to
1. Locate turn signal connectors inside the headlight specification.
and disconnect. See steps 1 and 2 to access
connectors: Headlight Bulb Replacement, page
17.10
2. Remove screw (1) and nut (2) to remove turn signal
from front fork.
Turn Signal Bolt: 18 ft-lbs (24.4 Nm)

3. Installation is performed by reversing the

removal procedure. Torque all fasteners to
specification.

Turn Signal Bolt: 18 ft-lbs (24.4 Nm)

Rear Turn Signal, Removal / Installation

1. Remove the tail light assembly. See Tail / Brake /
License Plate Light, Removal / Installation, page
17.12.

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SPEEDOMETER SERVICE • (2) Indicator Lights
• (3) Multi-Function Display (MFD)
Instrument Cluster
For detailed information regarding MODE
selection and Multi-Function Display operation
refer to the Owner’s Manual.
The instrument cluster includes the speedometer,
indicator lamps and Multi-Function Display (MFD).

• (1) Speedometer
17
Indicator Lights
LIGHT INDICATES CONDITION
The transmission is in neutral.
Neutral

The headlight switch is set to high

beam. This indicator will flash if
High Beam
there is a problem with the low or
high beam light.
The turn signal indicator flashes
when the left, right, or both turn
Turn Signal signals (hazard) are active. If there
is a problem in the signal system,
the lamps will flash at twice the
normal rate.
This indicator light appears when
there are 0.5 gallons of fuel
Low Fuel remaining in the tank.

Hazard Flashers

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LIGHT INDICATES CONDITION

If this lamp illuminates while the
engine is running, see your dealer
promptly. The light will remain on if
the tilt sensor shuts down the
Check Engine engine. If abnormal sensor or
engine operation is detected the
light will remain on as long as the
fault condition exists. Retrieve the
error codes for diagnosis.
International Units ONLY: The
indicator remains on until the anti-
lock system activates, which occurs
when vehicle speed exceeds 6
Anti-Lock Brakes NOT Activated MPH (10 km/h). When the lamp is
illuminated, the anti-lock brakes
will not activate, but the
conventional brake system will
continue to operate normally.
When metric mode is selected,
Vehicle Speed Units speed displays in kilometers per
hour.
When standard mode is selected,
Vehicle Speed Units speed displays in miles per hour.

Multi-Function Display (MFD) MODES AVAILABLE

The power switch must be ON to access the MFD. Use Trip Odometer 2 DC Voltage
the mode switches to toggle through the modes of the
MFD and to change settings in the display. The LH Gear Indicator
mode switch (1) is located on the backside of the LH
switch cube. Odometer
The odometer displays total distance traveled.

Trip Odometers
The trip odometers (Trip 1 and Trip 2) display total
distance traveled since being reset. To reset a trip
odometer, toggle to the trip odometer, then press and
hold the LEFT-TOGGLE switch until the trip odometer
resets to zero.

Engine Speed
Engine Speed displays in revolution per minute (RPM).

DC Voltage
MODES AVAILABLE The volt meter displays battery voltage. If the engine
Odometer Engine Speed is not running, approximate battery voltage displays. If
the engine is running, approximate charging voltage
Trip Odometer 1 Clock displays.

Gear Position

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Gear position displays at all times while the engine is SWITCH TESTING
running, unless a fault occurs with the gear position
sensor. Brake Light Switch Test
1. Place the motorcycle in an upright position with
Instrument Cluster, Removal / front wheel clamped in a wheel vise.
Installation 2. Locate the brake light switch connector (1) on the
1. Remove four speedometer screws (6). right control and disconnect.

2. Press tab (7) down to remove the connector from

speedometer. 3. Set multi meter to measure resistance. 17
4. Connect meter leads to each terminal of the front
brake switch (2).

3. Installation is performed by reversing the removal

procedure.

5. Apply the front brake.

Resistance Specification: Continuity with lever

depressed
Instrument Cluster Mount Screws
22 ft-lbs (29.8 Nm)

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6. Locate the rear brake light switch connector (3). Clutch Switch Test
1. Disconnect clutch switch (1) 2 pin connector.
Measure the resistance of the switch with lever
pulled to handlebar (less than 1 Ohm resistance)
and with lever released (OL).

7. Connect meter leads to each terminal of the rear

brake switch connector (4).

Side Stand Switch Test

1. Inspect side stand. Be sure that when the side
stand is fully retracted (UP) that the switch plunger
is extended and that when the side stand is
extended (down) the plunger is depressed.
2. Remove the voltage regulator bracket to access
the side stand switch connector and disconnect.
See Rectifier / Regulator Replacement, page
15.29.
3. Set multi meter to measure resistance and insert
meter leads into appropriate jacks.
4. Place one meter lead onto each of the side stand
8. Apply the rear brake. switch terminal pins.

Resistance Specification: Continuity with pedal 5. Read resistance with the side stand switch plunger
depressed depressed and extended.

Switch Depressed (Stand DOWN): No Continuity

(OL)
Switch Extended (Stand UP): Continuity (Less than
1Ω)

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Gear Position Switch Test 2. Set multi meter to measure resistance.
1. Disconnect the gear position switch (1) 2– pin 3. Connect one meter lead to each of the pins on the
connector (2) located at the rear of the engine switch connector.
above the voltage regulator.
4. Watch the resistance readings as the transmission
is shifted into Neutral. The meter readings be less
than 1 ohm with transmission in Neutral and OL in
all other gears.

BREAKOUT WIRING DIAGRAMS

Animated Wiring Diagram Overview 17
2015 Indian Motorcycle Electronic Service Manual
To provide world class diagnostic tools our dealer technicians have come to expect, Indian Motorcycle has taken
select circuit diagrams and added animated current flow. Using this tool will allow dealership technicians to
quickly isolate and diagnose problems within an electrical circuit. The user interface (UI) provides an intuitive
way to animate current flow into and out of controllers, sensors, switches and relays, showing both power supply
(+) and path to ground (-).

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Starting Circuit, Wiring Diagram

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Ignition System, Wiring Diagram

17

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Throttle Control, Wiring Diagram

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MAIN WIRING DIAGRAMS
Wiring Diagrams
Main wiring diagrams are located in the back of the printed manual.
Click HERE to view wiring diagrams.

17

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NOTES

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 A Brake Fluid
Changing........................................................ 14.18
ABS Module, Replacement .................................. 14.16 Brake Fluid Replacement .................................... 14.17 IX
ABS System Brake Lever
Special Tools ..................................................... 14.3 Inspection, Front ............................................... 2.19
Air Box Lubrication, Front.............................................. 2.19
Assembly View ................................................. 5.10 Brake Lever Reserve Inspection .......................... 14.20
Installation ........................................................ 5.18 Brake Light
Removal............................................................ 5.18 Operation Overview........................................ 17.12
Air Filter, Replacement ........................................... 2.8 Removal / Installation ...................................... 17.12
Animated Wiring Diagrams ................................ 17.19 Brake Light Switch
Assembly ............................................................. 7.32 Testing............................................................ 17.17
Axle Inspection, Front......................................... 11.14 Brake Pads
Axle Inspection, Rear.......................................... 12.14 Replacement, Front ......................................... 14.21
Replacement, Rear .......................................... 14.21
Brake Pedal
B Inspection ......................................................... 2.19
Balance Shaft Lubrication ....................................................... 2.20
Assembly View ............................................... 10.15 Brake System
Installation ...................................................... 10.17 ABS Brake Fluid Change.................................. 14.18
Removal.......................................................... 10.17 ABS General Information ................................. 14.12
Service Specifications ....................................... 10.3 ABS Module Replacement ............................... 14.16
Special Tools ..................................................... 10.3 ABS Module, Assembly View ........................... 14.11
Battery ABS System Safety Precautions ........................ 14.12
Assembly View ............................................... 15.10 Assembly View, Front Brake .............................. 14.4
Charging, In Service ....................................... 15.13 Assembly View, Line Routing............................. 14.6
Charging, New ................................................ 15.12 Assembly View, Rear Brake ............................... 14.5
Current Drain Test........................................... 15.24 Bleeding, Front Brakes .................................... 14.19
Inspection ............................................... 2.29, 15.13 Bleeding, Rear Brakes ..................................... 14.18
Installation ...................................................... 15.11 Disc Removal / Installation, Front..................... 11.15
Load Test ........................................................ 15.17 Disc Removal / Installation, Rear...................... 12.16
Maintenance ..................................................... 2.28 Front Brake Pads, Replacement ....................... 14.21
Removal.......................................................... 15.11 Front Caliper Installation ................................. 14.26
Safety Precautions ............................................. 15.3 Front Caliper Service ...................................... 14.25
Storage ............................................................. 2.30 Front Caliper, Assembly View ........................... 14.9
Testing............................................................ 15.13 Front Master Cylinder Service ......................... 14.23
Battery Box Lever Reserve Inspection ................................ 14.20
Installation ...................................................... 15.12 Precautions ..................................................... 14.17
Removal.......................................................... 15.11 Rear Brake Pads, Replacement ........................ 14.21
Battery Box, Assembly View ............................... 15.10 Rear Caliper Installation.................................. 14.29
Battery Charging .................................................. 2.29 Rear Caliper Service ....................................... 14.28
Battery Installation................................................ 2.30 Rear Caliper, Assembly View .......................... 14.10
Bearing Clearance Inspection............................. 10.30 Rear Master Cylinder Service.......................... 14.27
Bearing Selection Rear Master Cylinder, Assembly View............... 14.8
Connecting Rod .............................................. 10.31 Service Notes .................................................... 14.2
Belt Service Specifications ....................................... 14.3
Adjustment ....................................................... 2.33 Special Tools ..................................................... 14.3
Alignment ......................................................... 2.33 Torque Specifications ........................................ 14.3
Inspection ......................................................... 2.32 Troubleshooting.............................................. 14.30
Installation ........................................................ 12.7 Vacuum Bleeder .............................................. 14.18
Removal............................................................ 12.7 Wheel Speed Sensor Adjustment (Air Gap) ..... 14.15
Specifications.................................................... 2.32 Wheel Speed Sensor Replacement .................. 14.14
Tension Measurement ....................................... 2.32 Brakes
Body Brake Pad Inspection, Front ............................... 2.24
Service Notes ...................................................... 3.2 Brake Pad Inspection, Rear ................................ 2.24
Special Tools ....................................................... 3.2 Brake Pedal, Inspection ..................................... 2.19
Brake Bleeding Precautions ................................ 14.17 Brake Pedal, Lubrication ................................... 2.20
Brake Disc Fluid Level Inspection ....................................... 2.23
Removal / Installation, Front ............................ 11.15 Front Brake Lever, Inspection ............................ 2.19
Removal / Installation, Rear ............................. 12.16 Front Brake Lever, Lubrication ........................... 2.19

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Braking System Assembly View ................................................... 9.6
ABS Overview of Operation ............................. 14.13 Disassembly ..................................................... 9.14
ABS System Components................................. 14.13 Inspection ......................................................... 9.15
Break-In, Engine..................................................... 2.7 Installation ........................................................ 9.18
Breather, Inspection.............................................. 2.24 Pinion Shaft Bearing Inspection ........................... 9.8
Pinion Shaft Installation ....................................... 9.9
Pinion Shaft Removal ........................................... 9.8
C Pinion Shaft Seal Replacement ............................. 9.9
Rack, Removal / Installation............................... 9.13
Caliper Removal............................................................ 9.13
Front, Installation ............................................ 14.26 Service Notes ...................................................... 9.2
Front, Rebuilding ............................................ 14.25 Service Specifications ......................................... 9.2
Front, Removal ................................................ 14.25 Special Tools ....................................................... 9.2
Rear, Installation ............................................. 14.29 Torque Specifications .......................................... 9.2
Rear, Rebuilding ............................................. 14.28 Troubleshooting................................................ 9.22
Rear, Removal ................................................. 14.28 Clutch Cable
Caliper, Front Lubrication ....................................................... 2.17
Assembly View ................................................. 14.9 Removal / Installation ...................................... 11.12
Caliper, Rear Clutch Lever
Assembly View ............................................... 14.10 Free Play Adjustment ........................................ 2.18
Cam Chain Lubrication ....................................................... 2.17
Installation ........................................................ 7.15 Clutch Pinion Shaft
Removal............................................................ 7.15 Assembly View ................................................... 9.5
Service ............................................................. 7.11 Clutch Rack
Service Notes .................................................... 7.11 Removal / Installation ........................................ 9.13
Cam Chain Guide Clutch Switch
Installation ........................................................ 7.16 Circuit Test...................................................... 15.19
Lower, Removal ................................................. 7.14 Removal / Installation ...................................... 15.20
Upper, Installation............................................. 7.22 Testing............................................................ 17.18
Upper, Removal ................................................ 7.11 Coil, Ignition
Cam Chain Tensioner Removal / Installation ........................................ 16.6
Inspection ......................................................... 7.11 Compression Test (Wet), Engine ........................... 2.28
Installation ........................................................ 7.21 Compression Test, Engine .................................... 2.27
Removal............................................................ 7.11 Connecting Rod
Cam Drive Shaft Bearing Clearance Inspection ......................... 10.30
Installation ................................................ 7.15, 7.17 Bearing Inspection .......................................... 10.30
Removal............................................................ 7.14 Bearing Selection ............................................ 10.31
Cam Timing.......................................................... 7.19 Inspection ............................................... 8.10, 10.28
Camshaft Inspection, Big End ......................................... 10.29
Drive Sprocket Installation................................. 7.17 Installation ...................................................... 10.33
Inspection ......................................................... 7.26 Removal.......................................................... 10.28
Sprocket Removal ............................................. 7.12 Side Clearance................................................ 10.28
Timing ................................................................ 7.9 Connecting Rods
Camshaft Sprocket Service Specifications ....................................... 10.3
Installation ........................................................ 7.19 Controls, Assembly View...................................... 11.4
Timing .............................................................. 7.19 Conversion Chart
CamshaftCam Drive Shaft Metric ............................................................... 1.17
Drive Sprocket Removal .................................... 7.13 Conversion Charts........................................ 1.17–1.18
Removal............................................................ 7.13 Measurement .................................................... 1.19
Charcoal Canister................................................. 2.25 SAE................................................................... 1.17
Charging System Temperature ..................................................... 1.19
Output Test ..................................................... 15.24 Coolant Drain / Fill ....................................... 2.14, 4.19
Service Notes .................................................... 15.3 Coolant Fill / Bleeding.......................................... 4.21
Service Specifications ....................................... 15.5 Coolant Flow Diagram ............................................ 4.6
Special Tools ..................................................... 15.5 Coolant Level Inspection ...................................... 2.10
Torque Specifications ........................................ 15.5 Coolant Strength / Type................................ 2.10, 4.18
Troubleshooting.............................................. 15.22 Coolant Temperature Sensor ................................ 4.24
Checking Oil Level ................................................. 2.8 Cooling System Hoses .......................................... 2.12
Clutch Cooling System Overview .................................... 2.10
Assembly .......................................................... 9.16 Cooling System Pressure Cap Test ................ 2.11, 4.19

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Cooling System Pressure Test ....................... 2.11, 4.18 Cylinder Head, Exploded View .............................. 7.8
Cooling System Troubleshooting .......................... 4.25
Crankcase IX
Assembly ........................................................ 10.36 D
Assembly View ................................................. 10.6
Assembly, Left Side ......................................... 10.34 Diagnostic Trouble Codes (DTC) .......................... 5.33
Assembly, Right Side....................................... 10.34 Digital Wrench
Bolt Location ..................................................... 10.9 Communication Errors ...................................... 5.47
Disassembly ................................................... 10.21 Diagnostic Connector........................................ 5.47
Resealing ........................................................ 10.36 ECM Reflash...................................................... 5.51
Separation....................................................... 10.21 ECM Replacement ............................................ 5.47
Torque Sequence .............................................. 10.9 Feature Map ...................................................... 5.50
Crankcase Emission Control ................................. 1.11 Guided Diagnostics........................................... 5.47
Crankcase Ventilation, Inspection ......................... 2.24 Overview .......................................................... 5.47
Crankshaft Serial Number Location ..................................... 5.48
Assembly View ................................................. 10.7 Update Information ........................................... 5.47
Cleaning ......................................................... 10.33 Update Process ................................................. 5.48
Inspection ....................................................... 10.32 Version Updates ................................................ 5.48
Installation ...................................................... 10.35 Discs, BrakeBrake System
Locking for Service ........................................... 10.4 Disc, Inspection .............................................. 14.22
Main Bearing Inspection.................................. 10.33 Inspection ....................................................... 14.22
Main Bearing Oil Clearance ............................ 10.33 Drill Sizes
Removal.......................................................... 10.27 Metric ............................................................... 1.17
Service Notes .................................................... 10.3 SAE................................................................... 1.17
Service Specifications ....................................... 10.3 Drive Belt
Special Tools ..................................................... 10.3 Adjustment ....................................................... 2.33
Troubleshooting.............................................. 10.39 Alignment ......................................................... 2.33
Crankshaft Position Sensor (CPS) Resistance Inspection ......................................................... 2.32
Inspection........................................................... 16.6 Installation ........................................................ 12.7
Crankshaft Position Sensor, Test / Replace ............ 5.45 Removal............................................................ 12.7
Current Drain, Testing ........................................ 15.24 Specifications.................................................... 2.32
Cylinder Tension Measurement ....................................... 2.32
Assembly View ................................................... 8.4 Drive Sprocket
Bore Measurement .............................................. 8.6 Installation ........................................................ 12.9
Inspection ........................................................... 8.6 Removal............................................................ 12.8
Installation ........................................................ 8.12 Drive Sprocket Inspection..................................... 12.9
Removal.............................................................. 8.5 Drive Sprocket, Cover
Service Notes ...................................................... 8.2 Removal / Installation ........................................ 12.8
Service Specifications ......................................... 8.3 Driven Sprocket
Special Tools ....................................................... 8.2 Inspection ....................................................... 12.11
Torque Specifications .......................................... 8.2 Installation ...................................................... 12.12
Warpage Measurement ....................................... 8.9 Removal.......................................................... 12.11
Cylinder / Piston
Troubleshooting................................................ 8.14
Cylinder Head E
Assembly .......................................................... 7.32 ECM
Disassembly ..................................................... 7.28 Connector Map ................................................. 5.31
Inspection ......................................................... 7.29 Connectors ....................................................... 5.41
Installation ........................................................ 7.33 Disconnect ........................................................ 5.41
Removal............................................................ 7.26 Pinout Chart ...................................................... 5.31
Special Tools ....................................................... 7.3 Pinout Testing ................................................... 5.41
Cylinder Head / Valve Train Reflash Procedure ............................................. 5.51
Service Notes ...................................................... 7.3 Removal / Installation ........................................ 5.42
Cylinder Head / Valves ECM Connector Map ............................................ 16.4
Service Specifications ......................................... 7.4 ECM Replacement Information ............................. 5.47
Torque Specifications .......................................... 7.4 EFI
Troubleshooting................................................ 7.37 Service Notes ...................................................... 5.3
Cylinder Head Temperature Sensor Service Precautions............................................. 5.5
Replacement ..................................................... 5.43 Service Specifications ......................................... 5.4
Test................................................................... 5.43 Special Tools ....................................................... 5.4

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 Torque Specifications .......................................... 5.4 Flywheel
Electrical System Installation ........................................................ 9.21
Service Notes .................................................... 17.2 Removal............................................................ 9.20
Special Tools ..................................................... 17.2 Flywheel Removal .............................................. 15.28
Torque Specifications ........................................ 17.2 Foot Pegs, Passenger
Electronic Fuel Injection (EFI) Installation .......................................................... 3.7
Sensor Locations ............................................... 5.11 Removal.............................................................. 3.7
Electronic Throttle Control Module Fork
Removal............................................................ 5.45 Assembly ........................................................ 11.22
Emission Control Systems..................................... 1.10 Assembly View ................................................. 11.7
Emission Sources.................................................. 1.10 Disassembly ................................................... 11.18
Engine Installation ...................................................... 11.25
Compression Test ............................................. 2.27 Removal.......................................................... 11.16
Compression Test (Wet) .................................... 2.28 Frame
Locking the Crankshaft...................................... 10.4 Assembly View ................................................... 3.3
Engine Break-In Procedure ..................................... 2.7 Service Notes ...................................................... 3.2
Engine Installation.................................................. 6.7 Special Tools ....................................................... 3.2
Engine Number Location ........................................ 1.2 Frame Removal / Installation................................. 3.10
Engine Removal Front Axle Inspection.......................................... 11.14
Assembly View ................................................... 6.3 Front Brake, Assembly View ................................. 14.4
Preliminary Steps ................................................ 6.4 Front Fork
Removing Engine from Frame ............................. 6.5 Inspection ....................................................... 11.21
Service Notes ...................................................... 6.2 Front Wheel
Service Specifications ......................................... 6.2 Assembly View ............................................... 11.10
Special Tools ....................................................... 6.2 Bearing Inspection .......................................... 11.15
Torque Specifications .......................................... 6.2 Inspection ....................................................... 11.14
Engine, Assembly Views Removal / Installation ...................................... 11.13
Cam Chains ........................................................ 7.6 Front Wheel & Suspension
Camshafts ........................................................... 7.7 Troubleshooting.............................................. 11.30
Cylinder Head ..............................................7.7–7.8 Front Wheell
Engine, Oil / Filter Change ..................................... 2.9 Bearing Replacement ...................................... 11.16
Engine, Timing ....................................................... 7.9 Fuel Filter, Replacement ....................................... 5.24
EVAP System ........................................................ 2.25 Fuel Injection
Evaporative Emissions Control ............................. 1.11 Overview of Operation ...................................... 5.30
Evaporative Emissions System .............................. 2.25 Fuel Injector
Evaporative System Removal / Installation ........................................ 5.43
Line Routing, 49 State .......................................... 5.6 Fuel Injector Resistance Test................................. 5.44
Line Routing, CA ................................................. 5.7 Fuel Level Sensor,Resistance Test ......................... 5.27
Exhaust Fuel Line
Assembly View ................................................. 5.13 Routing, 49 State.................................................. 5.6
Head Pipe, Removal .......................................... 5.15 Routing, CA......................................................... 5.7
Muffler Removal ................................................ 5.14 Fuel Pressure
Muffler, Installation............................................ 5.14 Inspection ......................................................... 5.20
Exhaust Emission Control ..................................... 1.10 Specification ..................................................... 5.20
Exhaust Valve Lash - Tappet Selection Matrix ........ 7.36 Test................................................................... 5.20
Fuel Pump
Current Draw Test ............................................. 5.28
F Installation ........................................................ 5.24
Pressure Test..................................................... 5.20
Fault Codes .......................................................... 5.33 Removal............................................................ 5.23
Fender, Front Supply Voltage Test........................................... 5.28
Installation .......................................................... 3.8 Fuel Rail
Removal.............................................................. 3.7 Removal / Installation ........................................ 5.43
Fender, Rear Fuel System
Installation .......................................................... 3.9 Assembly View ................................................... 5.8
Removal.............................................................. 3.8 Depressurization ............................................... 5.21
Fenders EFI Overview .................................................... 5.30
Assembly View ................................................... 3.5 Inspection ......................................................... 2.26
Final Drive Line Routing, 49 State .......................................... 5.6
Troubleshooting.............................................. 12.23 Line Routing, CA ................................................. 5.7

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 Priming............................................................. 5.29 Ignition System
Service Notes ...................................................... 5.3 Service Notes .................................................... 16.2
Service Precautions............................................. 5.5 Service Specifications ....................................... 16.2 IX
Service Specifications ......................................... 5.4 Special Tools ..................................................... 16.2
Special Tools ....................................................... 5.4 Test 1: Battery Voltage Inspection ...................... 16.5
Torque Specifications .......................................... 5.4 Test 2: Spark ..................................................... 16.5
Troubleshooting................................................ 5.53 Test 3: Ignition Coil Power and Ground Signal.... 16.5
Fuel Tank Test 4: Ignition Coil Resistance .......................... 16.6
Assembly View ................................................... 5.9 Test Flowchart ................................................... 16.4
Installation ........................................................ 5.26 Testing Precautions ........................................... 16.3
Mounting ............................................................ 5.9 Torque Specifications ........................................ 16.2
Removal............................................................ 5.21 Troubleshooting Basics ..................................... 16.3
Vent Inspection (49 State) .................................. 2.25 Inspection .......................................... 2.26, 7.32, 12.14
Vent Inspection (CA) ......................................... 2.25 Instrument Cluster
Fuse Box Overview ........................................................ 17.15
Assembly View ......................................... 17.5–17.6 Instrument Panel..................................................... 3.9
Fuse Application Chart...................................... 17.7 Intake Manifold, Removal / Installation.................. 5.20
Location ............................................................ 2.35 Intake Valve Clearance - Tappet Selection
Locations .......................................................... 17.6 Matrix................................................................. 7.35
Fuses
Location ............................................................ 2.35
Replacement ..................................................... 2.35 L
License Plate Light
Assembly View ................................................. 17.4
G Removal / Installation ...................................... 17.12
Gear Position Switch Load / Tip Over Module........................................ 17.9
Neutral Indicator Test ...................................... 15.18 Connector Map ................................................. 17.9
Test................................................................. 17.19 Load / Tipover Module ......................................... 5.46
Gear Ratios........................................................... 10.3 Load/Tip Over Module
Gross Vehicle Weight Rating (GVWR) ..................... 1.8 Removal / Installation ...................................... 17.10
Guided Diagnostics .............................................. 5.47

M
H Main Bearing
Handlebar Inspection ....................................................... 10.33
Assembly View ................................................. 11.6 Oil Clearance Inspection................................. 10.33
Removal / Installation ...................................... 11.11 Maintenance
Head Light Engine Break-In Procedure.................................. 2.7
Assembly View ................................................. 17.3 Periodic Maintenance Interval Table ................... 2.3
Bulb Replacement ........................................... 17.10 Quick Reference Guide ....................................... 2.3
Head Pipe ............................................................ 5.15 Service Notes ...................................................... 2.7
Exhaust Special Tools ....................................................... 2.7
Head Pipe, Installation ................................... 5.16 Table .................................................................. 2.5
Installation ........................................................ 5.16 Maintenance Procedures ........................................ 2.8
Headlight Maintenance, Specifications.................................... 2.3
Aim Adjustment ................................................ 2.36 Manufacturer Label Location................................... 1.3
Aim Inspection .................................................. 2.35 Master Cylinder
Horn Assembly View, Rear......................................... 14.8
Removal / Installation ...................................... 17.12 Front, Rebuilding ............................................ 14.23
Front, Removal ................................................ 14.23
Rear, Rebuilding ............................................. 14.27
I Rear, Removal ................................................. 14.27
Model Number Decoder ......................................... 1.2
Idle Speed, Adjustment ........................................ 2.15 Model Number Location ......................................... 1.3
Ignition Coil Model Numbers...................................................... 1.4
Power and Ground Signal Test ........................... 16.5 Motor Mounts, Assembly View................................ 6.3
Removal / Installation ........................................ 16.6 Muffler
Resistance Test.................................................. 16.6 Installation ........................................................ 5.14
Ignition Side Cover Removal................................. 3.10 Removal............................................................ 5.14

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 N Inspection ......................................................... 8.10
Piston Ring
Noise Emission Control......................................... 1.10 Inspection ........................................................... 8.9
Installation ........................................................ 8.11
Profile & Orientation............................................ 8.5
O Removal.............................................................. 8.9
Oil Change Pressure Lubrication Oil Pump Installation ............ 4.14
Checking Oil Level.............................................. 2.8 Pressure Oil Pump Removal .................................. 4.13
Oil Change, Procedure ........................................... 2.9 Primary Cover
Oil Cooler Assembly View ................................................... 9.3
Inspection ......................................................... 4.16 Installation .......................................................... 9.7
Installation ........................................................ 4.16 Primary Drive
Removal............................................................ 4.16 Service Notes ...................................................... 9.2
Oil Cooler, Exploded View ..................................... 4.5 Service Specifications ......................................... 9.2
Oil Level, Check ..................................................... 2.8 Special Tools ....................................................... 9.2
Oil Pressure Sensor, Test....................................... 4.11 Torque Specifications .......................................... 9.2
Oil Pump Troubleshooting................................................ 9.22
Installation ........................................................ 4.14 Primary Drive Cover
Oil Pump, Exploded View....................................... 4.7 Removal.............................................................. 9.7
Oiling System Priming the Fuel System ....................................... 5.29
Cooling System ................................................... 4.3
General Information ............................................ 4.2
Oil Flow Diagram .............................................. 4.10 R
Oil Pressure Test ............................................... 4.11
Radiator ............................................................... 4.21
Operation ........................................................... 4.2 Radiator Inspection / Cleaning ............................. 2.13
Service Notes ...................................................... 4.2 Rear Axle
Service Specifications ......................................... 4.3
Inspection ....................................................... 12.14
Special Tools ....................................................... 4.2 Rear Brake, Assembly View .................................. 14.5
Torque Specifications .......................................... 4.3 Rear Sprocket Inspection .................................... 12.11
Troubleshooting.................................................. 4.2
Rear Sprocket Installation ................................... 12.12
Oiling System, Assembly Views
Rear Sprocket Removal ....................................... 12.11
Cooling System ................................................... 4.5 Rear Wheel
Lubrication System.............................................. 4.7
Bearing Inspection .......................................... 12.15
Output Shaft Seal Replacement ............................. 12.9
Bearing Replacement ...................................... 12.15
Owner’s Manuals, Part Numbers ............................. 1.8 Inspection ....................................................... 12.14
Removal / Installation ...................................... 12.13
Rear Wheel and Suspension
P Assembly View ................................................. 12.4
P-Codes ............................................................... 5.33 Special Tools ..................................................... 12.2
Paint Torque Specifications ........................................ 12.2
Color, By Model .................................................. 1.9 Rear Wheel, Assembly View................................. 12.6
PCV System, Inspection ........................................ 2.24 Reflash Authorization ............................................ 5.51
Pinion Shaft, Clutch Regulated Voltage Test ....................................... 15.24
Bearing Inspection .............................................. 9.8 Regulator / Rectifier
Installation .......................................................... 9.9 Assembly View ................................................. 15.9
Removal.............................................................. 9.8 Bracket, Replacement...................................... 15.29
Seal Replacement................................................ 9.9 Connector Inspection ...................................... 15.28
Piston Diode Leakage Test......................................... 15.29
Assembly View ................................................... 8.4 Replacement ................................................... 15.29
Clearance Worksheet.......................................... 8.7 Ride Height
Inspection ........................................................... 8.9 Adjustment ....................................................... 2.38
Installation ........................................................ 8.11 Inspection ......................................................... 2.38
Profile & Orientation............................................ 8.5 Rings
Removal.............................................................. 8.9 End Gap Measurement........................................ 8.9
Service Notes ...................................................... 8.2 Installation ........................................................ 8.11
Service Specifications ......................................... 8.3 Profile & Orientation............................................ 8.5
Special Tools ....................................................... 8.2 Removal.............................................................. 8.9
Torque Specifications .......................................... 8.2
Piston Pin

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 S Assembly View ............................................... 10.14
Inspection ....................................................... 10.24
Safety Labels .............................................................2 Removal.......................................................... 10.23 IX
Scavenge Oil Pump Shift Fork
Removal............................................................ 4.12 Assembly View ............................................... 10.14
Seat Removal.......................................................... 10.23
Assembly View ................................................... 3.5 Shift Pedal
Removal / Installation .......................................... 3.7 Adjustment ....................................................... 2.22
Sensor Diagnostics ............................................... 5.41 Inspection ......................................................... 2.22
Sensors, Location.................................................. 5.11 Shift Ratchet
Service Manuals, Part Numbers .............................. 1.8 Inspection ........................................................... 9.9
Service Notes Installation ........................................................ 9.11
Body ................................................................... 3.2 Removal.............................................................. 9.9
Brake System .................................................... 14.2 Shift Shaft Seal, Replacement ................................ 9.12
Clutch ................................................................. 9.2 Shifting
Crankshaft ........................................................ 10.3 Troubleshooting................................................ 9.22
Cylinder ............................................................. 8.2 Shock Absorber
Cylinder Head / Valve Train ................................ 7.3 Inspection ....................................................... 12.16
EFI ...................................................................... 5.3 Installation ...................................................... 12.17
Electrical System............................................... 17.2 Removal.......................................................... 12.16
Engine Removal .................................................. 6.2 Shock, Rear
Front Suspension............................................... 11.2 Preload Adjustment........................................... 2.38
Front Wheel ...................................................... 11.2 Preload Inspection ............................................ 2.38
Fuel System......................................................... 5.3 Side Stand Switch
Ignition System ................................................. 16.2 Test................................................................. 17.18
Maintenance ....................................................... 2.7 Sidestand
Oiling System...................................................... 4.2 Inspection ......................................................... 2.36
Piston.................................................................. 8.2 Lubrication ....................................................... 2.36
Primary Drive ..................................................... 9.2 Removal / Installation ........................................ 2.36
Rear Suspension................................................ 12.2 Spark Plug
Rear Wheel ....................................................... 12.2 Gap .................................................................. 2.26
Starting System ................................................. 15.3 Inspection ......................................................... 2.26
Tires ................................................................. 13.2 Installation ........................................................ 2.27
Transmission..................................................... 10.3 Removal............................................................ 2.26
Wheels ............................................................. 13.2 Special Tools ........................................................ 1.14
Service Specifications........................................... 13.3 ABS System ....................................................... 14.3
Balance Shaft..................................................... 10.3 Balance Shaft..................................................... 10.3
Brake System .................................................... 14.3 Body ................................................................... 3.2
Charging System............................................... 15.5 Brake System .................................................... 14.3
Clutch ................................................................. 9.2 By System ......................................................... 1.12
Connecting Rods............................................... 10.3 Charging System............................................... 15.5
Crankshaft ........................................................ 10.3 Clutch ................................................................. 9.2
Cylinder ............................................................. 8.3 Crankshaft ........................................................ 10.3
Cylinder Head / Valves ....................................... 7.4 Cylinder ............................................................. 8.2
EFI ...................................................................... 5.4 Cylinder Head / Valves ....................................... 7.3
Engine Removal .................................................. 6.2 EFI ...................................................................... 5.4
Front Suspension............................................... 11.3 Electrical System............................................... 17.2
Front Wheel ...................................................... 11.3 Engine Removal .................................................. 6.2
Fuel System......................................................... 5.4 Frame ................................................................. 3.2
Ignition System ................................................. 16.2 Front Suspension............................................... 11.2
Oiling System...................................................... 4.3 Front Wheel ...................................................... 11.2
Piston.................................................................. 8.3 Fuel System......................................................... 5.4
Primary Drive ..................................................... 9.2 Ignition System ................................................. 16.2
Rear Suspension................................................ 12.3 Locating............................................................ 1.12
Rear Wheel ....................................................... 12.3 Maintenance ....................................................... 2.7
Starting System ................................................. 15.5 Oiling System...................................................... 4.2
Tires ................................................................. 13.3 Ordering Information ........................................ 1.13
Wheels ............................................................. 13.3 Piston.................................................................. 8.2
Shift Arm Removal/Installation .............................. 9.12 Primary Drive ..................................................... 9.2
Shift Drum Rear Wheel and Suspension .............................. 12.2

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 Starting System ................................................. 15.5 Torque Specifications ........................................ 11.2
Transmission..................................................... 10.3 Suspension, Front Fork
Specifications, General........................................... 1.4 Disassembly ................................................... 11.18
Sprocket Suspension, Rear
Drive, Installation .............................................. 12.9 Service Notes .................................................... 12.2
Drive, Removal.................................................. 12.8 Service Specifications ....................................... 12.3
Driven, Inspection........................................... 12.11 Troubleshooting.............................................. 12.22
Driven, Installation .......................................... 12.12 Swing Arm
Driven, Removal.............................................. 12.11 Inspection ......................................................... 2.38
Inspection, Rear ................................................ 2.34 Swingarm
Sprocket, Drive, Inspection................................... 12.9 Assembly View ................................................. 12.4
Stake Nut Installation .......................................... 10.38 Bushing / Bearing Replacement....................... 12.19
Starter Installation ...................................................... 12.20
Solenoid, Ground Circuit Test.......................... 15.18 Removal.......................................................... 12.18
Starter Motor
Assembly View ................................................. 15.7
Current Draw Test ........................................... 15.21 T
Drive Gear, Inspection .................................... 10.19
Drive Gear, Installation.................................... 10.20 Tail Light
Drive Gear, Removal ....................................... 10.19 Assembly View ................................................. 17.4
Installation ...................................................... 15.21 Operation Overview........................................ 17.12
Removal.......................................................... 15.21 Removal / Installation ...................................... 17.12
Safety Information ........................................... 15.14 Thermostat ........................................................... 4.23
Starter Solenoid Thermostat Housing Cover Removal /
Ground Circuit Test ......................................... 15.18 Installation .......................................................... 3.10
Positive Circuit Test ......................................... 15.20 Throttle Body
Starting Circuit Removal............................................................ 5.45
Starting Circuit Wiring Diagram ...................... 17.20 Throttle Control .................................................. 17.22
Starting System................................................... 15.17 Timing Components, Exploded View...................... 7.6
Circuit Operation ............................................ 15.15 Timing Marks ......................................................... 7.9
Diagnostic Table ............................................. 15.14 Tire & Wheel
Service Notes .................................................... 15.3 Troubleshooting.............................................. 13.11
Service Specifications ....................................... 15.5 Tire Removal, General .......................................... 13.5
Special Tools ..................................................... 15.5 Tire Wear Patterns ................................................ 13.4
Torque Specifications ........................................ 15.5 Cupping ........................................................... 13.4
Troubleshooting, No Crank ............................. 15.16 Tires............................................................. 13.5–13.6
Troubleshooting, Starter Drive ........................ 15.17 Balance Dots ..................................................... 13.6
Wiring Diagram .............................................. 15.15 Balancing .......................................................... 13.8
Stator Directional Arrows ............................................ 13.6
Assembly View ................................................. 15.8 Inflation / Precautions........................................ 13.6
Ground Continuity Test ................................... 15.26 Information ......................................................... 1.3
Installation ...................................................... 15.28 Inspection ......................................................... 2.15
Output Test ..................................................... 15.25 Ozone Cracking ................................................ 13.4
Removal.......................................................... 15.27 Pressure............................................................ 2.15
Resistance Test................................................ 15.26 Repair Precautions ............................................ 13.9
Stator Cover Installation........................................ 9.19 Service Notes .................................................... 13.2
Stator Cover Removal ........................................... 9.19 Service Specifications ....................................... 13.3
Steering Head Size Specifications............................................. 2.15
Bearing Adjustment......................................... 11.27 Specifications...................................................... 1.3
Bearing Inspection ............................................ 2.37 Tread Wear ....................................................... 13.4
Storage, Battery .................................................... 2.30 Valve Stem Installation, Metal .......................... 13.10
Suspension Valve Stem Installation, Rubber ....................... 13.10
Assembly View, Front........................................ 11.7 Valve Stem, Inspection .................................... 13.10
Suspension, Front TMAP Sensor
Fork Assembly ................................................ 11.22 Overview .......................................................... 5.42
Fork Installation............................................... 11.25 Replacement ..................................................... 5.42
Fork Removal .................................................. 11.16 Tools, Special ....................................................... 1.14
Service Notes .................................................... 11.2 Torque Specifications
Service Specifications ....................................... 11.3 Brake System .................................................... 14.3
Special Tools ..................................................... 11.2 Charging System............................................... 15.5
Clutch ................................................................. 9.2

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 Cylinder ............................................................. 8.2 Valve Spring, Free Length..................................... 7.29
Cylinder Head / Valves ....................................... 7.4 Valve Stem
EFI ...................................................................... 5.4 Inspection ....................................................... 13.10 IX
Electrical System............................................... 17.2 Installation, Metal............................................ 13.10
Engine Removal .................................................. 6.2 Installation, Rubber ......................................... 13.10
Front Suspension............................................... 11.2 Valve Timing ........................................................ 7.19
Front Wheel ...................................................... 11.2 Valve Train
Fuel System......................................................... 5.4 Special Tools ....................................................... 7.3
Ignition System ................................................. 16.2 Valves
Oiling System...................................................... 4.3 Inspection ......................................................... 7.30
Piston.................................................................. 8.2 Wear Patterns.................................................... 7.31
Primary Drive ..................................................... 9.2 Valves, Exploded View ........................................... 7.8
Rear Wheel and Suspension .............................. 12.2 Vehicle Identification Number ................................ 1.2
Starting System ................................................. 15.5 VIN Decoder .......................................................... 1.2
Trademark Information..............................................5 VIN Location........................................................... 1.3
Transmission Voltage Output Test ............................................ 15.24
Assembly View ............................................... 10.11 Voltage Regulator
Gear Ratios ....................................................... 10.3 Assembly View ................................................. 15.9
Gear Train ...................................................... 10.16
Inspection ....................................................... 10.24
Installation ...................................................... 10.35 W
Power Flow...................................................... 10.16
Removal.......................................................... 10.23 Water Pump.......................................................... 4.22
Service Notes .................................................... 10.3 Wheel
Special Tools ..................................................... 10.3 Inspection ......................................................... 13.9
Troubleshooting.............................................. 10.39 Wheel Bearings
Triple Clamp Inspection, Front ............................................... 2.37
Assembly View ................................................. 11.9 Wheel Speed Sensor
Bearing Adjustment......................................... 11.27 Adjustment (Air Gap) ...................................... 14.15
Installation ...................................................... 11.27 Replacement ................................................... 14.14
Removal.......................................................... 11.26 Wheel, Front ...................................................... 11.10
Troubleshooting Bearing Inspection .......................................... 11.15
Brake System .................................................. 14.30 Bearing Replacement ...................................... 11.16
Crankshaft ...................................................... 10.39 Inspection ....................................................... 11.14
Final Drive ...................................................... 12.23 Removal / Installation ...................................... 11.13
Front Wheel & Suspension............................... 11.30 Service Notes .................................................... 11.2
Rear Suspension.............................................. 12.22 Service Specifications ....................................... 11.3
Rear Wheel ..................................................... 12.22 Special Tools ..................................................... 11.2
Tire & Wheel ................................................... 13.11 Torque Specifications ........................................ 11.2
Transmission................................................... 10.39 Wheel, Rear
Turn Signal Assembly View ................................................. 12.6
Front, Removal / Installation ............................ 17.14 Bearing Inspection .......................................... 12.15
Operation Overview........................................ 17.14 Bearing Replacement ...................................... 12.15
Rear, Removal / Installation (All Models) ......... 17.14 Inspection ....................................................... 12.14
Removal / Installation ...................................... 12.13
Service Notes .................................................... 12.2
Service Specifications ....................................... 12.3
V Troubleshooting.............................................. 12.22
Vacuum Bleeder ................................................. 14.18 Wheels
Valve Clearance Adjustment ................................. 2.40 Service Notes .................................................... 13.2
Valve Clearance Assembly ................................... 7.24 Service Specifications ....................................... 13.3
Valve Clearance Inspection .................................. 2.39 Wiring Diagram
Valve Cover Animated, Overview ....................................... 17.19
Installation ........................................................ 7.23 Ignition System ............................................... 17.21
Removal............................................................ 7.23 Wiring Diagrams
Valve Guide Chassis ........................................................... 17.23
Removal / Installation ........................................ 7.32 Fairing ............................................................ 17.23
Valve Seat Rear Harness................................................... 17.23
Inspection ......................................................... 7.32 Speedometer .................................................. 17.23
Valve Seat Reconditioning .................................... 7.32

IX.9
9925346 R01 - 2015 Indian Motorcycle Service Manual
© Copyright 2014
 2015 SCOUT HARNESS-CHASSIS,SCHEMATIC PIN
A
FUNCTION
LICENSE PLATE LIGHT GROUND
B STOP LAMP POWER OUTPUT
C LICENSE PLATE LIGHT POWER
WIRE COLOR LEGEND PIN FUNCTION D REAR LEFT TS LAMP GROUND OUTPUT
BG BEIGE (TAN) P1 HEADLIGHT HIGH BEAM POWER E TAIL LIGHT POWER

REAR_LIGHTING
E = ENGINE GROUND
BK BLACK P2 HEADLIGHT GROUND F REAR RIGHT TS LAMP GROUND OUTPUT
BU LIGHT BLUE P3 LOW BEAM SWITCH OUTPUT
DB DARK BLUE
C = CHASSIS GROUND
BN BROWN

PSN_LAMP_NEG
PSN_LAMP_POS
GY GRAY

HEADLIGHT
GN LIGHT GREEN
NC = SWITCH NORMALLY CLOSED

FRONT_RH_TS
FRONT_LH_TS
DG DARK GREEN
OG ORANGE NO = SWITCH NORMALLY OPEN

BRAKE_SW
PK PINK

HORN_NEG
HORN_POS
RD RED
VT VIOLET (PURPLE) HARNESS: 2412549_Rev01-02
WH WHITE
YE YELLOW
SHEET NO. 1 OF 2
CL CLEAR
TWO WIRE COLORS ARE SHOWN
WITH MAIN/TRACE COLORS.
EXAMPLE:RD/YE = RED WITH
YELLOW TRACE.

P1 P2 F E D
A B C
2 1 2 1
P3
LOAD_MODULE_IN

P8 P7 P6 P5 P4 P3 P2 P1
001 YE/WH
1 1 P1 P2 P3 A BCDE F 2 1 1 1 PIN FUNCTION
002 DB/YE
P1 START SWITCH OUTPUT (TO LOAD MOD)
P2 CLUTCH SWITCH OUTPUT (TO LOAD MOD)

E212 DB
ACCF-3 BN/PK

E224 DB/RD
ACCF-2 BN/PK
003 VT/WH

017 GY/DG

GND2-2 BK
HIGH-3 YE

GND1-3 BK

008 DG

GND1-2 BK
E151 PK/DB
ACCR-5 BN/PK
E236 DB
ACCR-4 BN/PK
E248 DB/RD

006 BK/YE
GND5-2 BK/WH
GND1-4 BK
ACCF-6 BN/PK
P3 LEFT TURN SIGNAL SWITCH OUTPUT (TO LOAD MOD)
004 VT/OG
P4 RIGHT TURN SIGNAL SWITCH OUTPUT (TO LOAD MOD)
005 YE/VT P5 FRONT BRAKE SWITCH OUTPUT (TO LOAD MOD)
P6 REAR BRAKE PRESSURE SWITCH OUTPUT (TO LOAD MOD)
006 BK/YE
P7 NEUTRAL SWITCH OUTPUT (TO LOAD MOD)
019 BK/PK P8 TIP-OVER SENSOR SIGNAL RETURN

E204 BN/YE

LOAD_MODULE_OUT

P8 P7 P6 P5 P4 P3 P2 P1
E107 YE/WH
E119 DB/YE PIN FUNCTION
P1 START SWITCH OUTPUT (TO ECM)
E120 VT/WH P2 CLUTCH SWITCH OUTPUT (TO ECM)
E108 VT/OG P3 LEFT TURN SIGNAL SWITCH OUTPUT (TO ECM)
P4 RIGHT TURN SIGNAL SWITCH OUTPUT (TO ECM)
E124 YE/VT P5 FRONT BRAKE SWITCH OUTPUT (TO ECM)
E217 BK/YE P6 REAR BRAKE PRESSURE SWITCH OUTPUT (TO ECM)
P7 NEUTRAL SWITCH OUTPUT (TO ECM)
E233 BK/PK P8 TIP-OVER SENSOR (TOS) SIGNAL
E218 OG/WH

E126 BN/GN
LOAD_MODULE_PWR

1 2
IGNSW-8 PK

PIN FUNCTION
LH_CONTROL P01 HEADLIGHT SWITCH POWER
P02 LOW BEAM SWITCH OUTPUT
P03 HIGH BEAM SWITCH OUTPUT

P09 P07 P05 P03 P01

024 YE/PK
P04 LH CONTROL SWITCH GROUND

P10 P08 P06 P04 P02

008 DG
P05 RIGHT TURN SIGNAL SWITCH OUTPUT (TO LOAD MOD)
HIGH-1 YE P06 LEFT TURN SIGNAL SWITCH OUTPUT (TO LOAD MOD)
GND5-3 BK/WH P07 HORN SWITCH POWER INPUT
004 VT/OG P08 HORN SWITCH OUTPUT POWER
PIN FUNCTION P09 MODE SWITCH OUTPUT
003 VT/WH
P1 NEUTRAL SWITCH OUTPUT (TO LOAD MOD) P10 CLUTCH SWITCH OUTPUT (TO LOAD MOD)
P2

ACCF-4 BN/PK
P1 P2 GSS 017 GY/DG
P1

019 BK/PK 007 WH/BK

IN GEAR
002 DB/YE
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
NEUTRAL
LOW
SPLICE_HIGH HEADLIGHT HIGH
PIN FUNCTION ENGPWR-4 VT/PK HIGH-1 YE
3

1 VEHICLE SPEED SENSOR GROUND FREE

1 2 3

HIGH-3 YE 1 2 HIGH-2 YE
VSS E232 DG/BN
2

2 VEHICLE SPEED SENSOR OUTPUT LEFT

3 VEHICLE SPEED SENSOR POWER GND3-6 BK/WH TURN PUSH
1

RIGHT
THROTTLE_BODY FREE
E203 OG/YE
HORN
1 2 3 4 5 6

PIN FUNCTION
E220 VT/RD PUSH
1 ETC MOTOR (-)
C09-1 PK/RD FREE
2
3
TPS SIGNAL RETURN
TPS +3.3V REFERENCE E138 BN/DB MODE PUSH
SPLICE_GND5
4 ETC MOTOR (+) E105 BN/WH GND5-3 BK/WH GND5-4 BK/WH FREE
5
6
THROTTLE POSITION SENSOR 2 SIGNAL
THROTTLE POSITION SENSOR 1 SIGNAL
C09-2 YE GND5-2 BK/WH
GND5-1 BK/WH
1 2 GND5-5 BK/WH
GND5-6 BK/WH
CLUTCH PUSH
GND5-7 BK/WH

FRONT_O2 PIN FUNCTION

PIN FUNCTION E205 BG/WH RH_CONTROL P1 RUN/STOP SWITCH GROUND
A B C D

P2 ECM RUN/STOP SWITCH INPUT

A FRONT O2 SENSOR HEATER POWER E202 GY/DB P3 START SWITCH GROUND
B FRONT HEATED OXYGEN SENSOR (HO2) CONTROL 2 E239 GY/YE

P6 P5 P4 P3 P2 P1
GND5-7 BK/WH P4 START SWITCH OUTPUT (TO LOAD MOD)
C FRONT HEATED OXYGEN (HO2) SENSOR SIGNAL 2 IGNSW-4 PK
E123 RD/BK P5 FRONT BRAKE SWITCH GROUND
D FRONT HEATED OXYGEN (HO2) SENSOR RETURN 1
P6 FRONT BRAKE SWITCH OUTPUT (TO LOAD MOD)
GND5-4 BK/WH
P1 P2 P3 P4 P5 P6
001 YE/WH
REAR_O2 SPLICE_ACCR GND5-5 BK/WH RUN/STOP
STOP
PIN FUNCTION E207 BG RUN
A B C D

005 YE/VT
A REAR O2 SENSOR HEATER POWER E230 GY/RD ACCR-4 BN/PK 1 2 ACCR-1 BN/PK FREE
B REAR HEATED OXYGEN (HO2) SENSOR CONTROL 1 E246 GY/WH ACCR-5 BN/PK ACCR-2 BN/PK START PUSH
C REAR HEATED OXYGEN (HO2) SENSOR SIGNAL 1 IGNSW-5 PK SPLICE_GND1 ACC-04 BN/PK ACCR-3 BN/PK
D REAR HEATED OXYGEN (HO2) SENSOR RETURN 2 ACCF-1 BN/PK FREE
GND1-4 BK
GND1-3 BK 2 1
GND1-2 BK
GND1-1 BK BRAKE PUSH

FRONT_INJECTOR

P6 P5 P4 P3 P2 P1
C08-2 YE/GN
PIN FUNCTION PIN FUNCTION
1 ENGPWR-6 VT/PK
1 FRONT FUEL INJECTOR POWER C08-3 YE/BK P1 PEDAL POSITION SENSOR 2 SIGNAL
2 FRONT FUEL INJECTOR DRIVER 2 2 E243 WH/GY P2 PEDAL POSITION SENSOR 2 RETURN
C08-1 YE/RD
C07-2 WH/GN
ETC_GRIP P3 PEDAL POSITON SENSOR 2 +5V SUPPLY
P4 PEDAL POSITION SENSOR 1 SIGNAL
C07-3 WH/BK P5 PEDAL POSITION SENSOR 1 RETURN
REAR_INJECTOR C07-1 WH/RD
P6 PPS 1 +5V REFERENCE
PIN FUNCTION
1 ENGPWR-5 VT/PK
1 REAR FUEL INJECTOR POWER
2 REAR FUEL INJECTOR DRIVER 1 2 E244 WH/DB

SPLICE_ACCF ACCR-3 BN/PK ACC_SW_PWR

1
C05-1 RD ACCF-1 BN/PK 1 2 ACCF-4 BN/PK
1

PIN FUNCTION
1 FRONT COIL POWER COIL_FRONT C05-2 BK
ACCF-2 BN/PK ACCF-5 BN/PK
2

ACCF-3 BN/PK ACCF-6 BN/PK

2 FRONT COIL GROUND
3 FRONT COIL SIGNAL 2 C05-3 WH
SPEEDOMETER
3

C03-1 YE

15 13 11 09 07 05 03 01
C03-2 DG

16 14 12 10 08 06 04 02
C05-4 SHLD
ACCF-5 BN/PK
IGNBRK-2 OG PIN FUNCTION
PIN FUNCTION C04-1 RD GND5-6 BK/WH 01 SPEEDOMETER CAN HIGH
1

8 7 6 5 4 3 2 1
1 REAR COIL POWER 02 SPEEDOMETER CAN LOW
COIL_REAR

16 15 14 13 12 11 10
C04-2 BK
2

2 REAR COIL GROUND 03 SPEEDOMETER SWITCHED POWER

HIGH-2 YE
3 REAR COIL SIGNAL 1 04 SPEEDOMETER CONSTANT POWER
C04-3 WH
3

05 SPEEDOMETER GROUND
023 BK/BN
C04-4 SHLD SPLICE_IGNSW 08 HIGH BEAM INDICATOR INPUT
IGNSW-4 PK 10 OIL PRESSURE SWITCH OUTPUT
SPLICE_GND4 IGNSW-8 PK IGNSW-6 PK 007 WH/BK
C05-2 BK FUELSND-3 BK/DG 12 MODE SWITCH OUTPUT
IGNSW-3 PK 1 2 IGNSW-5 PK
C04-2 BK 1 2 GND4-1 BK IGNSW-1 PK 13 FUEL LEVEL SENSOR SIGNAL
IGNSW-7 PK
IGNSW-2 PK
PIN FUNCTION E104 BN/GN
4 3 2 1

1 TMAP SENSOR SIGNAL RETURN E227 OG/DG

2 TMAP INTAKE AIR TEMPERATURE SIGNAL TMAP E223 BN/PK IGNITION_SW P1 P2 P3 P4
3 TMAP SENSOR +5V SUPPLY
E219 OG/BN
OFF

P4 P3 P2 P1
4 TMAP SENSOR MANIFOLD ABSOLUTE PRESSURE SIGNAL IGNBRK-3 OG
IGNSW-1 PK
ON
IGNBRK-4 OG
ACC
ACCR-1 BN/PK
SPLICE_FPPWR
E208 OG/BK FPPWR-2 VT/YE PIN FUNCTION
1

PIN FUNCTION
1 ENGINE COOLANT TEMPERATURE SENSOR RETURN ECT E215 OG/DB
FPPWR-3 VT/YE 1 2 FPPWR-1 VT/YE P1
P2
IGNITION SWITCH ON INPUT
IGNITION SWITCH ON OUTPUT
2

2 ENGINE COOLANT TEMPERATURE SENSOR SIGNAL P3 IGNITION ACC INPUT

SPLICE_GND2
P4 IGNITION SWITCH ACC OUTPUT
GND2-3 BK
GND2-1 BK 1 2 GND2-4 BK
GND2-5 BK
GND2-2 BK

PIN FUNCTION C06-1 RD

FUEL_PUMP
3 2 1

1
2
CRANKSHAFT POSITION SENSOR POSITIVE SIGNAL
CPS NEGATIVE SIGNAL CPS C06-2 BK
PIN FUNCTION
3 CRANK POSITION SENSOR SHIELD C06-3 SHLD
1 FUEL LEVEL SENSOR SIGNAL RETURN
FUELSND-2 BK/DG E206 BK/BU

4 3
2 1
FPPWR-2 VT/YE GND2-3 BK 2 FUEL PUMP GROUND
3 FUEL SENDER OUTPUT
4 FUEL PUMP POWER

PIN FUNCTION E235 DB/BK

PURGE
1

1 CANISTER PURGE VALVE (CPV) CONTROL

FPPWR-3 VT/YE
DIAGNOSTIC
2

2 PURGE VALVE POWER ENGBRK-3 VT

HGF EDCB A
ACCR-2 BN/PK
PIN FUNCTION

HGF E
DCB A
016 BK A DIAGNOSTIC CONNECTOR CONSTANT POWER
SPLICE_CAN_L B DIAGNOSTIC CONNECTOR SWITCHED POWER
D DIAGNOSTIC CONNECTOR GROUND
OIL_PRESSURE C02-2 DG
P1

023 BK/BN C03-2 DG 1 2 G DIAGNOSTIC CONNECTOR CAN LOW

C01-2 DG C02-2 DG C02-1 YE
SPLICE_CAN_H H DIAGNOSTIC CONNECTOR CAN HIGH
C03-1 YE
C01-1 YE 1 2 C02-1 YE
012 OG/RD
COOLING_FAN

A B
GND2-4 BK

ECM_1
PIN FUNCTION PIN FUNCTION GND2-5 BK

2
103 PEDAL POSITION SENSOR 2 RETURN 125 PEDAL POSITON SENSOR 2 +5V SUPPLY
104 TMAP SENSOR SIGNAL RETURN 126 TIP-OVER SENSOR +5V REF SPLICE_ENGPWR
GND3-2 BK/WH
SPLICE_GND3
GND3-6 BK/WH 013 DG/WH
START_SOLENOID
ENGPWR-5 VT/PK

1
105 TPS SIGNAL RETURN 131 COOLING FAN RELAY CONTROL
1 2 ENGPWR-6 VT/PK GND3-5 BK/WH 1 2 GND3-1 BK/WH
106 PEDAL POSITION SENSOR 1 RETURN 132 ECM CAN HIGH GND3-4 BK/WH
107 START SWITCH OUTPUT (TO ECM) 138 TPS +3.3V REFERENCE C05-1 RD ENGPWR-4 VT/PK
C04-1 RD GND3-3 BK/WH
108 RIGHT TURN SIGNAL SWITCH OUTPUT (TO ECM) 140 HEADLIGHT RELAY CONTROL
ENGPWR-2 VT/PK ENGPWR-1 VT/PK
111 PEDAL POSITION SENSOR 2 SIGNAL 141 STARTER SOLENOID RELAY CONTROL ENGPWR-3 VT/PK ENGPWR-7 VT/PK
115 ENGINE RELAY CONTROL 142 FUEL PUMP RELAY CONTROL
116 ECM SWITCHED POWER INPUT 144 ECM CAN LOW
119 CLUTCH SWITCH OUTPUT (TO ECM) 151 STOP LAMP POWER OUTPUT
120 LEFT TURN SIGNAL SWITCH OUTPUT (TO ECM) 153 ECM POWER GROUND 2
121 PEDAL POSITION SENSOR 1 SIGNAL 154 ECM POWER GROUND 3
123 ECM RUN/STOP SWITCH INPUT 155 ECM SWITCHED POWER 2
143

115

243

215

E115 GY/BK E243 WH/GY E215 OG/DB

124 FRONT BRAKE SWITCH OUTPUT (TO ECM) 156 ECM SWITCHED POWER 2
122

114

222

214

SPLICE_MFUSE
NUMBER CORESPOND TO CONNECTOR

NUMBER CORESPOND TO CONNECTOR

124

113

224

213

E124 YE/VT E224 DB/RD C06-1 RD MFUSE-2 RD 1 2 MFUSE-1 RD

MFUSE-3 RD
CAVITY NUMBER (IE. 110=CAVITY 10)

CAVITY NUMBER (IE. 210=CAVITY 10)

142

116

242

216

E142 GY IGNSW-6 PK
ACC-04 BN/PK

MFUSE-2 RD

MFUSE-3 RD
107

105

207

205

E107 YE/WH E105 BN/WH E207 BG E205 BG/WH

(MODULE A/LEFT EXIT ON ECM)

ECM 2

ENGBRK-3 VT
ENGBRK-4 VT
LAST 2 DIGITS OF 100 SERIES

LAST 2 DIGITS OF 200 SERIES

130

156

230

256

ENGPWR-2 VT/PK E230 GY/RD C04-3 WH

PIN FUNCTION
132

155

232

255

C01-1 YE ENGPWR-3 VT/PK E232 DG/BN

201 CPS NEGATIVE SIGNAL
123

138

223

238

202 FRONT HEATED OXYGEN (HO2) SENSOR SIGNAL 2 E123 RD/BK E138 BN/DB E223 BN/PK

ENGPWR-1 VT/PK
203 THROTTLE POSITION SENSOR 1 SIGNAL
144

137

244

237

C01-2 DG E244 WH/DB

SPLICE_ENGBRK
204 TIP-OVER SENSOR SIGNAL RETURN

HEADLIGHT

FUEL PUMP
D5 D9 C9 BUS1A BUS1B BUS2
131

125

231

225

IGNITION

BREAKER

BREAKER

012 OG/RD BREAKER

E131 BK/OG C08-1 YE/RD
FUTURE
C05-4 SHLD

205 FRONT HEATED OXYGEN (HO2) SENSOR RETURN 2

C06-3 SHLD
C04-4 SHLD

15 AMP

ENGINE
E140 DG/DB 15 AMP

E115 GY/BK 20 AMP

15 AMP

E131 BK/OG 20 AMP

BREAKER
FUSE

FUSE

FAN
1 2
206 FUEL LEVEL SENSOR SIGNAL RETURN
110

126

210

226

ENGPWR-7 VT/PK
E126 BN/GN C07-1 WH/RD
207 REAR HEATED OXYGEN (HO2) SENSOR RETURN 1

FPPWR-1 VT/YE
106

120

206

220

C07-3 WH/BK E120 VT/WH E206 BK/BU E220 VT/RD

ENGBRK-4 VT
208 ENGINE COOLANT TEMPERATURE SENSOR RETURN
D4 D8 C8 C6 C4 D6
IGNSW-7 PK

IGNSW-2 PK

IGNSW-3 PK

E141 WH/YE
210 PPS 1 +5V REFERENCE

013 DG/WH
133

149

SPLICE_SHLD_GND

233

249

E233 BK/PK

024 YE/PK

ENGBRK-2 VT
212 FRONT LEFT TS LAMP OUTPUT

ENGBRK-5 VT

E142 GY
ENGBRK-1 VT
127

117

227

217

FUELSND-1 BK/DG

E227 OG/DG E217 BK/YE

MFUSE-1 RD
213 CRANKSHAFT POSITION SENSOR POSITIVE SIGNAL

011 OG
010 VT/BK
009 YE
IGNBRK-2 OG

IGNBRK-1 OG

215 ENGINE COOLANT TEMPERATURE SENSOR SIGNAL

139

118

239

218

E239 GY/YE E218 OG/WH

1 2

217 REAR BRAKE PRESSURE SWITCH OUTPUT (TO ECM)

020 RD

021 RD

021 RD
020 RD
014 RD
145

104

245

204

E104 BN/GN E204 BN/YE

014 RD
218 TIP-OVER SENSOR (TOS) SIGNAL

015 BK
219 TMAP SENSOR MANIFOLD ABSOLUTE PRESSURE SIGNAL
109

101

209

201

C06-2 BK
022 BK

220 THROTTLE POSITION SENSOR 2 SIGNAL A3 B2 B3 A2 A7 B6 B7 A6 A5 B4 B5 A4 A9 B8 B9 A8 C3 D2 D3 C2

140

119

018 BK

240

219

223 TMAP SENSOR +5V SUPPLY E140 DG/DB E119 DB/YE E219 OG/BN
SPLICE_IGNBRK
SPLICE_FUELSND

224 FRONT RIGHT TS LAMP OUTPUT

146

102

246

202

E246 GY/WH E202 GY/DB A B 1 1

227 TMAP INTAKE AIR TEMPERATURE SIGNAL
P1 P2 P3
128

103

228

203

GND3-1 BK/WH

GND5-1 BK/WH

C08-3 YE/BK
2 1

E203 OG/YE
1 2

230 REAR HEATED OXYGEN (HO2) SENSOR SIGNAL 1

1
GND4-1 BK

232 VEHICLE SPEED SENSOR OUTPUT

111

121

211

221

C08-2 YE/GN C07-2 WH/GN 303 SERIES RELAY 303 SERIES RELAY 303 SERIES RELAY 303 SERIES RELAY 303 SERIES RELAY
GND1-1 BK

GND2-1 BK

233 NEUTRAL SWITCH OUTPUT (TO ECM)

- +
136

108

236

208

235 CANISTER PURGE VALVE (CPV) CONTROL E108 VT/OG E236 DB E208 OG/BK HEADLIGHT RELAY ENGINE RELAY FUEL PUMP RELAY FAN RELAY STARTER RELAY
018 BK
022 BK

016 BK
015 BK

IGNBRK-4 OG
IGNBRK-3 OG

236 REAR LEFT TS LAMP GROUND OUTPUT

FUELSND-3 BK/DG
FUELSND-2 BK/DG
148

154

248

254

GND3-5 BK/WH E248 DB/RD C05-3 WH

239 FRONT HEATED OXYGEN SENSOR (HO2) CONTROL 2

VOLT_REG
BATT_POS
MAIN_FUSE
ECM_1

SOLENOID
TOP VIEW
135

235

E235 DB/BK
240 SECONDARY AIR GROUND OUTPUT
ECM 2
BATT_NEG

243 FRONT FUEL INJECTOR DRIVER 2

147

247

GND3-3 BK/WH
244 REAR FUEL INJECTOR DRIVER 1
153

253

GND3-4 BK/WH 1
134

234

246 REAR HEATED OXYGEN (HO2) SENSOR CONTROL 1

152

252

247 ECM ELECTRONIC GROUND C09-2 YE

141

241

E141 WH/YE
248 REAR RIGHT TS LAMP GROUND OUTPUT
151

251

E151 PK/DB C09-1 PK/RD

129

229

250 ECM POWER GROUND 1

150

250

251 ETC MOTOR (+) GND3-2 BK/WH

112

212

E212 DB
252 ETC MOTOR (-)
254
256
FRONT COIL SIGNAL 2
REAR COIL SIGNAL 1
CHASSIS_GND
(COVER REMOVED)
 SCHEMATIC CABLE/WIRE TERMINATION TABLE SCHEMATIC CABLE/WIRE TERMINATION TABLE
HARNESS-CHASSIS,TERMINATION TABLE CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION INDEX CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION INDEX
FILE NAME: 2412549_Rev01.RSD
WIRE COLOR LEGEND
001 TXL 0.35 YE/WH LOAD_MODULE_IN P1 RH_CONTROL P4 START SWITCH OUTPUT (TO LOAD MOD) 1 ENGPWR-2 TXL 0.8 VT/PK ECM_1 156 SPLICE_ENGPWR 1 ECM SWITCHED POWER 2 110
BG
BK
BEIGE (TAN)
BLACK
E = ENGINE GROUND 002 TXL 0.35 DB/YE LH_CONTROL P10 LOAD_MODULE_IN P2 CLUTCH SWITCH OUTPUT (TO LOAD MOD) 2 ENGPWR-3 TXL 0.8 VT/PK ECM_1 155 SPLICE_ENGPWR 1 ECM SWITCHED POWER 2 111
003 TXL 0.35 VT/WH LH_CONTROL P06 LOAD_MODULE_IN P3 LEFT TURN SIGNAL SWITCH OUTPUT (TO LOAD MOD) 3 ENGPWR-4 TXL 0.5 VT/PK VSS 3 SPLICE_ENGPWR 2 VEHICLE SPEED SENSOR POWER 112
BU LIGHT BLUE
DB DARK BLUE
C = CHASSIS GROUND
BN BROWN
GY
GN
GRAY
LIGHT GREEN
004 TXL 0.35 VT/OG LH_CONTROL P05 LOAD_MODULE_IN P4 RIGHT TURN SIGNAL SWITCH OUTPUT (TO LOAD MOD) 4 ENGPWR-5 TXL 0.5 VT/PK REAR_INJECTOR 1 SPLICE_ENGPWR 2 REAR FUEL INJECTOR POWER 113
NC = SWITCH NORMALLY CLOSED
DG
OG
DARK GREEN
ORANGE NO = SWITCH NORMALLY OPEN
005 TXL 0.35 YE/VT RH_CONTROL P6 LOAD_MODULE_IN P5 FRONT BRAKE SWITCH OUTPUT (TO LOAD MOD) 5 ENGPWR-6 TXL 0.5 VT/PK FRONT_INJECTOR 1 SPLICE_ENGPWR 2 FRONT FUEL INJECTOR POWER 114
006 TXL 0.35 BK/YE LOAD_MODULE_IN P6 BRAKE_SW 2 REAR BRAKE PRESSURE SWITCH OUTPUT (TO LOAD MOD) 6 ENGPWR-7 TXL 0.5 VT/PK FUSEBLOCK A5 SPLICE_ENGPWR 2 FUEL PUMP RELAY COIL POWER 115
PK PINK
RD RED
VT VIOLET (PURPLE) HARNESS: 2412549_Rev01-02
WH
YE
WHITE
YELLOW
007 TXL 0.5 WH/BK LH_CONTROL P09 SPEEDOMETER 12 MODE SWITCH OUTPUT 7 FPPWR-1 TXL 0.8 VT/YE FUSEBLOCK A4 SPLICE_FPPWR 2 FUEL PUMP / IGNITION COIL RELAY OUTPUT 116
SHEET NO. 2 OF 2
CL CLEAR
TWO WIRE COLORS ARE SHOWN 008 TXL 1.0 DG LH_CONTROL P02 HEADLIGHT P3 LOW BEAM SWITCH OUTPUT 8 FPPWR-2 TXL 0.8 VT/YE FUEL_PUMP 4 SPLICE_FPPWR 2 FUEL PUMP POWER 117
009 TXL 2.0 YE FUSEBLOCK C8 FUSEBLOCK B3 HEADLIGHT CIRCUIT BREAKER OUTPUT 9 118
WITH MAIN/TRACE COLORS.
FPPWR-3 TXL 0.35 VT/YE PURGE 2 SPLICE_FPPWR 1 PURGE VALVE POWER
DRAWN BY: B.LANGLOIS 03-JAN-14
EXAMPLE:RD/YE = RED WITH
YELLOW TRACE.
010 TXL 0.8 VT/BK FUSEBLOCK C4 FUSEBLOCK B5 FUEL PUMP/COIL FUSE OUTPUT 10 FUELSND-1 TXL 0.5 BK/DG FUSEBLOCK D4 SPLICE_FUELSND 2 FUEL SENDER RESISTOR OUTPUT 119
011 TXL 1.0 OG FUSEBLOCK D6 FUSEBLOCK B9 COOLING FAN CIRCUIT BREAKER OUTPUT 11 FUELSND-2 TXL 0.35 BK/DG FUEL_PUMP 3 SPLICE_FUELSND 1 FUEL SENDER OUTPUT 120
012 TXL 2.0 OG/RD FUSEBLOCK A8 COOLING_FAN B COOLING FAN RELAY OUTPUT 12 FUELSND-3 TXL 0.35 BK/DG SPEEDOMETER 13 SPLICE_FUELSND 1 FUEL LEVEL SENSOR SIGNAL 121
013 TXL 0.8 DG/WH FUSEBLOCK C2 START_SOLENOID 1 STARTER RELAY OUTPUT POWER 13 GND1-1 TXL 2.0 BK CHASSIS_GND 1 SPLICE_GND1 1 POWER GROUND 1 122
014 TXL 3.0 RD VOLT_REG P3 SOLENOID 1 VOLTAGE REGULATOR POSITIVE 14 GND1-2 TXL 0.35 BK REAR_LIGHTING A SPLICE_GND1 1 LICENSE PLATE LIGHT GROUND 123
015 TXL 3.0 BK VOLT_REG P1 CHASSIS_GND 1 VOLTAGE REGULATOR GROUND 15 GND1-3 TXL 1.0 BK HEADLIGHT P2 SPLICE_GND1 2 HEADLIGHT GROUND 124
016 TXL 0.8 BK DIAGNOSTIC D CHASSIS_GND 1 DIAGNOSTIC CONNECTOR GROUND 16 GND1-4 TXL 0.5 BK PSN_LAMP_NEG 1 SPLICE_GND1 2 FRONT POSITION LAMP GROUND 125
017 TXL 0.8 GY/DG LH_CONTROL P08 HORN_POS 1 HORN SWITCH OUTPUT POWER 17 GND2-1 TXL 3.0 BK CHASSIS_GND 1 SPLICE_GND2 1 POWER GROUND 2 126
018 TXL 0.5 BK CHASSIS_GND 1 SPLICE_SHLD_GND 1 ECM SHIELD GROUND 18 GND2-2 TXL 0.35 BK HORN_NEG 1 SPLICE_GND2 2 HORN GROUND 127
019 TXL 0.35 BK/PK GSS P1 LOAD_MODULE_IN P7 NEUTRAL SWITCH OUTPUT (TO LOAD MOD) 19 GND2-3 TXL 0.8 BK FUEL_PUMP 2 SPLICE_GND2 2 FUEL PUMP GROUND 128
020 TXL 3.0 RD MAIN_FUSE B SOLENOID 1 MAIN FUSE INPUT 20 GND2-4 TXL 2.0 BK COOLING_FAN A SPLICE_GND2 2 COOLING FAN GROUND 129
021 STX 13.0 RD BATT_POS 1 SOLENOID 1 BATTERY POSITIVE 21 GND2-5 TXL 0.8 BK START_SOLENOID 2 SPLICE_GND2 1 STARTER SOLENOID GROUND 130
022 STX 13.0 BK BATT_NEG 1 CHASSIS_GND 1 BATTERY GROUND 22 GND3-1 TXL 1.0 BK/WH CHASSIS_GND 1 SPLICE_GND3 2 CLEAN GROUND 1 131
023 TXL 0.5 BK/BN SPEEDOMETER 10 OIL_PRESSURE P1 OIL PRESSURE SWITCH OUTPUT 23 GND3-2 TXL 0.8 BK/WH ECM 2 250 SPLICE_GND3 1 ECM POWER GROUND 1 132
024 TXL 1.0 YE/PK FUSEBLOCK A2 LH_CONTROL P01 HEADLIGHT RELAY OUTPUT 24 GND3-3 TXL 0.8 BK/WH ECM 2 247 SPLICE_GND3 1 ECM ELECTRONIC GROUND 133
ACC-04 TXL 0.5 BN/PK FUSEBLOCK D5 SPLICE_ACCR 1 FUEL SENDER RESISTOR POWER 25 GND3-4 TXL 0.8 BK/WH ECM_1 153 SPLICE_GND3 1 ECM POWER GROUND 2 134
ACCF-1 TXL 0.5 BN/PK SPLICE_ACCR 1 SPLICE_ACCF 1 ACCR FEED 26 GND3-5 TXL 0.8 BK/WH ECM_1 154 SPLICE_GND3 1 ECM POWER GROUND 3 135
ACCF-2 TXL 0.35 BN/PK FRONT_RH_TS 1 SPLICE_ACCF 1 FRONT RIGHT TURN SIGNAL POWER 27 GND3-6 TXL 0.5 BK/WH VSS 1 SPLICE_GND3 2 VEHICLE SPEED SENSOR GROUND 136
ACCF-3 TXL 0.35 BN/PK FRONT_LH_TS 1 SPLICE_ACCF 1 FRONT LEFT TURN SIGNAL POWER 28 GND4-1 TXL 0.5 BK CHASSIS_GND 1 SPLICE_GND4 2 POWER GROUND 4 137
ACCF-4 TXL 0.5 BN/PK LH_CONTROL P07 SPLICE_ACCF 2 HORN SWITCH POWER INPUT 29 GND5-1 TXL 0.5 BK/WH CHASSIS_GND 1 SPLICE_GND5 1 DIGITAL GROUND 5 138
ACCF-5 TXL 0.35 BN/PK SPEEDOMETER 03 SPLICE_ACCF 2 SPEEDOMETER SWITCHED POWER 30 GND5-2 TXL 0.5 BK/WH BRAKE_SW 1 SPLICE_GND5 1 REAR BRAKE SWITCH GROUND 139
ACCF-6 TXL 0.5 BN/PK PSN_LAMP_POS 1 SPLICE_ACCF 2 FRONT POSITION LAMP POWER 31 GND5-3 TXL 0.5 BK/WH LH_CONTROL P04 SPLICE_GND5 1 LH CONTROL SWITCH GROUND 140
ACCR-1 TXL 1.0 BN/PK IGNITION_SW P4 SPLICE_ACCR 2 IGNITION SWITCH ACC OUTPUT 32 GND5-4 TXL 0.5 BK/WH RH_CONTROL P3 SPLICE_GND5 2 START SWITCH GROUND 141
ACCR-2 TXL 0.8 BN/PK DIAGNOSTIC B SPLICE_ACCR 2 DIAGNOSTIC CONNECTOR SWITCHED POWER 33 GND5-5 TXL 0.5 BK/WH RH_CONTROL P5 SPLICE_GND5 2 FRONT BRAKE SWITCH GROUND 142
ACCR-3 TXL 0.5 BN/PK ACC_SW_PWR 1 SPLICE_ACCR 2 ACCESSORY CONNECTOR SWITCHED POWER 34 GND5-6 TXL 0.5 BK/WH SPEEDOMETER 05 SPLICE_GND5 2 SPEEDOMETER GROUND 143
ACCR-4 TXL 0.5 BN/PK REAR_LIGHTING E SPLICE_ACCR 1 TAIL LIGHT POWER 35 GND5-7 TXL 0.5 BK/WH RH_CONTROL P1 SPLICE_GND5 2 RUN/STOP SWITCH GROUND 144
ACCR-5 TXL 0.5 BN/PK REAR_LIGHTING C SPLICE_ACCR 1 LICENSE PLATE LIGHT POWER 36 HIGH-1 TXL 1.0 YE LH_CONTROL P03 SPLICE_HIGH 1 HIGH BEAM SWITCH OUTPUT 145
C01-1 TXL 0.5TP YE ECM_1 132 SPLICE_CAN_H 1 ECM CAN HIGH 37 HIGH-2 TXL 0.35 YE SPEEDOMETER 08 SPLICE_HIGH 2 HIGH BEAM INDICATOR INPUT 146
C01-2 TXL 0.5TP DG ECM_1 144 SPLICE_CAN_L 1 ECM CAN LOW 38 HIGH-3 TXL 1.0 YE HEADLIGHT P1 SPLICE_HIGH 1 HEADLIGHT HIGH BEAM POWER 147
C02-1 TXL 0.5TP YE DIAGNOSTIC H SPLICE_CAN_H 2 DIAGNOSTIC CONNECTOR CAN HIGH 39 IGNBRK-1 TXL 1.0 OG FUSEBLOCK D8 SPLICE_IGNBRK 1 IGNITION BREAKER OUTPUT 148
C02-2 TXL 0.5TP DG DIAGNOSTIC G SPLICE_CAN_L 2 DIAGNOSTIC CONNECTOR CAN LOW 40 IGNBRK-2 TXL 0.35 OG SPEEDOMETER 04 SPLICE_IGNBRK 1 SPEEDOMETER CONSTANT POWER 149
C03-1 TXL 0.5TP YE SPEEDOMETER 01 SPLICE_CAN_H 2 SPEEDOMETER CAN HIGH 41 IGNBRK-3 TXL 1.0 OG IGNITION_SW P1 SPLICE_IGNBRK 2 IGNITION SWITCH ON INPUT 150
C03-2 TXL 0.5TP DG SPEEDOMETER 02 SPLICE_CAN_L 2 SPEEDOMETER CAN LOW 42 IGNBRK-4 TXL 1.0 OG IGNITION_SW P3 SPLICE_IGNBRK 2 IGNITION ACC INPUT 151
C04-1 TXL 0.5 RD COIL_REAR 1 SPLICE_ENGPWR 1 REAR COIL POWER 43 IGNSW-1 TXL 1.0 PK IGNITION_SW P2 SPLICE_IGNSW 2 IGNITION SWITCH ON OUTPUT 152
C04-2 TXL 0.5 BK COIL_REAR 2 SPLICE_GND4 1 REAR COIL GROUND 44 IGNSW-2 TXL 0.5 PK FUSEBLOCK A9 SPLICE_IGNSW 1 FAN RELAY COIL POWER 153
C04-3 TXL 0.5 WH ECM 2 256 COIL_REAR 3 REAR COIL SIGNAL 1 45 IGNSW-3 TXL 0.5 PK FUSEBLOCK C3 SPLICE_IGNSW 1 STARTER RELAY COIL POWER 154
C04-4 SHLD 0.5 SHLD NC SPLICE_SHLD_GND 2 REAR COIL SHIELD 46 IGNSW-4 TXL 0.35 PK FRONT_O2 A SPLICE_IGNSW 2 FRONT O2 SENSOR HEATER POWER 155
C05-1 TXL 0.5 RD COIL_FRONT 1 SPLICE_ENGPWR 1 FRONT COIL POWER 47 IGNSW-5 TXL 0.35 PK REAR_O2 A SPLICE_IGNSW 2 REAR O2 SENSOR HEATER POWER 156
C05-2 TXL 0.5 BK COIL_FRONT 2 SPLICE_GND4 1 FRONT COIL GROUND 48 IGNSW-6 TXL 0.5 PK ECM_1 116 SPLICE_IGNSW 2 ECM SWITCHED POWER INPUT 157
C05-3 TXL 0.5 WH ECM 2 254 COIL_FRONT 3 FRONT COIL SIGNAL 2 49 IGNSW-7 TXL 0.5 PK FUSEBLOCK A3 SPLICE_IGNSW 1 HEADLIGHT RELAY COIL POWER 158
C05-4 SHLD 0.5 SHLD NC SPLICE_SHLD_GND 2 FRONT COIL SHIELD 50 IGNSW-8 TXL 0.35 PK LOAD_MODULE_PWR 1 SPLICE_IGNSW 1 LOAD MODULE POWER 159
C06-1 TXL 0.35 RD ECM 2 213 CPS 1 CRANKSHAFT POSITION SENSOR POSITIVE SIGNAL 51 MFUSE-1 TXL 3.0 RD MAIN_FUSE A SPLICE_MFUSE 2 MAIN FUSE OUTPUT 160
C06-2 TXL 0.35 BK ECM 2 201 CPS 2 CPS NEGATIVE SIGNAL 52 MFUSE-2 TXL 3.0 RD FUSEBLOCK D9 SPLICE_MFUSE 1 FUSEBOX BUS D INPUT 161
C06-3 SHLD 0.35 SHLD CPS 3 SPLICE_SHLD_GND 2 CRANK POSITION SENSOR SHIELD 53 MFUSE-3 TXL 3.0 RD FUSEBLOCK C9 SPLICE_MFUSE 1 FUSEBOX BUS D INPUT 162
C07-1 TXL 0.35TT WH/RD ECM 2 210 ETC_GRIP P6 PPS 1 +5V REFERENCE 54 01/06/14
C07-2 TXL 0.35TT WH/GN ECM_1 121 ETC_GRIP P4 PEDAL POSITION SENSOR 1 SIGNAL 55
C07-3 TXL 0.35TT WH/BK ECM_1 106 ETC_GRIP P5 PEDAL POSITION SENSOR 1 RETURN 56
C08-1 TXL 0.35TT YE/RD ECM_1 125 ETC_GRIP P3 PEDAL POSITON SENSOR 2 +5V SUPPLY 57
C08-2 TXL 0.35TT YE/GN ECM_1 111 ETC_GRIP P1 PEDAL POSITION SENSOR 2 SIGNAL 58
C08-3 TXL 0.35TT YE/BK ECM_1 103 ETC_GRIP P2 PEDAL POSITION SENSOR 2 RETURN 59
C09-1 TXL 0.5TP PK/RD ECM 2 251 THROTTLE_BODY 4 ETC MOTOR (+) 60
C09-2 TXL 0.5TP YE ECM 2 252 THROTTLE_BODY 1 ETC MOTOR (-) 61
E104 TXL 0.5 BN/GN ECM_1 104 TMAP 1 TMAP SENSOR SIGNAL RETURN 62
E105 TXL 0.5 BN/WH ECM_1 105 THROTTLE_BODY 2 TPS SIGNAL RETURN 63
E107 TXL 0.35 YE/WH ECM_1 107 LOAD_MODULE_OUT P1 START SWITCH OUTPUT (TO ECM) 64
E108 TXL 0.35 VT/OG ECM_1 108 LOAD_MODULE_OUT P4 RIGHT TURN SIGNAL SWITCH OUTPUT (TO ECM) 65
E115 TXL 0.5 GY/BK ECM_1 115 FUSEBLOCK B6 ENGINE RELAY CONTROL 66
E119 TXL 0.35 DB/YE ECM_1 119 LOAD_MODULE_OUT P2 CLUTCH SWITCH OUTPUT (TO ECM) 67
E120 TXL 0.35 VT/WH ECM_1 120 LOAD_MODULE_OUT P3 LEFT TURN SIGNAL SWITCH OUTPUT (TO ECM) 68
E123 TXL 0.5 RD/BK ECM_1 123 RH_CONTROL P2 ECM RUN/STOP SWITCH INPUT 69
E124 TXL 0.35 YE/VT ECM_1 124 LOAD_MODULE_OUT P5 FRONT BRAKE SWITCH OUTPUT (TO ECM) 70
E126 TXL 0.35 BN/GN ECM_1 126 LOAD_MODULE_PWR 2 TIP-OVER SENSOR +5V REF 71
E131 TXL 0.5 BK/OG ECM_1 131 FUSEBLOCK B8 COOLING FAN RELAY CONTROL 72
E138 TXL 0.5 BN/DB ECM_1 138 THROTTLE_BODY 3 TPS +3.3V REFERENCE 73
E140 TXL 0.5 DG/DB ECM_1 140 FUSEBLOCK B2 HEADLIGHT RELAY CONTROL 74
E141 TXL 0.5 WH/YE ECM_1 141 FUSEBLOCK D2 STARTER SOLENOID RELAY CONTROL 75
E142 TXL 0.5 GY ECM_1 142 FUSEBLOCK B4 FUEL PUMP RELAY CONTROL 76
E151 TXL 0.35 PK/DB ECM_1 151 REAR_LIGHTING B STOP LAMP POWER OUTPUT 77
E202 TXL 0.35 GY/DB ECM 2 202 FRONT_O2 C FRONT HEATED OXYGEN (HO2) SENSOR SIGNAL 2 78
E203 TXL 0.5 OG/YE ECM 2 203 THROTTLE_BODY 6 THROTTLE POSITION SENSOR 1 SIGNAL 79
E204 TXL 0.35 BN/YE ECM 2 204 LOAD_MODULE_IN P8 TIP-OVER SENSOR SIGNAL RETURN 80
E205 TXL 0.35 BG/WH ECM 2 205 FRONT_O2 D FRONT HEATED OXYGEN (HO2) SENSOR RETURN 2 81
E206 TXL 0.35 BK/BU ECM 2 206 FUEL_PUMP 1 FUEL LEVEL SENSOR SIGNAL RETURN 82
E207 TXL 0.35 BG ECM 2 207 REAR_O2 D REAR HEATED OXYGEN (HO2) SENSOR RETURN 1 83
E208 TXL 0.5 OG/BK ECM 2 208 ECT 1 ENGINE COOLANT TEMPERATURE SENSOR RETURN 84
E212 TXL 0.35 DB ECM 2 212 FRONT_LH_TS 2 FRONT LEFT TS LAMP OUTPUT 85
E215 TXL 0.35 OG/DB ECM 2 215 ECT 2 ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 86
E217 TXL 0.35 BK/YE ECM 2 217 LOAD_MODULE_OUT P6 REAR BRAKE PRESSURE SWITCH OUTPUT (TO ECM) 87
E218 TXL 0.35 OG/WH ECM 2 218 LOAD_MODULE_OUT P8 TIP-OVER SENSOR (TOS) SIGNAL 88
E219 TXL 0.5 OG/BN ECM 2 219 TMAP 4 TMAP SENSOR MANIFOLD ABSOLUTE PRESSURE SIGNAL 89
E220 TXL 0.5 VT/RD ECM 2 220 THROTTLE_BODY 5 THROTTLE POSITION SENSOR 2 SIGNAL 90
E223 TXL 0.5 BN/PK ECM 2 223 TMAP 3 TMAP SENSOR +5V SUPPLY 91
E224 TXL 0.35 DB/RD ECM 2 224 FRONT_RH_TS 2 FRONT RIGHT TS LAMP OUTPUT 92
E227 TXL 0.5 OG/DG ECM 2 227 TMAP 2 TMAP INTAKE AIR TEMPERATURE SIGNAL 93
E230 TXL 0.35 GY/RD ECM 2 230 REAR_O2 C REAR HEATED OXYGEN (HO2) SENSOR SIGNAL 1 94
E232 TXL 0.5 DG/BN ECM 2 232 VSS 2 VEHICLE SPEED SENSOR OUTPUT 95
E233 TXL 0.35 BK/PK ECM 2 233 LOAD_MODULE_OUT P7 NEUTRAL SWITCH OUTPUT (TO ECM) 96
E235 TXL 0.35 DB/BK ECM 2 235 PURGE 1 CANISTER PURGE VALVE (CPV) CONTROL 97
E236 TXL 0.35 DB ECM 2 236 REAR_LIGHTING D REAR LEFT TS LAMP GROUND OUTPUT 98
E239 TXL 0.35 GY/YE ECM 2 239 FRONT_O2 B FRONT HEATED OXYGEN SENSOR (HO2) CONTROL 2 99
E243 TXL 0.5 WH/GY ECM 2 243 FRONT_INJECTOR 2 FRONT FUEL INJECTOR DRIVER 2 100
E244 TXL 0.5 WH/DB ECM 2 244 REAR_INJECTOR 2 REAR FUEL INJECTOR DRIVER 1 101
E246 TXL 0.35 GY/WH ECM 2 246 REAR_O2 B REAR HEATED OXYGEN (HO2) SENSOR CONTROL 1 102
E248 TXL 0.35 DB/RD ECM 2 248 REAR_LIGHTING F REAR RIGHT TS LAMP GROUND OUTPUT 103
ENGBRK-1 TXL 2.0 VT FUSEBLOCK C6 SPLICE_ENGBRK 1 ENGINE BREAKER OUTPUT 104
ENGBRK-2 TXL 2.0 VT FUSEBLOCK B7 SPLICE_ENGBRK 1 ENGINE RELAY POWER INPUT 105
ENGBRK-3 TXL 0.8 VT DIAGNOSTIC A SPLICE_ENGBRK 2 DIAGNOSTIC CONNECTOR CONSTANT POWER 106
ENGBRK-4 TXL 0.8 VT FUSEBLOCK D3 SPLICE_ENGBRK 2 STARTER RELAY INPUT POWER 107
ENGBRK-5 TXL 0.5 VT FUSEBLOCK A7 SPLICE_ENGBRK 1 ENGINE RELAY COIL POWER 108
ENGPWR-1 TXL 2.0 VT/PK FUSEBLOCK A6 SPLICE_ENGPWR 2 ENGINE RELAY OUTPUT POWER 109
01/06/14
Starting Circuit
Scout

RD

RD

RD
Fuse Box
A 1A D9

40A 15A D

20A Start C
Main Ignition
Engine Relay B
Fuse Breaker A
C2 D3 D2 C3 1 3 5 7 9

B C6 D8

DG/WH
OG

WH/YE
RD

VT

VT

PK
Battery RD
RD

Start 1 DG/WH
Solenoid 2 BK
RD

LH
P1 P2 P3 P4 P5

DB/YE P10
P6 P7 P8 P9 P10 Control
Starter

BK
BK/WH P1

RD/BK P2

BK/WH P3 P1 P2 P3 RH
P4 P5 P6
Control
YE/WH P4
P1 OG
BK/WH P5
Ignition P1 P2 P2 PK
Switch P4 P3
P3 OG

BK/PK P1
P1 P2 GSS
ECM 1
Top
12
48
36
24
58

View 19 DB/YE

41 WH/YE

23 RD/BK
49
37
25
13
1

ECM 1 7 YE/WH BN/YE P8

BK/PK P7 P1 P2 P3 P4
Load
Module In
DB/YE P2 P5 P6 P7 P8

ECM 2 YE/WH P1
ECM 2

33 PK/BK
13
25
37
49
1

4 BN/YE

18 OG/WH OG/WH P8
58
24
36
48
12

PK/BK P7
P4 P3 P2 P1 Load
P8 P7 P6 P5 Module Out
DB/YE P2

YE/WH P1
H
BK

/W
BK

Chassis
Ground
Engine Ignition
Scout

BN/GN 1
1 VT/PK
Front 1
Injector 2 2 WH/GY Engine OG/DG 2
TMAP
4 3 2 1
Relay BN/PK 3 Sensor
OG/BN 4

VT/PK
VT/PK
1 VT/PK VT/PK
Rear 1
Injector 2 2 WH/DB

RD
1 RD
Front 2 BK
RD 1
Coil
Ignition 3 2 1 3 WH
BK 2 3 2 1 CPS
SHLD SHLD 3

1 RD
Rear 2 BK
Coil
Ignition 3 2 1 3 WH

SHLD VT/PK 56 ECM 1

12
48
36
24
58
VT/PK 55

GY 42

Top

49
37
25
13
1
1 BK/BU View
2 BK BN/GN 4
Fuel 1 2
Pump 3 4 3 BK/DG
ECM 1
4 VT/YE
BK/DG

WH 56
ECM 2
Ignition WH 54
Switch ECM 2
WH/GY 43

WH/DB 44
Fuse Box
13
25
37
49
1

BN/PK 23
B4 GY
OG/DG 27
A5 VT/PK
Fuel Pump
A4 VT/YE RD 13
Relay
58
24
36
48
12

B5 VT/BK OG/BN 19

BK/BU 6
D BK 1
C

A
BK

BK

1 3 5 7 9
VT/BK

Fuel Pump Chassis

Fuse Ground
Engine Throttle Control
Scout

6 OG/YE YE/GN P1

5 VT/RD YE/BK P2

4 PK/RD YE/RD P3
Throttle 3 2 1 P3 P2 P1
ETC Grip
Body 6 5 4
3 BN/DB WH/GN P4 P6 P5 P4

2 BN/WH WH/BK P5

1 YE WH/RD P6

WH/GN
WH/RD

BN/WH
WH/BK

BN/DB
OG/YE

YE/GN
VT/RD

PK/RD

YE/RD

YE/BK
YE

10 20 3 52 51 6 11 5 38 25 3 21

ECM 2 ECM 1
12
48
36
24
58
13
25
37
49
1

49
37
25
13
1
58
24
36
48
12

ECM 2 ECM 1

Top View