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Indian Motorcycle 2003 Chief Vintage, Service Manual

The Indian Motorcycle 2003 Chief Vintage Service Manual is a must-have for motorcycle enthusiasts. This comprehensive manual provides detailed instructions and maintenance procedures for your Chief Vintage, ensuring optimal performance and longevity. Download it for free from manualshive.com, where user manuals are readily available for download.

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The Indian Chief Vintage motorcycle is equipped with 
an electronically controlled ignition system. As such, 
timing is programmed into the ignition module and does 
not require the static and dynamic adjustments required 
in past models. However, the following 

Thunder Heart 

Performance Corp.

 diagnostic checks can be 

performed to assess the performance of the system and 
the functioning of components within the system.

5PPMTSFRVJSFE

5/32

"

 hex bit

13/16

"

 deep-well socket

Pliers

Trigger plate and speedometer sensor tester, 
98-056 (with adapter harness)

Ignition module simulator, 98-055

Diagnostic kit (software and cable), 88-990

Laptop/personal computer

*HOJUJPO$PWFS 5SJHHFS1MBUF$IFDL

This test is used to determine if the sensor within the 
ignition cover is functioning without removing the cover 
from the motorcycle.

Check to make sure that both the ignition key and the 
engine stop switches are in the OFF position.

Disconnect the ignition cover (trigger plate) harness 
connector. This is the triangular-shaped, three-pin 
connector located between the frame rails under the 
engine.

Connect the trigger plate and speedometer sensor tester, 
98-056, to the connector from the ignition cover, using 
the adapter harness supplied with the tester.

Figure 7 — Trigger plate test connection

Note: 

Check to make sure that the location of the 

colored wire leads in the adapter harness connector 
correspond with the color indicators on the tester 
module. If not, change the wire locations in the adapter 
harness to match up with the tester.

Turn the tester’s power switch on. The power indicator 
light should be brightly lit. If not, replace the battery in 
the tester.

With the transmission in neutral, turn both the ignition 
key switch to the ON position and engine start switch to 
the RUN position.

Depress the start switch and observe the tester’s 
SENSOR indicator light as the engine turns over.

•

Indicator light cycles on and off

 — The sensor 

in the ignition cover is OK.

•

Indicator light does not cycle on and off

 — The 

sensor in the ignition cover is malfunctioning or 
there is a problem with the ignition rotor. Replace 
the cover or rotor as necessary. 

Disconnect and remove the tester from the ignition 
cover connector.

Connect the ignition cover (trigger plate) three-pin 
terminal to the chassis harness connector.

4QFFE4FOTPS$IFDL

This test is used to determine if the speed sensor is 
functioning without removing the sensor from the 
motorcycle.

Check to make sure that both the ignition key and the 
engine stop switches are in the OFF position.

Connect the trigger plate and speedometer sensor tester, 
98-056, to the connector from the speed sensor, using 
the adapter harness supplied with the tester. This is the 
flat-shaped, three-pin connector located at the right side 
of the transmission near the rear frame stanchion.

Note: 

Check to make sure that the location of the 

colored wire leads in the adapter harness connector 
correspond with the color indicators on the tester 
module. If not, change the wire locations in the adapter 
harness to match up with the tester.

Turn the tester’s power switch on. The power indicator 
light should be brightly lit. If not, replace the battery in 
the tester.  The SENSOR indicator may also be lit 
depending on the position of the sensor gear.

Summary of Contents for 2003 Chief Vintage

Page 1: ...P N 98 173 ...

Page 2: ...r each of the respective headings there are procedures for routine maintenance inspections and adjustments Procedures for removal and installation disassembly cleaning and inspection of component parts and assembly are included when more extensive repairs or a complete overhaul is required SPECIFICATIONS for all systems and components are included in one place near the end of the manual The sectio...

Page 3: ...ii 05 4 7 5 4 37 6 ...

Page 4: ... ENGINE TROUBLESHOOTING 10 Symptom Related Diagnostics 10 Basic Engine Tests 11 EMISSION CONTROL SYSTEM TROUBLESHOOTING 12 Evaporative System Checks 12 IGNITION SYSTEM TROUBLESHOOTING 12 Spark Plug Condition 12 Electronic Ignition Diagnostics 13 CARBURETOR TROUBLESHOOTING 17 TRANSMISSION AND DRIVE TROUBLESHOOTING 20 Transmission 20 Clutch 20 ELECTRICAL TROUBLESHOOTING 22 Electrical Troubleshooting...

Page 5: ...E SYSTEM SERVICE 69 Brake Fluid Level and Condition 69 Brake Pad Replacement 70 Brake Caliper Service 73 Brake Rotor Service 76 Master Cylinder Service 76 Hydraulic Brake Line Replacement 80 Replacing Brake Fluid and Bleeding the Hydraulic System 81 FRAME AND ACCESSORIES 83 FRAME AND ACCESSORIES SERVICE 83 Seat Removal and Installation 83 Fender Removal and Installation 84 Chassis Fairing Removal ...

Page 6: ...lug Replacement 124 Ignition Coil and Spark Plug Wire Replacement 124 Ignition Cover Housing Rotor Removal and Installation 125 Ignition Module Replacement 125 Ignition Timing Check and Adjustment 125 LUBRICATION SYSTEM 126 LUBRICATION SYSTEM SERVICE 126 Engine Oil and Oil Filter Replacement 126 Cleaning the Tappet Screen 126 Oil Line Inspection and Replacement 127 Oil Pump Removal and Installatio...

Page 7: ... and Adjustment 174 Engine and Transmission Alignment 182 REAR DRIVE 184 REAR DRIVE SERVICE 184 Rear Drive Belt Inspection Removal and Installation 184 Rear Wheel Alignment and Drive Belt Tension Adjustment 185 Drive Belt Handling and Storage 188 CLUTCH 189 CLUTCH SERVICE 189 Clutch Lever and Cable 189 Clutch Inspection and Adjustment 190 Clutch Removal and Installation 192 Clutch Disassembly and ...

Page 8: ...t 246 Brakes 246 Wheels and Tires 247 Front Fork and Suspension Torque Values 247 Rear Swingarm and Suspension Torque Values 247 Frame and Accessories Torque Values 248 ENGINE SPECIFICATIONS 249 General 249 Fits and Tolerances 249 Engine Fastener Torque Values 252 DRIVETRAIN SPECIFICATIONS AND TORQUE VALUES 254 Primary Clutch and Final Drive 254 Transmission Specifications and Torque Values 255 EL...

Page 9: ...viii 5 0 0 5 54 7 5 4 37 6 TOOLS AND EQUIPMENT 288 SPECIAL TOOLS 288 Tool Drawings 289 INDEX 291 ...

Page 10: ... to the beginning of the twentieth century Today the motorcycle carries forth the tradition and craftsmanship with five models Indian Chief standard Indian Chief Deluxe Indian Chief Roadmaster Indian Chief Springfield Indian Chief Vintage Figure 1 Indian Chief Vintage right side Figure 2 Indian Chief Vintage left side ...

Page 11: ...d cylinders found in earlier Indian Chief motorcycles At a compression ratio of 9 2 1 the engine produces 78 foot pounds of torque at 3800 rpm and 67 hp at 4750 rpm Figure 3 Indian POWERPLUS engine The piston connecting rods are a fork and blade style connected to a common crank pin joining two flywheels The crank pin is set between the pinion shaft flywheel to the right and the sprocket shaft fly...

Page 12: ...dian Chief Vintage Motorcycle left side 5SBOTNJTTJPO BOE SJWF Primary drive A dual track drive chain links the engine compensator sprocket with the clutch sprocket The wet type clutch utilizes 10 friction plates to transfer engine power smoothly to the transmission The 24 tooth compensator sprocket in combination with the 37 tooth clutch sprocket provides a reduction of 1 54 1 Transmission The tra...

Page 13: ...affixed to the frame tube just below the VIN plate Use the following table to interpret the VIN Example Model All Year All VIN Example 5CDNNCAJ 3G000002 Position Description Code Code Description 1 WMI 5 Supplied by SAE 2 WMI C Supplied by SAE 3 WMI D Supplied by SAE 4 Type C N M Motorcycle Stretched and raked smoothtail Chief 99 01 Motorcycle Single downtube monoshock frame Chief 02 Motorcycle Si...

Page 14: ...es off the motorcycle from disassembly cleaning and inspection to reassembly Generally all specifications including torque values are given in English measurements Where applicable however metric measurements and values are provided Note Indian Motorcycle Corporation continuously strives for improvements in product design quality and performance As a result of running changes made during the produ...

Page 15: ...6 05 4 7 5 4 37 6 ...

Page 16: ...d page 107 16 Check the enrichner operation and adjust it as required page 118 17 Check the engine idle speed adjustment page 118 18 Inspect the fuel valve petcock fuel lines and fittings for leaks pages 107 and 108 19 Clean the battery connections page 234 20 Check the operation of electrical equipment and switches page 239 21 Check the condition of the spark plugs page 12 22 Check the ignition t...

Page 17: ... adjust as required page 189 14 Inspect the air filter and clean or replace it as required page 103 15 Inspect the fuel filter screen clean or replace it as required page 107 16 Check the enrichner operation and adjust it as required page 118 17 Check the engine idle speed adjustment page 118 18 Inspect the fuel valve petcock fuel lines and fittings for leaks pages 107 and 108 19 Clean the battery...

Page 18: ...ht rating Damaged tire s or improper front rear tire combination Replace front tire and or rear tire with recommended size and type Irregular front or rear tire wear pattern Replace front tire and or rear tire with recommended size and type Incorrect tire inflation pressure Fill tires to recommended inflation pressure Rear shock absorber and spring assembly damaged worn or spring rate incorrectly ...

Page 19: ...ls or at coil Damaged wire insulation causing short circuit Fuel system clogged by water or dirt Fuel vent system plugged Engine difficult to start Battery low on charge Spark plugs in bad condition have improper gap or are partially fouled Incorrect spark plugs Spark plug cables in bad condition and shorting Damaged wire or loose connection s at one of the battery terminals or at the coil Carbure...

Page 20: ...dicates defective intake valve Crankcase vent indicates worn piston rings Air escaping through the valves may indicate incorrect pushrod length Check that the correct length pushrods are installed in each location OHJOF PNQSFTTJPO 5FTU The engine compression test provides a quick method to uncover engine faults Make sure the battery is fully charged Run the engine to attain normal operating temper...

Page 21: ...ICE section for removal and installation instructions 5PPMT SFRVJSFE Small file Wire brush OTQFDUJPO BOE MFBOJOH Visually inspect the electrodes for erosion and both the electrodes and insulators for the nature of any accumulated deposits A spark plug with light powder like brown or tan deposits and very little erosion of the electrodes is a normal condition and the plugs can be reinstalled Howeve...

Page 22: ...ch up with the tester Turn the tester s power switch on The power indicator light should be brightly lit If not replace the battery in the tester With the transmission in neutral turn both the ignition key switch to the ON position and engine start switch to the RUN position Depress the start switch and observe the tester s SENSOR indicator light as the engine turns over Indicator light cycles on ...

Page 23: ...UJPOBM IFDL This operational check substitutes the ignition module tester in place of the motorcycle s ignition cover trigger plate cam sensor The tester simulates the engine operating through a wide range to check the ignition coil spark wires and spark plugs 1SPDFEVSF Check to make sure that the ignition key and the engine stop switch are both in the OFF position Disconnect the ignition cover tr...

Page 24: ...foot pounds Make sure the threaded caps are tight on the plug terminal and connect the plug wires to the spark plugs Disconnect and remove the ignition module tester from the harness connector Connect the ignition cover trigger plate three pin terminal to the chassis harness connector HOJUJPO PEVMF 0QFSBUJPOBM IFDL A laptop or personal computer and the SmartLink diagnostic software by Thunder Hear...

Page 25: ...16 5306 4 005 7 5 4 37 6 Figure 12 Typical operation check screen ...

Page 26: ... tube bottom of float bowl or vent breather side of carburetor Sticking damaged or worn needle valve and seat Clean or replace as necessary Adjust float level 1PPS VFM DPOPNZ Problem Remedy Damaged misrouted or incorrectly seated enrichener cable Replace reroute or correctly seat enrichener cable Check for perceptible free play in enrichener cable Incorrect jet needle main jet or pilot jet for tun...

Page 27: ...w setting incorrect Adjust pilot air screw to specification 1PPS 1BSU 5ISPUUMF 1FSGPSNBODF Problem Remedy Damaged misrouted or incorrectly seated enrichener cable Replace reroute or correctly seat enrichener cable Check for perceptible free play in enrichener cable Damaged or restricted fuel tank vent system Repair or unclog vent system Air leak between carburetor and cylinder heads Replace gasket...

Page 28: ...e valve and seat Little or poor accelerator pump output Verify operation and replace parts as required Adjust pump stroke to specification BSCVSFUPS BOE YIBVTU BDLGJSF Problem Remedy Backfire on cold engine with enrichener off Considered normal Actuate enrichener until engine warms Backfire on warm engine Excessively lean air fuel mixture Check fuel flow to carburetor blocked or restricted jets mi...

Page 29: ...r rod Repair replace or adjust as necessary Internal shift mechanisms damaged bent or misadjusted Repair replace or adjust as necessary Shift forks bent or damaged Replace as necessary Worn or damaged internal transmission components Repair replace and adjust as necessary VNQT 0VU PG FBS Problem Remedy Shifter rod improperly adjusted Adjust as necessary Shift forks or shifter improperly adjusted A...

Page 30: ...s warped Check and replace components as necessary Primary chain badly misaligned Verify proper alignment Replace components as necessary Damaged clutch assembly Repair or replace components as necessary MVUDI 4MJQT Problem Remedy Clutch controls improperly adjusted Adjust as necessary Friction discs worn Check and replace components as necessary Insufficient clutch spring tension Check and replac...

Page 31: ...st recharge or replace as necessary Loose or corroded connections Clean and tighten as necessary Faulty regulator Test and replace as necessary Faulty stator Test and replace as necessary Starter Motor Does Not Operate or Does Not Turn Engine Over Problem Remedy Engine stop switch in OFF position Place engine stop switch in RUN position Ignition switch in OFF position Place ignition switch in ON p...

Page 32: ...ury Load the battery at 50 of the Cold Cranking Amperage CCA rating using the load tester The voltage reading after 15 seconds of load should be 9 6 volts or above at 70 F 21 C To avoid tester or battery damage do not leave the tester load dial ON for more than approximately 20 seconds If the battery fails to maintain 9 6 volts for 15 seconds at 70 F 21 C replace the battery Install the battery af...

Page 33: ...minals Connecting leads with charger ON could cause a spark resulting in a battery explosion and can result in serious personal injury Set the charging rate and voltage of the battery charger Follow the charge rate and time recommendations of the battery manufacturer Turn the battery charger ON When finished charging turn the battery charger to OFF and disconnect the charger leads from the battery...

Page 34: ...Draw test With the key turned OFF connect an ammeter in series between the battery negative terminal and the negative battery lead with lead disconnected from battery An alternative is to use an ammeter with an inductive pickup clamped around the negative battery cable with cable connected Check for current flow on a scale that is safe for the ammeter The ammeter should read zero current flow If c...

Page 35: ...ation is capable of meeting electrical power demands which include ignition lighting and the use of accessories The tests are also helpful in isolating the problem to the regulator the alternator or the circuit wiring Note The battery must be in good condition and at a full state of charge prior to conducting the following tests If not the results of the tests will be inaccurate and inconclusive 4...

Page 36: ... the meter set to the ohm s scale read the resistance Repeat the procedure this time with the leads connected between the second stator terminal and ground Both readings should indicate infinity If not there is a short to ground in the stator Replace the stator Figure 18 Stator short to ground test 4UBUPS 3FTJTUBODF IFDL Connect the leads of a volt ohmmeter between one of the two terminals at the ...

Page 37: ... results of the tests will be inaccurate and inconclusive 4UBSUFS VSSFOU SBX 5FTU Make sure that the ignition switch is in the OFF position and the transmission is in NEUTRAL To avoid accidental engine starting while conducting the test carefully twist the spark plug boots and disconnect the plug wires from the spark plugs Connect the ammeter clamping the 1000 amp induction pickup around the posit...

Page 38: ... broken wires with a multi meter on continuity to determine if the signal is getting to the source Start from the wire at the connector with one end of the probe and the other end of the wire at the source with the other probe You should read zero resistance on the meter If you don t get a reading or anything above 0 06 replace the wire Figure 23 Electrical harness controller moduel JBHOPTUJD 4USJ...

Page 39: ...switch the EHC distributes the 12v signal from the switch to the horn via the J 1 pin 4 and J 5 pin 2 is returned through the groundside of the horn Note You can perform this test with the EHC pin out diagram to any function you are having trouble with Just follow the pin out diagram for the circuit sending power and the return power 3FTJTUBODF 5FTUT An ohmmeter can be used to check for continuity...

Page 40: ...attery A maintenance free battery with 100 charge will read 13 0 volts DC A lead antimony battery with 100 charge will read 12 7 volts DC A lead calcium battery with 100 charge will read 12 6 volts DC Press the starter button and read the battery cranking voltage displayed on the volt ohmmeter Figure 25 Voltage drop test for slow cranking starter 0UIFS 7PMUBHF SPQ 5FTUT Voltage drop tests can be p...

Page 41: ... Check the pull in capability of the solenoid using a 12 volt test battery and three jumper wires of a suitable gauge and length Connect a jumper wire from the negative battery terminal to the starter terminal of the solenoid Connect a second jumper wire from the negative battery terminal to a good ground on the solenoid housing Connect a third jumper wire from the positive battery terminal to the...

Page 42: ...acket Figure 28 ILM fork slider with caliper bracket top and Paioli fork slider bottom The axle pinch bolt in the Paioli suspension is inserted at the bottom of the right fork slider The ILM suspension has the pinch bolt inserted from the side Figure 29 Axle pinch bolts ILM left and Paioli right The oil seal on the ILM suspension is recessed into the top of the fork slider and is retained with a s...

Page 43: ...tall the drain plug and copper sealing washer into the right fork tube and tighten to specification Perform the same procedure on the left fork tube PSL 5VCF 1SPDFEVSFT 5PPMT SFRVJSFE 6 mm hex bit 1 2 hex bit 21 mm open end wrench 5 8 wrench and or socket 3 4 wrench and or socket 1 3 8 wrench and or socket Flat blade screwdriver Torque wrench Motorcycle lift PSL 5VCF 3FNPWBM Using a motorcycle lif...

Page 44: ...fork tube pinch bolts located in the lower fork bracket using a 5 8 wrench Figure 35 Loosen fork tube pinch bolts Remove the fork tube cap from each fork tube using a 1 3 8 wrench Figure 36 Remove fork tube cap Slide the fork tube assembly from the upper and lower fork brackets Figure 37 Remove fork tube assemblies Turn the fork tube upside down in a pan to drain any remaining oil Repeat the proce...

Page 45: ...ng the plug from the upper fork tube The preloaded spring can force parts out rapidly causing personal injury or injury to others Exercising care slowly remove the plug from the fork tube using a 21 mm wrench The plug can pop from the tube as it nears the end of the threads Set the plug aside and remove the long spacer washer and spring from the upper fork tube Remove the pinch bolt from the fork ...

Page 46: ...l leakage Prior to assembly replace all parts found to be worn or damaged during the inspection process PSL 5VCF TTFNCMZ Coat all parts of the front fork assembly with fresh oil of the specified type for Indian motorcycles Slide the short top out spring onto the damping tube from the tapered bottom end With the spring in position insert the damping tube into the upper fork tube and push it through...

Page 47: ...rk oil without fork disassembly fill the fork assembly with 9 ounces 266 cc of the specified fork oil PSL 5VCF OTUBMMBUJPO Slide the fork tube assembly into position in the upper and lower fork brackets Figure 39 Fork assembly installation Install the fork tube cap screw using a 1 3 8 socket and tighten the screw to specification Install the front tire and wheel assembly Tighten the axle nut to sp...

Page 48: ...ccessory that may affect the weight of the front fork assembly Using a lift raise the front of the motorcycle just high enough to bring the front wheel off the ground Swing the wheel slowly back and forth to get a feeling for any rough spots tightness or flat spots Replace the races and bearings if flat spots or roughness are found Note Flat spotting of a bearing race may occur from a heavy blow t...

Page 49: ...reload Refer to Bearing Preload Adjustment in this section If the fall away distance is OK install the windshield and any other accessories that were removed for the test Lower the motorcycle to the ground and remove the lift FBSJOH 1SFMPBE EKVTUNFOU With the motorcycle supported on a lift and the front wheel off the ground adjust bearing preload using this procedure Remove the seat dash fuel tank...

Page 50: ...ification as required Install the windshield and any other accessories that were removed Lower the motorcycle to the ground and remove the lift 4UFFSJOH 4UFN JTBTTFNCMZ BOE TTFNCMZ If either triple clamp the stem or bearings are worn or damaged in any way the unit can be disassembled and parts replaced as required 5PPMT SFRVJSFE 1 16 hex bit 3 16 hex bit 6 mm hex bit 1 2 hex bit 1 1 2 wrench and o...

Page 51: ...sembly Place the triple clamp and handlebar in a secure position out of way Note It is recommended to place heavy padding over the fuel tanks and secure the triple clamp and handlebar in place on the padding Figure 49 Upper triple clamp removal Loosen the adjusting nut at the top of the fork stem using a spanner wrench Tap the top of the stem to loosen it from the upper bearing using a soft faced ...

Page 52: ...driver handle from the bottom of the stem tube and seat it against the remover Note A suitable remover installer can be obtained from a tool supplier or the bearing manufacturer These may be multi piece units with collets that lock onto the race With the remover tool and driver handle in position on the upper race drive the race out through the top of the stem tube Remove the lower bearing race us...

Page 53: ... fender using the procedures in the FRAME AND ACCESSORIES SERVICE section Install the front wheel following the procedure in the WHEELS AND TIRE SERVICE section Tighten the crown nut to specification and bend the washer tab up to lock the nut in place Recheck the front wheel fall away following the procedure under Steering Stem Inspection and Adjustment in this section Lower the front wheel to the...

Page 54: ...y from the handlebar and secure it in a position on the motorcycle where it is out of way Remove the retaining screws from the brake lever and master cylinder assembly using a 5 32 hex bit Remove the assembly from the handlebar Secure it in a position out of way Figure 56 Brake lever master cylinder removal Using a 5 32 hex bit remove the retaining screws from the throttle switch housing and caref...

Page 55: ...esses are properly routed through the handlebar the upper fork clamp and along the frame top tube to the power distribution module Figure 59 RH switch assembly installation Place the brake lever and master cylinder assembly in position at the right side of the handlebar Install the retaining screws using a 5 32 hex bit and tighten the screws to specification Figure 60 Brake lever master cylinder i...

Page 56: ...3 4641 4 0 47 3 3 4641 4 0 4 37 4IPDL CTPSCFS Figure 61 Rear shock absorber assembly 5PPMT SFRVJSFE 3 16 hex bit 1 4 hex bit 9 16 wrench and or socket 1 1 16 wrench Spanner wrench with 2 3 4 pin centers Torque wrench ...

Page 57: ...s are being loosened Figure 63 Shock absorber removal Pull the bolts out and remove the shock absorber from the chassis 4IPDL CTPSCFS OTQFDUJPO BOE EKVTUNFOU Inspect the shock absorber for any damage to the spring and for oil leaks from the body Inspect the rubber bushing on each end of the shock for deterioration The bushing acts as a cushion between the shock mounting eye and the bolt Replace th...

Page 58: ...the floor and remove the lift Apply blue threadlock to the three battery box mounting screws Place the battery box in position on the frame and install the screws Secure the wiring harness in position against the battery box using new tie straps Install the battery following the procedures under CHARGING SYSTEM SERVICE Install the rear fender saddlebag brackets rear engine guard saddlebags and sea...

Page 59: ...50 3 3 4641 4 0 7 5 4 37 6 4XJOHBSN Figure 66 Rear swingarm assembly 5PPMT SFRVJSFE 3 8 hex bit 15 16 wrench and or socket Bearing driver Torque wrench Arbor or hydraulic press ...

Page 60: ...aring bore Inspect the bearing for wear or damage The bearings should be reasonably tight yet swivel and rotate freely in the socket If the bearings are excessively worn and loose the swingarm must be replaced 4XJOHBSN 1JWPU FBSJOH 3FQMBDFNFOU The pivot bearings are a press fit in the swingarm and are retained by a snap ring on the inner surface of the arm Figure 68 Pivot bearing To replace a bear...

Page 61: ... 70 Loosening pinch screw Remove the axle nut lock washer and flat washer from the left side of the axle using a 3 4 socket Use a 1 2 hex bit to prevent the axle from turning as the axle nut is being removed Figure 71 Axle nut removal Before removing the axle note the position of the spacers on each side of the wheel Figure 72 Note spacer position Carefully remove the axle from the front wheel and...

Page 62: ...installed remove the nut washers axle and spacers from the fork sliders Clean the parts and then apply a light coating of grease to the axle Apply a light coat of grease to the lips of the seals in the wheel hub Insert the threaded end of the axle into and through the right fork slider flush with the inside of the slider Position the right side spacer inside the right fork slider and capture it wi...

Page 63: ...tightening the axle nut Tighten the right side axle pinch bolt to specification using a 6 mm hex bit Figure 77 Tightening axle pinch bolt IFDLJOH BOE EKVTUJOH 8IFFM FBSJOH OE 1MBZ Wheel bearing end play should be checked and adjusted if necessary after removing and installing the tire and wheel or after replacing components such as bearings axle or hub Wheel bearing end play on all models for both...

Page 64: ...ench and or socket Torque wrench Belt tension gauge Motorcycle lift 3FNPWBM Raise the motorcycle off the ground using a suitable lift Remove the saddlebags and brackets rear engine guard and rear fender following the procedures in the FRAME AND ACCESSORIES SERVICE section Using a 6 mm hex bit remove the two mounting screws securing the brake caliper to the right fork of the swingarm Secure the cal...

Page 65: ...sening axle adjuster nut Remove the rear drive belt from the wheel sprocket Figure 82 Removing the drive belt Before removing the axle note the position of the spacers on each side of the wheel Support the tire and wheel assembly and carefully remove the axle from the rear wheel and swingarm Note One method of supporting the wheel and tire assembly for removal of the axle is to adjust the motorcyc...

Page 66: ...me Place the drive belt in position on the wheel sprocket Figure 84 Drive belt installation Adjust the drive belt tension by tightening the adjuster nuts the same number of turns recorded for removal Figure 85 Adjusting belt tension Adjust the lift to raise the rear wheel off the ground so that the wheel can be rotated to check belt tracking Check the belt tracking by rotating the wheel in both fo...

Page 67: ...er or suitably sized hex socket 4FBM BOE FBSJOH 3FNPWBM Note The bearings and mating races are matched sets DO NOT mix bearings and races Remove only one bearing at a time to lubricate it and then install it in its original position Remove the seal from the left side of the wheel hub using a seal removal tool or screwdriver Remove the seal from the left side of the wheel hub using a seal removal t...

Page 68: ... on the outer edge of the seal and place the seal in position on the hub Ensure that the seal is aligned squarely and carefully drive the seal into the wheel hub using a seal driver or suitable hex socket Continue to tap the seal inward until it is seated against the bearing Note The diameter of the driver or hex socket should be slightly smaller than the outside diameter of the seal Figure 91 Ins...

Page 69: ...pply red threadlock to the threads of the five mounting screws Install the mounting screws and tighten the screws to 16 24 foot pounds using a 3 16 hex bit and torque wrench 3FBS 8IFFM SBLF 3PUPS Figure 93 Rear wheel assembly The brake rotor is attached to the rear wheel hub on the right side with five screws If the rotor is being removed for resurfacing or for access to the wheel spokes mark the ...

Page 70: ...hows that there are many spokes loose re truing of the wheel may be required 5PPMT SFRVJSFE 6 mm open end or spoke wrench Long screwdriver or metal rod Motorcycle lift 5JHIUFOJOH PPTF 4QPLFT SPOU BOE 3FBS 8IFFMT Using a lift raise the motorcycle so that the tires are off the ground Starting with the front wheel tap each spoke in the center with a long screwdriver and note each spoke s tone Spokes ...

Page 71: ...s not mean the tire s handling characteristics are not affected A rear tire used primarily for touring typically wears in the center creating squared edges This squared edge wear pattern may cause an odd feeling when the bike is leaned over in a turn The tire should be replaced if any odd handling characteristics are encountered Figure 98 Wear indicator painted for clarity Front tire wear typicall...

Page 72: ...essure at GVWR 36 psi 2 53 kgf cm2 Tire pressures should be checked when the tires are COLD Again hot tires will show a pressure increase DO NOT let air out of a hot tire to bring it down to the cold pressure setting Releasing air will allow the tire to heat even further and possibly lead to failure 5JSF OTQFDUJPO Visually inspect the tire for any cuts cracks and bubbles on the tread surface and s...

Page 73: ... tire in position on the upper edge of the wheel Be sure the tire is positioned correctly for its designed forward direction of rotation Using the tire irons and protectors pry the lower bead over the rim edge and into the center Press the bead against the lower seat of the rim Partially inflate the tube for easier installation Align the tube valve stem with the stem hole in the rim and insert the...

Page 74: ...lace a straightedge against the brake rotor mounting surface and extend it over the rim edge Using a scale measure the distance between the rim and the straightedge The specified offset is Front wheel 29 32 Rear wheel 15 16 Repeat the process at two more locations on the rim The 60 spoke wheels are fitted with hook type spokes the hook end of which is inserted into the hub flange Spokes are insert...

Page 75: ...n Note Gather spokes in the right upper flange into small groups and secure them with tape or rubber bands to keep them out of the way while spokes in the left lower are being assembled to the rim Assemble the spokes to the rim starting with the outer spokes on the lower hub flange Insert the first of these spokes in a clockwise pattern through the properly angled lower hole just to the left of th...

Page 76: ...ightedge to the left side of the wheel and repeat the procedure for the same point Compare the measurements The measurements should be the same for a properly centered rim Figure 106 Measuring lateral clearance If the measurements are not the same adjust the spokes in the indicated group using a 1 4 spoke wrench or a 3 32 hex bit to center the rim A spoke wrench is preferred The hex bit may not se...

Page 77: ...osite the spoke group where rim contact is made Next tighten the six spokes in the group where contact is made Make the adjustment incrementally turning all indicated spokes one turn at a time until clearance is gained Excessive pointer clearance low spot indicates that the rim is too far into the hub axle center at this point and needs to be moved out Loosen the six spokes in the group with exces...

Page 78: ...oir cap from the master cylinder located on the right handlebar using a 2 Phillips screwdriver Figure 110 Front master cylinder cover removal View the bottom of the reservoir for any debris Remove the old fluid and flush the system if necessary The fluid level should be within 1 4 from the top of the reservoir Add fluid if needed Figure 111 Brake fluid level USE ONLY DOT 5 BRAKE FLUID DOT 5 fluid ...

Page 79: ...the lining thickness becomes 1 16 or less Never change just one pad in a caliper Pads must be replaced in sets Figure 113 Brake pad comparison Check the thickness of the brake pads Figure 114 Checking brake pad thickness If a pad change is required an initial bedding in is necessary The bedding in should be performed in the dealer s motorcycle parking lot by the mechanic If the rear pads are being...

Page 80: ...asuring points SBLF 4IJN 1BSU VNCFST If the clearance is less than 0 015 on the outside measuring points the outer surface of the rotor A not the wheel side check to see if the caliper is already shimmed and re adjust Figure 117 Outside measuring points If the caliper is not already shimmed and the clearance cannot be increased to 0 015 there is a misalignment If the clearance between the two meas...

Page 81: ...per Figure 120 Caliper mounting shim location if equipped Slip the caliper from the mounting bracket and off the brake rotor Remove the push pin from the brake pad retaining pin and slide the retaining pin from the caliper Remove the brake pad clip from the top of the pads Remove the pads from the caliper OTUBMMBUJPO Before seating the pistons into the caliper thoroughly wipe any brake dust dirt a...

Page 82: ...o the brake system will occur if you install any other fluid SBLF BMJQFS 4FSWJDF 5PPMT SFRVJSFE 5 mm hex bit 6 mm hex bit 9 16 wrench SPOU BMJQFS 3FNPWBM BOE OTUBMMBUJPO 3FNPWBM Remove the bolt securing the front brake line to the caliper using a 9 16 wrench Position the brake line out of the way and cover the fitting to prevent contamination Inspect the copper sealing washers at the line fitting ...

Page 83: ...o secure the caliper install and tighten the two mounting screws to specification using a 6 mm hex bit Position the brake line fitting to the caliper Make sure one copper sealing washer is on each side of the fitting Thread the fitting bolt into the caliper and tighten to specification using a 9 16 wrench Bleed the front brake hydraulic system Refer to Replacing Brake Fluid and Bleeding the Hydrau...

Page 84: ...ge Inspect the caliper for leaks in the piston area and between caliper halves Replace the caliper as necessary Note There are no serviceable components for these calipers If the caliper is damaged or worn in any way replace the caliper as a unit Figure 125 Rear brake caliper assembly OTUBMMBUJPO Slide the caliper over the rear brake rotor and into position on the mounting bracket at the swing arm...

Page 85: ...parate the hydraulic brake line at the outlet fitting on the front master cylinder using a 7 16 wrench Support the master cylinder outlet fitting using a 9 16 wrench while removing the brake line Remove the outlet fitting and copper sealing washer from the master cylinder using a 9 16 wrench Inspect the washer and replace as necessary Remove the two handlebar clamp screws using a 4 mm hex bit Supp...

Page 86: ... master cylinder assembly to the right side handlebar install the clamp and two screws and tighten to specification using a 4 mm hex bit Install the outlet fitting with copper sealing washer and tighten to specification using a 9 16 wrench Thread the hydraulic brake line onto the outlet fitting Tighten the brake line to specification using a 7 16 wrench Add DOT 5 hydraulic brake fluid to the reser...

Page 87: ...he support bracket Apply red threadlock to the two rear master cylinder retaining screws Install the screws leaving them slightly loose Seat the dust boot to the master cylinder Assemble the brake switch into the hydraulic brake line fitting with a copper sealing washer on each side of the fitting Position the assembly through the rear master cylinder support bracket and into the master cylinder T...

Page 88: ...POU BTUFS ZMJOEFS MFBOJOH BOE OTQFDUJPO Inspect the cover gasket dust boot cup and piston O ring for wear softening enlargement cuts and tears Replace these parts as necessary Examine the cylinder bore for scratches grooves and excessive wear If any of these conditions are found replace the master cylinder assembly Make sure the ports in the bottom of the reservoir are clear of debris or sediment ...

Page 89: ...e top of the reservoir USE ONLY DOT 5 BRAKE FLUID DOT 5 fluid is silicone based and not compatible with DOT 3 4 or 5 1 Damage to the brake system will occur if you install any other fluid Bleed the hydraulic brake system Refer to Replacing Brake Fluid and Bleeding the System in this section for procedures Check for proper brake operation ZESBVMJD SBLF JOF 3FQMBDFNFOU 5PPMT SFRVJSFE 3 8 wrench 7 16...

Page 90: ...nstallation purposes OTUBMMBUJPO Route the new rear brake line as noted during removal Make sure the line reaches both front and rear connections Install new tie straps to secure the line Place the bolt with copper sealing washer through the caliper fitting of the brake line Add the second copper sealing washer onto the bolt Thread the bolt into the rear caliper and tighten to specification using ...

Page 91: ...ition Pump the brake lever once or twice and hold Loosen the front caliper bleeder screw approximately 1 4 turn using a 7 16 wrench Tighten the bleeder screw Note Do not release the brake lever until the bleeder screw is fully closed Air can reenter the system Again pump the brake lever once or twice and hold Loosen the bleeder screw approximately 1 4 turn using a 7 16 wrench Tighten the bleeder s...

Page 92: ...re 133 Seat front retainer bracket Note If the motorcycle is equipped with a buddy seat there will be an additional screw at the center rear of the seat securing the seat to the fender Use a 5 32 hex bit to remove this screw OTUBMMBUJPO Place the seat in position over the frame making sure the front retainer bracket is hooked under the frame bracket Push down on the seat to align the seat side mou...

Page 93: ...nward just enough to clear the mounting pads on the sliders Figure 135 Removing front fender SPOU FOEFS OTUBMMBUJPO If not already done cover the fork legs and front fender with a suitable protective covering Apply blue threadlock to the first 1 4 of the threads on each of the six mounting screws With the help of an assistant gently guide the front fender between the two fork tube assemblies Align...

Page 94: ...nting screws and plate With an assistant holding the fender remove the side mounting screws and chrome plates Then remove the fender 3FBS FOEFS OTUBMMBUJPO Apply blue threadlock to the threads of the rear fender mounting screws With the help of an assistant place the rear fender assembly in position on the motorcycle Figure 137 Rear fender installation With the assistant holding the fender in plac...

Page 95: ...ex bit Then remove each fairing by removing the two screws at the rear of each Note The left fairing has a cutout fitted with grommet This cutout fits over the ignition switch which is mounted to the frame To install the fairings in the reverse order of removal BTI 3FNPWBM BOE OTUBMMBUJPO 5PPM SFRVJSFE 5 32 hex bit 1SPDFEVSF To remove the dash remove the screw at the rear of the panel using a 5 32...

Page 96: ...uring the harness Figure 142 Lighting connectors Using a 5 32 hex bit remove the two front turn signal light housing mounting screws at the bottom of the spotlight and remove the housing To install the housing reverse the order of removal 4QPUMJHIUT VMC 3FQMBDFNFOU Using a 2 Phillips screwdriver remove the screw and the lens retainer ring from the spotlight housing Carefully pull the lens assembly...

Page 97: ...mounting screws Lift the windshield from its mounting Figure 144 Remove windshield Remove the spotlight stabilizer bar using a 3 16 hex bit Figure 145 Stabilizer bar removal Support the spotlight assembly and remove the two mounting screws Remove the spotlight bracket from its mounting location Figure 146 Spotlight assembly removal Install the spotlight assembly in the reverse order of removal App...

Page 98: ...ash Panel Removal and Installation in this section for the procedure Remove the headlight and trim ring assembly as necessary Refer to Headlight Assembly Replacement in this section Carefully pull the headlight and trim ring from the headlight housing Unplug the harness connector from the headlight and remove the assembly Remove the tie straps along the routing of the headlight assembly harness an...

Page 99: ... lead along the six nylon mounting blocks and through the hole at the left side of the fender Make sure the rubber grommet is in place at the hole Then secure the lead with new tie straps at the nylon mounting blocks Tighten the housing retaining nuts to specification 5BJMMJHIU TTFNCMZ Figure 152 Taillight assembly VMC 3FQMBDFNFOU Bulbs are easily replaced by removing the respective lens to gain a...

Page 100: ...he floorboard If required loosen the jam nut and adjust the stop screw to the desired height before installing the floorboard VEEZ 1FH 1SPDFEVSF If equipped the buddy pegs provide folding foot rests for the rear seat passenger The indexed pegs are mounted in the stanchions at the left and right sides of the frame just forward of the rear wheel A single mounting screw accessed from inside the frame...

Page 101: ... to specification 8JOETIJFME 3FNPWBM BOE OTUBMMBUJPO 5PPM SFRVJSFE 3 16 hex bit 3FNPWBM Using a 3 16 hex bit loosen but do not remove the upper and lower mounting screws securing the spotlight bracket to the fork assembly Do this on both sides of the fork assembly Figure 154 Loosening mounting screws Lift the windshield from its mounting Figure 155 Remove windshield OTUBMMBUJPO To install the wind...

Page 102: ... and Front Turn Signal Spotlight and Headlight Procedures in this section Remove the fork cover plate mounting screws using a 1 8 hex bit Figure 158 Removing fork cover plate mounting screws FBEMJHIU PVTJOH 4VQQPSU SBDLFU 3FNPWBM BOE OTUBMMBUJPO When necessary the headlight housing and fork cover plate support bracket can be removed for replacement purposes 1SPDFEVSF Remove the support bracket bol...

Page 103: ...VJSFE 3 32 hex bit 5 32 hex bit 11 32 wrench SPOU FOEFS 5JQ 3FNPWBM BOE OTUBMMBUJPO 3FNPWBM Remove the two mounting screws and nuts securing the front fender tip to the front fender using a 3 32 hex bit and an 11 32 wrench Figure 161 Removing front fender tip Slip the front fender tip from the fender OTUBMMBUJPO Position the fender tip to the edge of the front fender with the ends of the tip align...

Page 104: ...n 11 32 wrench 3FBS FOEFS 3BJM OTUBMMBUJPO Carefully position the rear fender rail over the fender tip to align the holes of the rail with the tapped holes in the fender Apply blue threadlock to the four rail screws and install them Tighten the rail screws to specification using a 5 32 hex bit VHHBHF 3BDL 3FNPWBM BOE OTUBMMBUJPO 5PPM SFRVJSFE 5 32 hex bit 3FNPWBM Remove the four mounting screws se...

Page 105: ...ove the nylock nut from the stud on the frame horn and cover bracket using a 1 2 socket or wrench Figure 168 Remove horn mounting nut Remove the horn and mounting strap from the frame mount Remove the washer To install the horn and horn cover reverse the order of removal Tighten the fasteners to specification Apply blue threadlock to the horn cover mounting screws before installation OHJOF VBSET 5...

Page 106: ...uard into position on the engine guard mounting brackets of the frame Figure 171 Positioning front engine guard Thread in the bolts and tighten them to specification using a 1 4 hex bit The washers go against the head of the bolts Install the horn and horn cover following the procedure under Horn Cover and Horn Removal and Installation in this section 3FBS OHJOF VBSE 3FNPWBM BOE OTUBMMBUJPO 3FNPWB...

Page 107: ...cification using 1 4 hex bit right side lower mounting bolt requires 9 16 socket or wrench Perform the same service on the opposite side rear engine guard as necessary 4BEEMFCBHT BOE 4BEEMFCBH SBDLFUT 5PPMT SFRVJSFE 5 32 hex bit 1 4 hex bit 5 16 hex bit 4BEEMFCBH 3FNPWBM BOE OTUBMMBUJPO 3FNPWBM Unbuckle the three saddlebag straps to open the saddlebag Figure 174 Opening the saddlebag Open the top ...

Page 108: ...ers into position on the saddlebag bracket The rubber dampers go against the bracket and the fender washers are placed on top of the dampers against the saddlebag Carefully set the saddlebag onto the bracket over the washers and rubber dampers Make sure the lower screws enter the washers and dampers Thread the upper back screws into the saddlebag bracket Thread the lower shoulder screws into the s...

Page 109: ...with washers Leave loose at this time Figure 180 Installing bracket and bolts Apply blue threadlock to the front saddlebag bracket mounting bolt Install the front saddlebag bracket mounting bolt through the bracket and rear engine guard Tighten the mounting bolt to specification using a 1 4 hex bit Tighten the two upper bracket and fender mounting bolts to specification using a 5 16 hex bit Perfor...

Page 110: ... frame thoroughly removing all accumulated oil grease and dirt Visually inspect all welds and joints Look closely for signs of cracks pitting and corrosion Look for areas with damaged or peeling paint and subsequent corrosion Inspect bearing seats in the steering tube and swingarm pivots for wear distortion or other damage Inspect engine and transmission mounting pads and all mounting brackets to ...

Page 111: ...air cleaner housing Motorcycles for use in California are equipped with air cleaners having a solenoid and butterfly assembly These components are used to minimize evaporative emissions The butterfly assembly covers the inlet to the air cleaner and is closed when the engine is not running and the key is turned off The solenoid opens the butterfly assembly when the key is turned on Figure 183 Evapo...

Page 112: ...ement for excessive dirt build up at the 500 mile service interval and thereafter at the 5 000 mile interval for normal conditions Inspect the air filter element more frequently when the motorcycle is operated in dusty conditions 5PPMT SFRVJSFE 1 2 hex socket 1 8 hex bit Slip joint pliers Flat blade screwdriver 3FNPWBM Remove the five air cleaner cover screws using a 1 8 hex bit Retain the screws ...

Page 113: ...t plates for reuse Figure 190 Remove air cleaner housing to bracket nuts Figure 191 Air cleaner housing and bracket exploded view Remove the air cleaner housing from the support brackets Pull the air cleaner to carburetor adapter off the carburetor Inspect the adapter seal and replace if necessary OTQFDUJPO Inspect the air filter element Replace the element if there is obvious damage to the filter...

Page 114: ...air cleaner housing over the support bracket studs Check the alignment of the adapter with the three cutouts of the air cleaner housing Install the support plates lock washers and nuts Tighten the nuts to specification using a 1 2 hex socket Figure 193 Securing air cleaner housing Align the filter element rear cover with the air cleaner housing Note the orientation of the rear cover to the housing...

Page 115: ...nstalling air filter element and front cover Install the bottom two air filter element cover screws and tighten to specification using a 1 8 hex bit Figure 197 Tightening air filter element front cover screws Position the air cleaner cover over the air filter element and air cleaner housing Install and tighten the five air cleaner cover screws to specification using a 1 8 hex bit Figure 198 Securi...

Page 116: ...mporarily correct the problem by allowing more fuel to reach the carburetor The problem will reappear however when the fuel in the tanks reaches the reserve level 5PPMT SFRVJSFE 1 open end wrench Flat blade screwdriver MFBOJOH UIF 1FUDPDL JMUFS 4DSFFO Place a clamp on the fuel crossover tube located between the left and right fuel tanks Turn the petcock fuel supply valve to the off position Figure...

Page 117: ...e or cuts Replace the hose sections as necessary with hose of the specified type Turn the petcock fuel supply valve to the on position and view all joints for leakage Tighten the clamp securely at any joint where leaking is found Replace any clamps that are damaged or do not provide proper tension for a secure connection Inspect the petcock for leakage If the petcock mechanism is leaking replace t...

Page 118: ... rotator ring is seated correctly in the lower throttle housing section Carefully place the top throttle housing section onto the bottom section Install the two mounting screws and tighten very lightly Rotate the throttle checking for smooth operation Align the throttle switch housing so that the parting line is parallel with the ground Tighten the two housing mounting screws using a 5 32 hex bit ...

Page 119: ...t the engine and let it idle Move the handlebars left and right to the fork stops The rpm of the engine should not increase If it does loosen the forward throttle cable adjuster until the engine rpm does not rise when the handlebars are turned Once the front carburetor opening cable has been adjusted check the free travel of the rear carburetor closing cable Check the cable connections at the carb...

Page 120: ...ne is flammable and explosive Work in a well ventilated area when draining gasoline and drain it into an approved container for gasoline storage Failure to follow this warning could result in an explosion and or fire which may cause serious personal injury and or death and damage to the motorcycle Disconnect and remove the vent and crossover tubes Figure 209 Fuel crossover tube and fuel supply lin...

Page 121: ...OL OTUBMMBUJPO Place the right fuel tank in position at the side of the upper frame tube and install the center and upper front mounting screws and washers using a 1 2 socket Tighten the screws to specification Figure 214 Fuel tank installation right shown Install the lower front mounting screw and bright finish collar using a 3 16 hex bit Tighten the screw to specification Repeat the above steps ...

Page 122: ... the dash panel and the screw at the rear of the dash using a 5 32 hex bit Figure 217 Dash panel front retaining screw Using a 5 32 hex bit tighten the rear screw to specification Figure 218 Dash panel rear retaining screw Reconnect the battery positive cable and then the negative cable to the battery terminals Refer to the procedure under Battery and Cables in the CHARGING SYSTEM SERVICE section ...

Page 123: ...hrottle closed Opening the throttle greatly reduces the action of the enrichener Note The enrichener cable is flexible and not likely to jam Check to make sure the cable is installed and adjusted correctly and that full operation occurs 5IF EMF JSDVJU The idle circuit is in operation between closed throttle and approximately 1 8 throttle opening Some notable components of the idle circuit are The ...

Page 124: ... the threads 2 Tighten the bolt to 18 in lb 3 Replace tabbed washer and bend flush against flat of bolt head BJO FU UP GVMM UISPUUMF With the jet needle raised fully the main jet controls fuel flow from 3 4 to full throttle DDFMFSBUPS 1VNQ Figure 221 Accelerator pump adjusters The accelerator pump has two adjustments one for the starting point of accelerator pump action and one for the end point o...

Page 125: ... idle becomes steady or begins surging or missing an air leak is present and should be corrected Check engine performance after correcting any air leaks before performing carburetor service BSCVSFUPS 3FNPWBM BOE OTUBMMBUJPO 5PPMT SFRVJSFE 7 16 open end wrench 12 combination wrench 9 16 open end wrench Flat blade screwdriver 3FNPWBM Turn the petcock fuel supply valve lever to the off position Using...

Page 126: ...es at the carburetor Figure 225 Disconnecting throttle cables Loosen the clamp retaining the carburetor to the intake manifold using a flat blade screwdriver and remove the carburetor from the engine Figure 226 Carburetor removal OTUBMMBUJPO Install the carburetor with the throttle bore flange positioned in the rubber carburetor mounting collar on the intake manifold Using a flat blade screwdriver...

Page 127: ...retor air inlet until fully seated Figure 230 Air cleaner mounting brackets To secure the air cleaner tighten the two bracket nuts to specification using a 1 2 combination wrench BSCVSFUPS BJOUFOBODF 5PPMT SFRVJSFE 2 5 mm hex bit 17 mm wrench 2 Phillips screwdriver Flat blade screwdriver Needle nose pliers There are few moving parts in these carburetors which do not require frequent servicing Howe...

Page 128: ...nd press down on the needle to snap the clip into place Make sure that you apply pressure near the clip to avoid bending the needle BJO FU Turn the petcock fuel supply valve to off Remove the drain plug using a 17 mm wrench Remove the main jet using a suitable flat blade screwdriver Replace the main jet Do not over tighten or cross thread the main jet 1JMPU FU Turn the fuel supply valve to off Rem...

Page 129: ...120 6 4 45 7 5 4 37 6 BSCVSFUPS MMVTUSBUJPOT Figure 232 Carburetor right side ...

Page 130: ... 7 5 4 37 6 6 4 45 121 Figure 233 Carburetor left side ...

Page 131: ...122 6 4 45 7 5 4 37 6 Figure 234 Carburetor exploded view ...

Page 132: ...Lever Pin 52 Pilot Air Screw O Ring 73 Float Bowl Seal Ring 11 Link Lever Pin 32 Throttle Lever 53 Fuel Fitting 74 Float Bowl 12 Throttle Valve TV 33 Accel Pump Spring 54 Fuel Fitting O Ring 75 Overflow Hose 13 Needle Retainer Screw 34 Accel Pump Screw 55 Idle Adjuster Packing 76 Drain Plug O Ring 14 Needle Retainer Clip 35 Accel Pump Spring 56 Idle Adjuster Washer 77 Drain Plug 15 TV Sealing Ring...

Page 133: ...and pull to disconnect the spark plug wires from the terminals at the back of the coil Remove the coil from the motorcycle Figure 235 Coil cover removal To install place the coil in position on the engine upper support bracket and temporarily install the mounting screws to hold the coil in position without cover while the terminal connections are made Plug the spark plug wires into the terminals a...

Page 134: ...f the pinion shaft with the alignment pin in the shaft slot Apply blue threadlock to the threads of the retaining screw and install the screw using a 1 8 hex bit Tighten the screw to 48 72 inch pounds Place a new gasket in position and install the ignition cover housing Apply blue threadlock to the threads of the cover screws and install the screws Tighten the screws to 8 12 foot pounds HOJUJPO PE...

Page 135: ...021 Apply a thin film of oil to the filter threads and to the gasket of the new filter Screw the filter into the filter mount until the gasket contacts the seating surface Tighten another 1 2 3 4 of a revolution Engine oil should be checked when warm and the motorcycle is vertical The oil level should be between the high and low marks on the dipstick Add oil if necessary Figure 238 Checking engine...

Page 136: ...wrench OTQFDUJPO BU 0JM 5BOL The oil tank has four points of inspection If a leak is found the 90 degree fitting can be tightened to specification using a 12 mm wrench If tightening to specification does not stop the leak remove the fitting and apply a thread sealant with Teflon to the threads and reinstall the fitting The rubber hose attachment points may leak also Again if a leak is found tighte...

Page 137: ... to catch any residual oil and remove the line from the fitting Using a flat blade screwdriver loosen the clamp securing the oil return line at the top side of the oil pump Remove the line from the fitting Figure 243 Pump oil supply and return line fittings foot rest and exhaust pipe removed for clarity Loosen the oil pump mounting screws with a 3 16 hex bit and remove the six screws Figure 244 Oi...

Page 138: ... the clamps using a flat blade screwdriver and disconnect the four oil lines at the right front corner of the tank Tag the lines for identification and proper reconnecting when the oil tank is installed From under the motorcycle frame loosen the four tank mounting screws using a 5 32 hex bit While supporting the tank remove the screws washers and isolators Lower and remove the tank from the motorc...

Page 139: ...s securely Proper connection is as follows Cam cover vent top left Pump bypass top center Filter return top right Oil pump supply right side Check that the tank drain plug is installed and tightened to specification Remove the fill tube cap and fill the tank with 3 quarts of Indian 20W 50 engine oil Replace the cap ...

Page 140: ...equipped with an evaporative emissions control system meeting regulations set forth by the California Air Resource Board CARB The evaporative system prevents fuel vapors hydrocarbons from escaping into the atmosphere The system consists of an air valve at the inlet port on the back of the air cleaner housing tank vapor valve a carbon canister and interconnecting vent and purge lines ...

Page 141: ...d to full open and does not bind Check the carbon canister for cracks or damage Vent and purge hoses should be in good condition without cracks or cuts Also check the hose routings to make sure that they are secure and away from hot engine components Vent and purge hoses contain flammable fuel vapors Hoses damaged by hot engine components can leak with possible ignition of escaping vapors and resu...

Page 142: ...ire leads from the harness clip located on the upper engine mounting bracket Disengage the solenoid harness connector Disconnect the solenoid actuating rod at the butterfly assembly lever using 0 050 hex bit Figure 250 Disconnect solenoid actuating rod at lever Remove the retaining nut securing the solenoid to the housing Remove the solenoid To install the solenoid reverse the order of removal ...

Page 143: ...e the two mounting bolts attaching the muffler to the support bracket Figure 251 Muffler mounting bolts Remove the muffler from the exhaust pipe exercising care to avoid damaging the exhaust pipe assembly To install the muffler reverse the order of disassembly Tighten the muffler mounting bolts to specification YIBVTU FBEFS 3FNPWBM BOE OTUBMMBUJPO 3FNPWBM Remove the muffler as described above Usin...

Page 144: ...move the two screws attaching the seat to the frame Slide the seat rearward and upward to remove Disconnect the battery cables negative cable first at the battery terminals Remove the screws at the front and rear of the instrument panel using a 5 32 hex bit Raise the panel carefully Disconnect the wiring from the panel Remove the instrument panel Figure 253 Instrument panel rear retaining screw Fi...

Page 145: ...rea when draining gasoline and drain it into an approved container for gasoline storage Failure to follow this warning could result in an explosion and or fire which can cause serious personal injury and or death and damage to the motorcycle Figure 255 Fuel tank mounting screws Figure 256 Fuel tank mounting screws Remove the tanks Figure 257 Remove fuel tanks Remove the fairings at each side of th...

Page 146: ...ontrol cables loosen the clamp at the intake manifold and remove the carburetor Figure 260 Carburetor mounting Disconnect the ignition wires from the spark plugs Remove the upper support bracket from the cylinder heads and the frame The ignition coil can remain attached to the bracket Figure 261 Removing upper support bracket Using a 9 16 wrench remove the nuts retaining the exhaust pipe at the fr...

Page 147: ...s below Place a drain pan under the drain plug at the bottom of the primary chain housing Remove the plug using a 3 4 wrench and allow the oil to drain from the housing When completely drained replace the plug and tighten Place a drain pan under the engine drain plug Remove the plug using a 3 4 wrench and drain any residual oil that may remain in the crankcase Replace the plug and tighten Remove t...

Page 148: ...nd chain adjuster Using a 1 1 2 socket remove the compensator retaining nut and remove the assembly from the sprocket shaft Using a 1 2 socket remove the four primary housing to engine mounting screws Note The two inner screws are locked by tabbed washers Bend the tabs back to unlock Figure 268 Primary housing mounting screws Disconnect the electrical leads from the oil pressure switch the ignitio...

Page 149: ...bolts Remove the rear engine mounting bolts using a 9 16 socket Figure 272 Rear engine mounting bolts Lift the engine from the chassis and mount it in an engine stand JIMS 1006T for disassembly and repair Note any shims placed under the engine case They must be returned to their original position when reinstalling the original engine OHJOF OTUBMMBUJPO Before installing the engine remove any debris...

Page 150: ...nd shift assembly in the same manner Apply blue threadlock to the shift rod screw Connect the shift rod at the transmission using a 3 16 hex bit Tighten the screw to 13 19 foot pounds Install the breather hoses and clamps on the fittings at the breather valve and the bottom of the cam cover Reattach the oil and vent hoses to the oil tank Connect the electrical leads to the oil pressure switch the ...

Page 151: ...s and clamps Tighten the clamps securely Connect the shutoff valve fuel line on the left tank to the carburetor Reconnect the wiring and then position the instrument panel over the fuel tanks and secure the panel with the socket head screw in the speedometer bezel and the socket head screw at the rear of the panel Using a 5 32 hex bit tighten the screws to specification Reconnect the battery posit...

Page 152: ...ng done remove the engine from the chassis and mount it in an engine stand JIMS 1006T If a repair involves a specific operation being done in chassis find the appropriate procedure s in this section and proceed 5PPM SFRVJSFE Engine stand 1006T available from JIMS 3PDLFS PY 1SPDFEVSFT The following procedures apply for both the front and rear rocker boxes 5PPMT SFRVJSFE 3 16 hex bit 1 4 hex bit Tor...

Page 153: ...er box base and the rocker arms can be removed as an assembly After removing the four screws from the rocker shaft support brackets remove the five screws retaining the rocker base to the cylinder head using a 3 16 hex bit Remove the rocker base gaskets and discard them 3PDLFS 4IBGU JTBTTFNCMZ BOE OTQFDUJPO If not already done remove the rocker shaft assembly from the base by prying on the support...

Page 154: ...ts must be positioned at the pushrod end of the arms where they interlock with the mounting screws in the right side support bracket Slide the slotted end of the shafts into the right support bracket and align the slots with the mounting screw holes Slide the left support bracket onto the other end of the shafts Figure 278 Rocker shaft assembly ...

Page 155: ...stall the screws in the support brackets Install the 1 3 4 long screws in the left support bracket and the 2 screws in the right Using a 1 4 hex bit and torque wrench tighten the screws to specification 16 20 foot pounds Tighten these four larger screws before tightening the five smaller screws Using a 3 16 hex bit and torque wrench tighten the five rocker base screws to 8 12 foot pounds Note As a...

Page 156: ... 7 5 4 37 6 147 1VTISPE BOE 5VCF 3FNPWBM BOE OTUBMMBUJPO 5PPM SFRVJSFE Small flat blade screwdriver Figure 282 Pushrod and tube assemblies early 2003 models ...

Page 157: ...and washer and discard if damaged Remove the second pushrod tube repeating the previous steps OTUBMMBUJPO Place the flat washer in position on the tube seat of the lifter block Figure 285 Installing flat washer in lifter block Lubricate and place an O ring in position at the bottom of the lower pushrod tube Lubricate and place an O ring in position at the top of the upper pushrod tube and slide th...

Page 158: ...orcycle lift under the transmission area of the frame and raise the motorcycle so that the rear wheel is off the ground Remove the pushrod tube clip of each pushrod tube using a small flatblade screwdriver at the base of the clip Pry the clip up and out all pushrods Figure 286 Removing pushrod tube clip With spring pressure released slide the lower pushrod tubes upward to reveal the pushrods Use e...

Page 159: ...nch require 2 1 2 full turns to achieve an increased length of 0 104 Holding the ball end adjuster 3 in place with a wrench use a second wrench on the upper pushrod hex 1 and rotate three full turns for 32 pitch threads or 2 1 2 turns for 24 pitch threads Figure 289 Adjusting pushrod Using a third wrench tighten the middle locknut hex 2 against the ball end adjuster 3 When snug tighten the locknut...

Page 160: ... 7 5 4 37 6 151 Figure 290 Cylinder head assembly ...

Page 161: ... from the engine Remove the gasket and the two dowel pins from the cylinder Discard the gasket JTBTTFNCMZ Note As the cylinder head is being disassembled mark all parts so they may be reinstalled in the same location To remove the valves from the cylinder head mount the valve spring compressor tool JIMS 96600 36B in a vise Mount the cylinder head in the tool with the collar flange positioned over ...

Page 162: ...ed guides Both intake and exhaust seats should be cut to 45 with nominal seat widths of 0 052 intake and 0 059 exhaust respectively To change the seat width to bring it within specification or raise or lower the seat cut the lead or trail angles as specified below Cutting the lead angle will raise and narrow the seat Cutting the trail angle will lower and narrow the seat Intake valve seats Lead an...

Page 163: ...hes of the head bolts Next clean out all oil and debris from the internal threads using a can of carburetor brake cleaner fitted with a spray tube Fully insert the spray tube into the bolt and work out from the base of the threads Use compressed air to final clean and dry the threads Apply a light coating of engine oil to the threads and flanges of the head bolts and loosely install the two short ...

Page 164: ... ZMJOEFS BOE 1JTUPO TTFNCMZ 1SPDFEVSFT 5PPMT SFRVJSFE Dental pik 2361 available from JIMS Piston lock ring tool available from JIMS Driver 96780 58A 2 requires modification Collar 96781 72 2 requires modification Refer to the SPECIAL TOOL REQUIREMENTS section for tool modification prints Piston ring compressor 1236 available from JIMS Piston ring expander 1235 available from JIMS Protective tubes ...

Page 165: ...ld the rod away from the crankcase and prevent damage to the case and rod Repeat the above steps to remove the second cylinder and piston if required ZMJOEFS OTQFDUJPO Check that the cylinder gasket surfaces are free from burrs and scratches Check the cylinder to cylinder head and cylinder to crankcase gasket surfaces for flatness Lay a straightedge across each surface and use a feeler gauge to me...

Page 166: ...s required Check that the wrist pin to piston clearance is within specification see Specifications Replace worn parts as required Check that the ring gaps of all piston rings are within specifications see Specifications Use the piston top surface to square each ring in the cylinder when measuring ring gaps Replace the rings if the ring gap is not within specification Figure 303 Checking piston rin...

Page 167: ...bricate the wrist pin and connecting rod with clean engine oil Place the piston in position on the connecting rod with the notched skirt facing the middle of the engine Then install the wrist pin Figure 306 Installing piston and wrist pin For early 2003 models set up the tools for installation of the spiral locks as follows Place a new spiral lock in the modified collar tool JIMS 96781 72 2 as sho...

Page 168: ...etain the wrist pin Install the C clip so that the sharp side faces out and the opening gap faces top or bottom Remove the protective sleeves from the cylinder studs Make sure the dowel pin is in position on the crankcase and install the cylinder base gasket Different gaskets are used for the front and rear cylinders Refer to the illustration to identify each for proper installation Lubricate the ...

Page 169: ... the mounting screws Using a 5 32 hex bit and torque wrench tighten the screws to the specification of 8 10 foot pounds Make sure the stator electrical leads are pressed against the crankcase If not positioned properly the leads can come in contact with the rotor and become damaged Figure 312 Properly positioned stator electrical leads Place blue threadlock on the stator plug setscrew Install and ...

Page 170: ...s in the two open holes using a 3 16 hex bit Remove the alignment pins and install the two remaining mounting screws Tighten the screws to 8 12 foot pounds Figure 314 Positioning lifter block assembly Repeat the process to install the front lifter block assembly 0JM 1VNQ 3FNPWBM BOE OTUBMMBUJPO Remove the tappet screen plug using a 1 4 hex bit Then remove the spring and tappet screen Inspect the s...

Page 171: ...ct the leads and connector for the sensor sealed in the cover If damaged repair or replace as necessary Position the rotor on the end of the camshaft with the alignment pin in the shaft slot Apply blue threadlock to the threads of the retaining screw and install the screw using a 1 8 hex bit Tighten the screw to 48 72 inch pounds Place a new gasket in position and install the ignition cover housin...

Page 172: ... Cam cover puller to be fabricated see Required Tools section Mainshaft sprocket locknut wrench 94660 37A available from JIMS Pinion gear installer puller available from JIMS Screw 96830 51 2 Puller 96830 51 3 Rod alignment tool 1010 available from JIMS Small hammer and drift Figure 317 Cam assembly ...

Page 173: ...h three screws Do not overtighten the screws Overtightening can damage the aluminum screws Turn the puller screw against the camshaft to remove the inner outer cam cover assembly from the crankcase Remove and discard the gasket Figure 319 Removing cam cover Note If the engine is not being disassembled and only the breather valve or cam is to be removed then align the timing marks on the gears befo...

Page 174: ...IMS 94555 55A to loosen and remove the nut Note The pinion gear nut is a left hand thread To remove turn the nut in a clockwise direction Figure 322 Removing pinion gear nut To remove the pinion gear install the pinion nut puller and screw JIMS 96830 51 3 and 96830 51 2 as shown Remove the gear from the pinion shaft Figure 323 Removing pinion gear Use a small hammer and drift to drive out the key ...

Page 175: ...alignment tool JIMS 1010 inserted through the connecting rod wrist pin bore to keep the shaft from turning Note The pinion gear nut is a left hand thread To install turn the nut in a counterclockwise direction Install the shim and thrust washer on the camshaft Install the thrust washer with the beveled side facing the inside of the case and the flat edge facing the rear lifter block mounting hole ...

Page 176: ...he threads of the cam cover mounting screws Install the cam cover and the seven screws around the perimeter of the cover Make sure the one shorter screw is installed in the lower cam cover hole Tighten the screws to 8 12 foot pounds Check camshaft end play as follows Slide the camshaft against the cam cover Measure end play with a gap gauge inserted between the camshaft shoulder and shim at the pi...

Page 177: ...tween early and later models however the case holes where the locator bolts were used are drilled larger for a loose fit like the remaining bolts The locator bolts are no longer necessary in terms of case alignment Note the locations of the alignment dowels after removing the bolts and separating the case halves JTBTTFNCMZ Mount the sprocket shaft holder JIMS 1034 in a vise Place the crankcase ass...

Page 178: ...lder Remove the sprocket shaft holder from the vise and mount the flywheel rebuilding jig JIMS 1071 in the vise Figure 331 Flywheel rebuilding jig mounted in vise Mount the left case half flywheel and crank assembly pinion shaft facing down on the rebuilding jig Install the crank disassembly removing tool JIMS 1047 TP on the left case half and tighten the mounting bolts Figure 332 Crank disassembl...

Page 179: ... nicks and scratches cracks or other damage Repair or replace the case if necessary Inspect the case alignment dowels for damage and secure fit in the case Apply a thin coating of Teflon thread dope to the drain plug and install the plug in the left case half using a 5 16 hex bit Tighten the plug to 18 foot pounds Clean and inspect the bearings and races for wear or damage Replace parts as require...

Page 180: ...t shaft Lubricate the race Place the left case half in position on the sprocket shaft Make sure that the connecting rods are properly positioned in the cylinder bores Figure 336 Placing left case half on sprocket shaft Install the outer bearing and spacer on the output shaft using the sprocket shaft bearing installation tool set JIMS 97225 55 and the mainshaft sprocket locknut wrench JIMS 94660 37...

Page 181: ...e that the connecting rods are centered in the cylinder bores and place the right case half in position on the pinion shaft For later 2003 models make sure to align the dowel pins and that the case halves mate together properly Apply blue threadlock to the threads of the crankcase bolts Note The six 5 16 bolts are through bolts retained with nuts The shorter 3 8 bolt is threaded into the case The ...

Page 182: ...hex bit T Figure 342 Chain adjustment inspection cover Remove the inspection cover and gasket Discard the gasket Inspect the chain for looseness by lifting up on the chain Inspect the chain for excessive wear or visible damage through the inspection cover Also check the tensioner shoe for excessive wear or bracket damage T Figure 343 Chain tensioner visible through inspection cover If the chain is...

Page 183: ...n to specification Disconnect the shift rod from the shift lever using a 3 16 hex bit Using a 3 16 hex bit remove the 15 screws around the perimeter of the outer primary drive housing T Figure 344 Removing primary drive housing screws Remove the outer housing Remove the gasket from the housing and inspect it Replace the gasket if it is distorted or damaged Drain any remaining oil from the housing ...

Page 184: ...r assembly Loosen the chain tensioner nylock nut using a 9 16 hex socket or wrench Figure 347 Removing chain tensioner nylock nut Slide the tensioner assembly down to provide maximum slack in the chain Figure 348 Sliding tensioner down to loosen chain ...

Page 185: ...the compensator spring cup if the spring height is less than 0 600 Figure 350 Measuring spring cup height Working at the clutch end of the primary chain remove the six clutch pressure plate retaining screws and springs using a 10 mm hex socket Figure 351 Removing pressure plate screws and springs To gain access to the clutch hub retaining nut remove the pressure plate from the clutch hub and sproc...

Page 186: ...r the tab of the lock washer to unlock the starter drive pinion assembly retaining bolt and then remove the bolt using a 7 16 hex socket Remove the starter motor drive pinion assembly from the inner primary drive housing Figure 355 Removing starter motor drive pinion assembly Remove the starter motor Refer to the STARTING SYSTEM SERVICE section for starter motor removal Remove the two screws locat...

Page 187: ... necessary replace the starter drive pinion bushing using a suitable driver Drive a new bushing in flush with the surface of the housing The bushing should be wiped clean and dry before installation OTUBMMBUJPO Install a new O ring in the groove on the engine to inner primary housing mounting flange on the engine crankcase Figure 358 Installing O ring Apply a thin coat of Loctite 598 or Permatex U...

Page 188: ...ive pinion assembly Install the starter drive pinion assembly retaining bolt with washers through the drive pinion assembly Thread the bolt into the starter motor and tighten to specification using a 7 16 socket Refer to the STARTING SYSTEM SERVICE section for drive pinion assembly installation Slide the large spacer for the engine compensator sprocket onto the splines of the crankshaft and next t...

Page 189: ...e sprocket shaft Inadequate application of threadlock will gradually loosen the nut causing wear and damage in the housing and can lead to component failure Install the compensator assembly with retaining nut and machined spacer onto the splined crankshaft extension Lightly lubricate the components before installation Thread the nut onto the end of the crankshaft and tighten to specification using...

Page 190: ...n tensioner is located in the slot of the anchor plate Measure the slack at the middle of the top chain run The correct amount of slack should be a total up and down movement of 9 16 on a cold chain Figure 367 Checking primary chain slack adjustment Note If the tensioner has been adjusted to its upper limit and the chain cannot be properly adjusted the chain is excessively worn and must be replace...

Page 191: ...sure all fasteners and drain plug are tightened and that no leaks are evident Reconnect the shift rod to the shift lever Apply blue threadlock to the first four threads of the bolt and tighten to 15 18 foot pounds torque OHJOF BOE 5SBOTNJTTJPO MJHONFOU Use the following procedure to properly align the engine and transmission with the inner primary housing when the engine and or transmission have b...

Page 192: ...ent check remove the inner primary The primary should slip off with no binding If binding is detected repeat the above procedures 6QQFS OHJOF PVOU PMU 5PSRVF 4FRVFODF Lightly snug the two engine mount bolts 18 19 The engine mount must be loose enough to allow movement when tightening bolt 20 Torque the upper frame engine mount bolt 20 to 75 foot pounds Torque the two 3 8 bolts 18 19 to 29 31 foot ...

Page 193: ... 3FNPWBM Raise the motorcycle so that the rear wheel is off the ground For rear drive belt service remove the primary drive components along with the rear wheel saddlebags rear engine guard fender and suspension components Refer to PRIMARY DRIVE SERVICE REAR SUSPENSION SERVICE FRAME AND ACCESORIES SERVICE and BRAKE SYSTEM SERVICE for procedures Slip the rear drive belt from the sprocket and remove...

Page 194: ...When reassembled adjust the rear wheel alignment and rear drive belt tension and deflection 3FBS 8IFFM MJHONFOU BOE SJWF FMU 5FOTJPO EKVTUNFOU The indicators of a misaligned drive belt and rear wheel are screeching or clicking during travel or screeching chirping during acceleration Other indicators include the need for early drive belt replacement and excessive wear on the left or right edges of ...

Page 195: ...Figure 381 Measuring right side center to center distance Compare the measured distances between left and right sides If there is any difference between sides rotate the right side axle adjusting nut using a 1 2 wrench until the right side equals the left side Recheck side to side measurements using the alignment tool and adjust as necessary With the rear wheel properly aligned adjust belt tension...

Page 196: ...e belt travel left to right on the sprocket With the belt to the right side of the sprocket it should take approximately 15 revolutions of the rear wheel for the belt to track to the left Excessive travel or force to the left or right can cause the belt to ride up on the sprocket flanges which can cause screeching chirping or clicking and eventual drive belt damage In severe cases of excessive dri...

Page 197: ...r the drive sprockets DO NOT use a screwdriver or bar to pry the belt off or onto the sprockets When storing or packaging a belt for shipment DO NOT bend the belt forward teeth closing in a circle any smaller than 5 in diameter Figure 384 Minimum forward bend 5 circle Similarly DO NOT bend the belt backward teeth spreading in a circle any smaller than 10 in diameter Figure 385 Minimum backward ben...

Page 198: ...ever pivot pin using an external snap ring pliers Figure 386 Snap ring removal Push up on the pivot pin and pull it from the lever and bracket With the pin removed slowly pull the lever and cable out from the bracket Figure 387 Clutch lever and cable removal Remove the nylon cable retaining pin and cable end from the lever Use care to keep the nylon bushings from falling out of the lever Clean and...

Page 199: ...ed affects clearances and clutch adjustment A clutch adjustment should only be done after the motorcycle has cooled to the normal ambient temperature 5PPMT SFRVJSFE 3 16 hex bit 5 mm hex bit 7 16 wrench 1 2 wrench 14 mm wrench 3 4 thin wall socket Drain pan Motorcycle lift Torque wrench EKVTUNFOU 1SPDFEVSF Raise the motorcycle to a comfortable working height using a lift Place a drain pan under th...

Page 200: ... jam nut Figure 391 Clutch adjusting screw and jam nut Pull the clutch lever on the handlebar several times to free the cable and set the clutch release Grasp the cable end ferrule and pull it away from the clutch lever bracket At the same time turn the cable adjuster to provide a gap of 1 16 1 8 between the shoulder on the ferrule and the bracket Figure 392 Clutch cable end ferrule gap With the c...

Page 201: ...a comfortable working height using a lift To remove the complete clutch assembly clutch pack hub and sprocket case refer to the PRIMARY DRIVE SERVICE section for instructions If only the clutch pack requires service proceed with the following steps Place a drain pan under the primary drive housing under the drain plug Using a 3 4 thin wall socket remove the drain plug to allow the primary housing ...

Page 202: ... springs and pressure plate following the procedure under Clutch Disassembly and Assembly in this section OTUBMMBUJPO Note The following installation procedure applies when only the clutch pack is removed for service If the complete clutch assembly clutch pack hub and sprocket case is removed refer to the PRIMARY DRIVE SERVICE section for installation instructions Install the judder spring seat fi...

Page 203: ...lign the tabs of the friction discs during installation The last disc installed should be a friction disc goes against the pressure plate Also the last friction disc should be installed with the tabs offset from the previous friction discs installed Figure 402 Disc orientation Place the pressure plate in position on the clutch hub If not already done loosen the clutch adjuster jam nut and back out...

Page 204: ...oved it can be serviced by cleaning inspecting and replacing parts as required 5PPMT SFRVJSFE External snap ring pliers Internal snap ring pliers Bearing remover installer Press MFBOJOH BOE OTQFDUJPO Clean all parts except the friction discs with a suitable solvent solution Rinse the parts and blow dry with compressed air Check the friction surfaces of the discs for wear chipped or missing lining ...

Page 205: ...l of the hub Place a suitable pilot in position on the inner shaft of the hub and press the hub from the bearing Remove the sprocket case from the press Using an internal snap ring pliers remove the snap ring retaining the bearing in the sprocket case bore Place the sprocket case back in the press again with the primary chain side up With a suitable bearing remover or sleeve in position against th...

Page 206: ... 7 5 4 37 6 65 197 Figure 409 Clutch assembly ...

Page 207: ...ure 410 Pivot bolt head to primary housing clearance If interference is detected the transmission shift lever may not be seated deeply enough or the lever inclination may not be correct Loosen the shift lever pinch bolt using a 1 4 hex bit Push the shift lever inward to create clearance between the inner primary housing and pivot bolt head If this does not provide the necessary clearance remove th...

Page 208: ...ift rod clockwise to shorten or counterclockwise to lengthen as required Note It may be necessary to loosen the jam nut and adjust the shift rod length at the rear pivot to maintain adequate thread engagement at both socket ends Install the front pivot bolt and check the operation of the foot control through the shift points Remove the pivot bolt and readjust the shift rod length if necessary Tigh...

Page 209: ... The magnetic drain plug is also located on the right side of the transmission in the trapdoor just below the housing cover 5PPMT SFRVJSFE 3 16 hex bit 3 8 hex bit Drain pan IBOHJOH UIF 0JM If equipped remove the exhaust pipe to transmission bracket and fasteners using a 1 2 wrench and a 1 4 hex bit Place a drain pan in position below the right side housing cover Remove the drain plug from the tra...

Page 210: ...cycle and ride it to bring the transmission oil up to normal operating temperature Stop the motorcycle and with the oil warmed check to ensure the proper oil level following the procedure below Add oil if required Check for any oil leaks after riding IFDLJOH 5SBOTNJTTJPO 0JM FWFM Make sure the engine is at normal operating temperature Place the motorcycle in a full upright position on level ground...

Page 211: ...mission before proceeding to the next step Using a suitable lift raise the motorcycle off the ground to a comfortable working height Disconnect the clutch control cable by one of the following two methods If the oil has not been drained disconnect the cable from the handlebar control and the retainer bracket on the frame This frees the cable to be removed with the transmission If the transmission ...

Page 212: ...E section Figure 424 Removing inner primary drive housing shown with rear wheel swingarm removed removal not required Remove the starter motor Refer to the STARTING SYSTEM SERVICE section for the removal procedure Figure 425 Remove starter motor Disengage the speedometer pickup wiring harness connector Release the drive belt tension as follows so that the belt can be removed from the transmission ...

Page 213: ... from under the frame mounting pad using a 9 16 wrench Figure 428 Removing transmission mounting nuts Note and mark the location of shims if used on the mounting studs between the transmission and mounting pad on the frame The shims must be installed in the same location when the transmission is installed Lift the transmission up from the mounting pad and remove it from the motorcycle Figure 429 R...

Page 214: ...meter pickup wiring harness connector Install the inner primary housing and primary drive assembly following the procedure in the PRIMARY DRIVE SERVICE section Figure 433 Installing primary drive chain and sprockets With the inner primary housing installed tighten the five transmission flange nuts to specification using a 9 16 socket and torque wrench Adjust the rear drive belt tension tighten the...

Page 215: ...ure the fairings and tighten to specification using a 5 32 hex bit Figure 436 Tightening fairing screws Lower the motorcycle to the ground and remove the lift Install the oil tank following the procedure in the LUBRICATION SYSTEM SERVICE section Remove the fill plug and fill the transmission with 20 24 ounces of Indian 80 90W transmission oil or its equivalent DO NOT overfill the transmission ...

Page 216: ...n drive gear tool available from JIMS Shaft installer available from JIMS Trapdoor bearing remover and installer avail able from JIMS Trapdoor puller available from JIMS Main drive gear bearing tool available from JIMS 5SBOTNJTTJPO JTBTTFNCMZ Place a drain pan under the transmission Remove the drain screw from the trapdoor using a 5 mm hex key and drain the oil Figure 437 Remove the drain screw Re...

Page 217: ...m supports using a 7 16 socket Figure 440 Removing shift drum supports Pull the shift pawl away from the pins in the shift drum Lift the shift drum and end supports from the transmission housing Figure 441 Remove drum and end supports from housing From the left side of the transmission remove the locking plate holding the sprocket nut using a 3 16 hex bit socket Figure 442 Remove locking plate ...

Page 218: ...on remove the set screw holding the shifting fork rod using a 1 4 hex bit socket Figure 444 Remove set screw from left side of transmission Tap the shift fork rod from the transmission housing using a brass punch Loosen the nuts on the end of the mainshaft and countershaft using a 1 1 16 socket Do not remove the nuts at this time Figure 445 Loosening mainshaft and countershaft nuts Remove the six ...

Page 219: ...ocket spacer from the splined gear 5th gear or main gear protruding from the left side of transmission After removal view the spacer and note chamfer The chamfer will be placed toward the inside of the transmission during assembly Figure 449 Removing sprocket spacer from splined gear BJO FBS UI FBS 3FNPWBM GSPN BTF Remove the main drive gear 5th gear from the transmission case using a JIMS Main Dr...

Page 220: ...ts Replace if damage is found Remove the main bearing retaining ring Remove the main bearing using a JIMS 5 Speed Main Bearing Remover or press The bearing must be replaced after using this tool Figure 453 Removing main bearing Press the new bearing into the case just past the retaining ring groove Use a JIMS 5 Speed Transmission Main Drive Gear Tool If using a press select a socket slightly small...

Page 221: ...JIMS tool will set the seal to the correct depth Figure 457 Installing new main seal BTF FFEMF FBSJOH OTQFDUJPO BOE 3FQMBDFNFOU Inspect the needle bearing pressed into the left case Look for any pitting or grooving of the needles The countershaft spins on this bearing If it needs to be replaced press the bearing from the case with a hydraulic press Figure 458 Inspecting needle bearing at left of c...

Page 222: ...nes first into the bearing from inside the case Press the main gear 5th gear into the transmission case using a JIMS 5 Speed Main Drive Gear tool Figure 459 Installing main gear into case Lubricate a new quad seal and slip it onto the 5th gear PVOUFSTIBGU BOE BJOTIBGU JTBTTFNCMZ It is important during this disassembly to lay out the pieces in the correct sequence Use egg cartons to place parts in ...

Page 223: ...r Gently pry the split cage roller bearing from the countershaft and inspect the needles for pitting or grooving Figure 463 Removing split cage roller bearing Remove the 3rd gear retaining ring Figure 464 Removing the 3rd gear retaining ring Remove the 3rd gear from the countershaft and inspect for damage Figure 465 Removing 3rd gear from countershaft ...

Page 224: ...retaining ring and thrust washer from the mainshaft Gently pry the split cage roller bearing from the mainshaft and inspect the needles for pitting or grooving Figure 468 Removing split cage roller bearing To provide support for the trapdoor roller bearings leave the remaining four gears on the shafts Press the countershaft from the bearing using JIMS Transmission Cover trapdoor Bearing Remover an...

Page 225: ... 472 Remove and inspect 1st gear for damage Gently pry the split cage roller bearing from the mainshaft and inspect the needles for pitting or grooving Figure 473 Remove and inspect split cage roller bearing Slip the spacer from the countershaft Slip 4th gear from the countershaft Slip 1st gear from the countershaft Inspect both shafts for pitting grooving and excess wear Replace as necessary FBSJ...

Page 226: ...gs and thrust washers in each location BJOTIBGU Figure 475 Mainshaft Figure 476 Trapdoor end of mainshaft Slip 1st gear onto the trapdoor end of the mainshaft shift dogs facing toward 4th gear Figure 477 Slip 1st gear onto trap door end of mainshaft Place a retaining ring onto the mainshaft capturing 1st gear using snap ring pliers Figure 478 Installing retaining ring Slip a thrust washer onto the...

Page 227: ...talling thrust washer onto countershaft Slip a split bearing onto the trapdoor side of the countershaft Figure 483 Installing split bearing onto countershaft Slip 1st gear onto the countershaft with engagement dogs first Figure 484 Installing 1st gear onto countershaft Slip 4th gear onto the countershaft with spacer side first Figure 485 Installing 4th gear onto countershaft ...

Page 228: ...ut step Slip the mainshaft into the tapered spacer with step through the left side trapdoor bearing Place the countershaft tapered spacer without step onto the right trapdoor bearing The tapered face of the spacer goes toward the bearing The taper allows oil to flow to the bearing Slip the countershaft into the tapered spacer without step through the right side trapdoor bearing Align the mainshaft...

Page 229: ...ainshaft followed by a split cage roller bearing Figure 491 Installing thrust washer and split bearing Slip 3rd gear onto the mainshaft with the engagement dogs facing upward away from trapdoor Slip another thrust washer onto the mainshaft followed by a retaining ring Figure 492 Installing 3rd gear retaining ring on mainshaft Slip 2nd gear onto the mainshaft with the shift fork groove toward the t...

Page 230: ...countershaft Place a retaining ring above 3rd gear followed by a thrust washer Figure 495 Installing retaining ring above 3rd gear Slip a new split cage roller bearing onto the countershaft Figure 496 Installing split bearing onto countershaft Slip 2nd gear onto the countershaft with engagement dogs toward the trapdoor Figure 497 Installing 2nd gear onto countershaft ...

Page 231: ...haft Figure 500 Installing transmission case over shafts Check that the alignment pins are aligned with their mating holes in the trapdoor Gently tap the trapdoor with a soft faced hammer until seated against the case Apply blue threadlock to the six trapdoor retaining bolts Install the four lower 5 16 bolts through the trapdoor and thread them into the case Install the two upper 1 4 bolts through...

Page 232: ...n drive gear with large chamfer on spacer facing inward The chamfer prevents the square cut seal from being crushed Figure 503 Sprocket spacer showing chamfer Figure 504 Installing spacer onto main drive gear Grease a new main drive gear seal on the inside and outside diameter Slip the seal over the sprocket spacer Slide a JIMS Seal Driver over the mainshaft transmission input Thread the tool guid...

Page 233: ...he transmission case Slide the bullet nosed sleeve tool over the mainshaft Prevents seal damage from shaft splines Figure 507 Installing seal over sleeve tool on mainshaft Slide the seal off the sleeve and toward the main drive gear transmission output Slip the seal driver onto the mainshaft Tap the driver with a mallet until the seal is fully seated The JIMS driver sets the seal to the correct de...

Page 234: ...e pin offset to the right Figure 511 Shift forks Orient the transmission with the trapdoor to the left Load all forks with the pin facing you Loading sequence is from left to right Load the 4th gear fork onto the groove in 1st gear of the mainshaft Load the 1st and 2nd gear fork onto the groove in 3rd gear of the countershaft Load the 3rd and 5th gear fork onto the groove in 2nd gear of the mainsh...

Page 235: ......

Page 236: ...ough all the gears checking for full engagement of the plunger to cam Continue to rotate the adjustment screw until full engagement is achieved while up shifting and down shifting MVUDI PWFS OTUBMMBUJPO Replace the clutch cable O ring with a new one Thread the clutch cable into the clutch cover Figure 519 Clutch cable with new O ring Remove the snap ring from the housing Remove the inner ramp and ...

Page 237: ...n the hex surface The machined washer surface goes toward the sprocket Clean the threads of the sprocket nut and mating threads on the mainshaft with alcohol or brake cleaner Apply red threadlock to the threads of the nut Slide the rear drive belt sprocket onto the mainshaft Make sure there is no grease on the threads of the mainshaft Clean the mainshaft threads if necessary Place a JIMS Sprocket ...

Page 238: ...g wiring The starter motor and solenoid are mounted above and to the rear of the transmission on the transmission flange plate The starter drive pinion is enclosed within the primary case Procedures for removal and installation of system components are included in this section Procedures for testing the system are included under Electrical System Tests in the TROUBLESHOOTING section Figure 524 Sta...

Page 239: ...onnect the shift rod from the transmission lever using a 3 16 hex bit Figure 525 Transmission shift rod Place a drain pan under the drain plug at the bottom of the primary chain housing Remove the plug using a 3 4 wrench and allow the oil to drain from the housing When completely drained replace the plug and tighten it to specification Remove the 15 screws at the perimeter of the outer primary hou...

Page 240: ... Tighten the screws to specification Apply blue threadlock to the shift rod screw Connect the shift rod at the transmission using a 3 16 hex bit Tighten the screw to specification Lower the motorcycle to the ground Lower the kickstand and remove the motorcycle lift Connect the battery ground cable to negative battery terminal Check for proper operation of the starter motor and drive 4UBSUFS PUPS 5...

Page 241: ...er rear location using a 1 2 socket Using a 1 4 hex bit install the mounting at the lower front location Tighten the screws to specification Install the starter drive pinion bolt following the procedure described under Starter Drive Pinion Connect the battery positive cable and start switch wire to the terminals on the starter solenoid Tighten the retaining nuts to specification using a 12 mm sock...

Page 242: ...ocedure under Battery and Cables in the CHARGING SYSTEM SERVICE section 4UBSUFS 3FMBZ The starter relay is located on the underside of the electronic control module at the top of the frame between the fuel tanks It is plugged into the module and can be replaced if required 5PPMT SFRVJSFE 5 32 hex bit Small flat blade screwdriver 4UBSUFS 3FMBZ 3FQMBDFNFOU Remove the seat from the motorcycle followi...

Page 243: ...l or add water However the battery terminals still need to be cleaned and checked for tightness at the recommended service intervals 5PPMT SFRVJSFE Flat blade screwdriver 10 mm wrench 3 16 hex bit 5 16 hex bit Ratchet wrench and 6 extension Wire brush MFBOJOH BOE OTQFDUJPO Remove the seat following the procedure in the FRAME AND ACCESSORIES SERVICE section Battery fluid contains sulfuric acid Do n...

Page 244: ...the screw to specification Install the seat following the procedure in the FRAME AND ACCESSORIES SERVICE section BUUFSZ 3FQMBDFNFOU The battery and or cables can be replaced if necessary at the time of cleaning and inspection following the above procedure Remember to always disconnect the ground cable first at the battery terminal when replacing either the positive or the negative cable or the bat...

Page 245: ...sator sprocket removal Remove the clutch assembly pressure plate and the clutch hub retaining nut Slide the clutch hub assembly primary drive chain chain tensioner and engine sprocket off the engine crankshaft and the transmission input shaft Refer to the PRIMARY DRIVE SERVICE section for procedures Remove the starter motor drive pinion and starter motor Refer to the STARTING SYSTEM SERVICE sectio...

Page 246: ...sitioned properly the leads can come in contact with the rotor and be damaged Tighten the set screw using a 3 32 hex bit to secure the connector in place Install the inner primary drive housing the starter motor and drive pinion and the primary drive chain sprockets and tensioner Refer to the PRIMARY DRIVE SERVICE section and the STARTING SYSTEM SERVICE section for procedures Place the compensator...

Page 247: ... regulator wire leads at the stator connector on the engine crankcase Figure 542 Voltage regulator stator terminal connection Disconnect the regulator battery wire leads at the connector under the frame crossmember at the front engine mount Using a 7 16 socket remove the nuts and lock washers from the two mounting studs Remove the regulator from the frame gusset To install the regulator reverse th...

Page 248: ...en transmission neutral light is on Pull in the clutch lever in and depress the START button The engine should not turn over Toggle the Engine Stop switch to the RUN position Make sure the green transmission neutral light is on Pull the clutch lever in and quickly depress the START button The engine should turn over SBLF JHIU Pull the front brake lever in The rear brake light should illuminate fol...

Page 249: ...to the frame Disconnect the wires from the terminals of the circuit breaker using a 3 8 wrench Remove the nut from the mounting stud using a 3 8 wrench and remove the circuit breaker from the battery box To install the circuit breaker reverse the order of removal 4QFFEPNFUFS BOE 8BSOJOH JHIU 3FQMBDFNFOU 5PPMT SFRVJSFE 5 32 hex bit Phillips screwdriver BTI 3FNPWBM To gain access to the speedometer ...

Page 250: ... rear of the panel Tighten the screws to specification using a 5 32 hex bit Reconnect the battery positive cable and then the negative cable to the battery terminals Refer to the procedure under Battery and Cables in the CHARGING SYSTEM SERVICE section Place the seat in position on the frame and install the two screws to attach the seat to the frame using a 3 16 hex bit Tighten the screws to speci...

Page 251: ...op throttle housing section onto the bottom section Install the two mounting screws and tighten very lightly Rotate the throttle checking for smooth operation Align the throttle switch housing so that the parting line is parallel with the ground Tighten the two housing mounting screws using a 5 32 hex bit Again check for proper throttle rotation Remove the screws one at a time and reapply blue thr...

Page 252: ...H B 4XJUDI BOE BSOFTT TTFNCMZ Remove the seat from the motorcycle following the procedure in the FRAME AND ACCESSORIES SERVICE section Disconnect the battery cables at the battery terminals negative cable first Refer to the procedure under Battery and Cables in the CHARGING SYSTEM SERVICE section Remove the screw at the rear of the dash panel using a 5 32 hex bit Remove the screw at the front of t...

Page 253: ...and remove the harness from the cable Leave the cable in the handlebar for installation of the harness Figure 551 Harness routing through upper fork bracket Attach the module terminal end of the new harness to the cable This is a temporary connection Use care in making this connection by wrapping the terminals to protect them during installation Using the cable carefully pull the wire harness inte...

Page 254: ...amount of blue threadlock to the switch housing mounting screws Carefully place the top housing section onto the bottom section Install the two mounting screws and tighten very lightly Align the switch housing so that the parting line is parallel with the ground and tighten the two mounting screws using a 5 32 hex bit Apply blue threadlock to the two clutch lever assembly clamp screws Position the...

Page 255: ...n Specification Brake pad Ferodo P N 50 061 front Ferodo P N 50 062 rear Brake pad thickness 0 205 0 215 in new 0 062 in worn minimum Brake rotor Minimum allowed thickness 0 180 in FASTENER TORQUE Part Torque Value Banjo adapter 90 degree line connection 100 in lbs Banjo retaining bolt at caliper 18 20 ft lbs front and rear Banjo retaining bolt at rear master cylinder 12 15 ft lbs Brake bleeder va...

Page 256: ...in FASTENER TORQUE Part Torque Value Axle retaining nut 50 55 ft lbs front 60 65 ft lbs rear Rear axle adjuster nuts 50 60 in lbs Rear wheel sprocket mounting bolts 65 ft lbs FASTENER TORQUE Part Torque Value Paioli Damping tube screws 16 17 ft lbs Drain screw 6 7 ft lbs Fork cover plate screws 8 10 ft lbs Fork stem nut lower short tall Tighten as required to achieve correct fall away Fork leg cap...

Page 257: ...screws 23 in lbs Headlight bracket to lower triple clamp bolts 29 ft lbs Headlight housing mounting bolt and nut 38 44 ft lbs Headlight lamp assembly screws 5 7 ft lbs Horn mounting nut 20 24 ft lbs Horn cover screws 7 9 ft lbs Kickstand mounting bolt 25 ft lbs License plate bracket 5 7 ft lbs Luggage rack 7 9 ft lbs Mirror mounting nuts 22 ft lbs Rear engine guard bolts 29 ft lbs upper 22 25 ft l...

Page 258: ...0 cu in Compression ratio Pre 1908 engine 9 5 1 Post 1908 Engine 9 2 1 Horsepower 67 bhp at 4750 rpm Torque 78 ft lbs at 3800 rpm Engine red line 5500 rpm Item Standard Fit Wear Limits Rocker arm to bushing press fit 0 004 0 002 in Less than 0 002 in Rocker arm shaft to bushing 0 0005 0 002 in Exceeds 0 0035 in Rocker arm shaft to shaft supports 0 0010 0 0024 in Exceeds 0 0035 in Rocker arm end pl...

Page 259: ...02 in max Valve stem protrusion from cylinder head Pre 1800 engine Post 1800 engine 2 015 2 035 in 2 035 2 055 in Exceeds 2 079 in Exceeds 2 079 in Valve to guide Intake 0 0013 0 0022 in Exceeds 0 0035 in Exhaust 0 0017 0 0026 in Exceeds 0 0040 in Valve springs Free length 2 256 in Pressure outer spring compressed to 1 250 in 269 lbs Pressure inner spring compressed to 1 437 in 47 5 lbs Item Stand...

Page 260: ... end play 0 005 0 015 in Exceeds 0 025 in Sprocket shaft bearing cups to crankcase press fit 0 005 0 003 in Less than 0 003 in Pinion shaft outer race to crankcase press fit 0 001 0 002 in Less than 0 001 in Item Standard Fit Wear Limits Connecting rod to crank pin 0 0004 0 0017 in Exceeds 0 002 in Pinion shaft to bearing 0 0004 0 0010 in Exceeds 0 001 in Sprocket shaft to bearing press fit 0 0005...

Page 261: ...gine nameplate screws 7 9 ft lbs right screw snug 1 4 turn left screw Evaporator door shaft link retaining screw 1 1 5 in lbs Exhaust head pipes flange to cylinder 10 12 ft lbs Exhaust header bracket to transmission 13 19 ft lbs Exhaust header clamp to header bracket 13 19 ft lbs Exhaust shield clamps 65 75 in lbs Exhaust studs 8 12 ft lbs Fuel tank mounting bolts 15 19 ft lbs rear 19 23 ft lbs fr...

Page 262: ... screws 8 12 ft lbs Rocker shaft support bracket screws 16 20 ft lbs Spark plugs 18 ft lbs Speedometer bracket nuts 4 6 in lbs Sprocket shaft nut 310 ft lbs Stator mounting screws 8 10 ft lbs Tappet screen plug 8 12 ft lbs Timing plug 8 12 ft lbs Upper engine mounting bracket bolts 29 31 ft lbs to engine 75 ft lbs to frame Valve cover screws 8 12 ft lbs Part Torque Value ...

Page 263: ...r ratios primary through transmission and final drive 1st gear 10 13 1 2nd gear 6 92 1 3rd gear 5 00 1 4th gear 3 85 1 5th gear 3 13 1 FASTENER TORQUE Part Torque Value Clutch cover retaining bolts 7 9 ft lbs Clutch hub nut 51 59 ft lbs Clutch pressure plate screws 71 84 ft lbs Compensating sprocket nut 150 ft lbs Outer primary cover screws 10 ft lbs Primary chain adjuster screw 25 ft lbs Primary ...

Page 264: ...seal installation depth 0 050 in below Mainshaft 5th gear inner bearing installation depth 0 060 0 080 in Mainshaft 5th gear outer bearing installation depth 0 315 0 340 in FASTENER TORQUE Part Torque Value Chassis plate to frame 35 38 ft lbs Countershaft nut 45 55 ft lbs Mainshaft nut 45 55 ft lbs Shift drum support block mounting bolts 7 9 ft lbs Shift paw adjusting screw locknut 20 24 ft lbs Sh...

Page 265: ...n lbs Coil cover mounting screws 12 14 ft lbs Ground cable terminal screw to frame 17 19 ft lbs Ignition module screws 7 9 ft lbs Ignition switch mounting 15 ft lbs Regulator rectifier assembly mounting screws 8 10 ft lbs Solenoid assembly nut 6 8 ft lbs Solenoid link screw 1 5 2 in lbs Starter cable nut ground to starter 15 20 ft lbs Starter motor cable retaining nuts 65 80 in lbs Starter mount s...

Page 266: ...adlock Crankcase drain plug threads Teflon pipe dope Crankcase joint sprocket side to pinion side Loctite 510 Gasket Eliminator Cylinder stud threads Red threadlock Engine nameplate screw threads Blue threadlock Exhaust stud threads Red threadlock Hose fittings 90 degree crankcase cam cover and oil pump Teflon pipe dope Ignition housing mounting screw threads Blue threadlock Ignition rotor screw t...

Page 267: ...lock Front engine guard bolt threads Blue threadlock Front fender mounting screw threads Blue threadlock Fuel tank mounting screw threads Blue threadlock Ground cable terminal screw to frame Di electric grease Handlebar clamp cover screw threads Blue threadlock Handlebar control mounting screw threads Blue threadlock Handlebar top clamp to clamp base mounting screw threads Blue threadlock Headligh...

Page 268: ...ds Blue threadlock Spotlight signal retaining nut threads Blue threadlock Spotlight signal windshield retaining screw threads Blue threadlock Starter cable retaining nuts at starter Di electric grease Starter driveshaft jackshaft retaining screw threads Blue threadlock Starter mounting stud bolt threads Blue threadlock Transmission shift rod capscrew nut threads Blue threadlock Transmission to cha...

Page 269: ...260 4 5 4 7 5 4 37 6 44 4 8 3 3 4 Figure 552 Front chassis harness diagram ...

Page 270: ... 7 5 4 37 6 4 5 4 261 Figure 553 Rear chassis harness diagram ...

Page 271: ...262 4 5 4 7 5 4 37 6 5 0 4 45 3 Figure 554 POWERPLUS 100 engine ignition system ...

Page 272: ...ubes to the cam gearcase From the second pressure port oil is pumped through channels in the gearcase and cam cover to provide lubricating oil to the pinion shaft bushing crankshaft bearings connecting rods and pistons Pressure created within the crankcase on piston downstroke then forces oil from the crankcase into the breather valve From the breather valve the oil is sprayed into the cam gearcas...

Page 273: ...ugh the countershaft gears and then through the output drive gear not shown Neutral All three sliding gears 1st 2nd and 3rd are disengaged so that there is no transfer of power between the mainshaft and countershaft gears Figure 556 Transmission in neutral 1st gear On the countershaft the sliding 3rd gear is engaged with the 1st gear allowing power to flow through the mainshaft and countershaft 1s...

Page 274: ...59 Power flow in 3rd gear 4th gear Both the 2nd and 3rd sliding gears are disengaged from other gears The mainshaft sliding 1st gear is moved into engagement with the 4th gear locking the gear to the mainshaft so that power flows between the 4th speed gears Figure 560 Power flow in 4th gear 5th gear On the mainshaft the sliding 1st gear is disengaged from the 4th gear and the sliding 2nd gear is m...

Page 275: ...Part Description Qty 1 01 396 Intake manifold 1 2 01 212 Flange intake 2 3 01 213 D ring intake 2 4 96 142 Screw socket head 5 16 18 x 7 8 4 5 01 217 Mounting flange 1 6 96 822 Bolt hex head 5 16 18 x 1 1 4 2 7 97 005 Nut hex nylock 5 16 18 2 8 01 149 Mount bracket 1 9 Clamp Clamp 1 ...

Page 276: ... 7 5 4 37 6 44 3 8 4 267 Figure 563 Intake manifold Item Part Number Part Description Qty 10 02 284 Nut 1 4 20 12 pt 1 ...

Page 277: ...e fitting 90 1 6 01 189 Oil filter bung 1 7 01 106 Bearing cam inner 1 8 01 060 Dowel pin 1 4 x 3 4 1 9 01 161 Dowel pin hollow 2 10 01 010 Bearing set left case 1 11 01 011 Spacer left drive shaft 1 12 01 250 Seal left case 1 13 01 014 Pinion bearing right case 1 14 01 059 Retainer ring RH shaft bearing 1 15 01 280 Bolt 5 16 24 x 5 63 5 16 01 281 Bolt 3 8 16 x 2 875 1 ...

Page 278: ...96 894 Washer flat 1 4 6 21 96 394 Nut 1 4 28 1 22 01 090 Switch oil pressure 1 23 01 085 Screen tappet 1 24 01 086 Spring tappet screen 1 25 01 087 Plug tappet spring 1 26 01 253 O ring tappet plug 1 27 01 044 Timing plug 1 28 01 321 Seal O ring 1 32 01 054 Plug oil pressure 1 Item Part Number Part Description Qty ...

Page 279: ... 8 4 7 5 4 37 6 Figure 565 Crankcase Item Part Number Part Description Qty 4 01 003 Cylinder stud 3 8 16 x 6 8 29 94 033 Rotor alternator 1 30 94 035 Stator alternator 1 31 96 965 Screw socket head 10 24 x 1 1 ...

Page 280: ... 5 4 37 6 44 3 8 4 271 Figure 566 Crankcase Item Part Number Part Description Qty 5 29 101 Hose fitting 90 1 15 01 280 Bolt 5 16 24 x 5 63 5 17 01 282 Bolt 1 4 28 x 5 38 1 18 01 285 Bolt 5 16 24 x 5 07 1 ...

Page 281: ...wheel set 1 2 01 031 Shaft left side output 1 3 01 033 Nut sprocket shaft 1 4 01 034 Nut pinion shaft 1 5 01 035 Key right shaft crank pin 2 6 01 036 Key shaft left flywheel 1 7 01 912 Connecting rod set 1 8 01 026 Bearing connecting rod 1 9 01 063 Shaft right side pinion 1 10 01 172 Crank pin flywheel 1 ...

Page 282: ...sket cam cover 1 18 97 121 Screw socket head 1 4 20 x 3 4 1 19 97 120 Screw socket head 1 4 20 x 1 1 4 6 21 01 254 Gasket ignition cover 1 22 00 033 Ignition rotor 1 23 96 290 Screw button head 10 32 x 3 4 1 24 00 130 Trigger housing 1 25 96 224 Screw socket head 1 4 20 x 5 8 2 26 29 101 Fitting 90 1 8 x 3 8 1 ...

Page 283: ...ar oil pump 1 3 01 049 Spacer oil pump drive gear 1 4 01 068 Gear pinion red 1 5 01 064 Nut pinion gear 1 6 01 097 01 Cam shim 0 050 1 6 01 097 02 Cam shim 0 055 1 6 01 097 03 Cam shim 0 060 1 6 01 097 Cam shim 0 065 1 7 01 105 Thrust washer cam 1 8 01 095 Camshaft carb 1 9 01 073 Breather valve 1 10 01 074 Thrust washer breather valve 1 ...

Page 284: ... Part Description Qty 12 01 905 Base assembly cam cover 1 13 01 134 Cam cover outer 1 14 01 251 Seal cam cover 1 15 01 056 Form ring bottom 1 16 01 057 Form ring middle 1 17 01 058 Form ring top 1 27 01 141 Dowel pin inner 1 4 x 1 2 1 28 96 031 Screw socket head 1 4 20 x 1 2 3 ...

Page 285: ... 44 3 8 4 7 5 4 37 6 Figure 571 Oil pump Item Part Number Part Description Qty 4 01 262 Gasket oil pump 1 5 29 101 Hose fitting 90 1 6 96 879 Screw socket head 1 4 20 x 1 3 4 6 8 96 828 Elbow barbed hose 1 ...

Page 286: ... 7 5 4 37 6 44 3 8 4 277 Figure 572 Oil pump and filter mounting Item Part Number Part Description Qty 9 96 021 Oil filter 1 ...

Page 287: ...r block assembly Item Part Number Part Description Qty 2 01 926 Lifter block front 1 4 01 179 Gasket lifter block front 1 5 01 180 Lifter 2 6 96 013 Screw socket head 1 4 20 x 7 8 4 11 01 167 Pushrod cover assembly 2 12 01 191 Clip pushrod cover 2 ...

Page 288: ...re 574 Rear lifter block assembly Item Part Number Part Description Qty 1 01 925 Lifter block rear 1 3 01 178 Gasket lifter block rear 1 5 01 180 Lifter 2 6 96 013 Screw socket head 1 4 20 x 7 8 4 11 01 167 Pushrod cover assembly 2 ...

Page 289: ...Part Number Part Description Qty 1 01 236 Front head assembly 1 3 01 145 Intake valve 1 940 1 4 01 150 Exhaust valve 1 610 1 5 01 165 Stud exhaust port 2 8 01 256 Gasket head 1 9 01 261 Valve seal 2 10 01 160 Valve spring set 1 11 05 002 Spark plug 1 12 01 159 Keepers 4 ...

Page 290: ...ylinder head assembly Item Part Number Part Description Qty 2 01 237 Rear head assembly 1 4 01 150 Exhaust valve 1 610 1 5 01 165 Stud exhaust port 2 8 01 256 Gasket head 1 10 01 160 Valve spring set 1 11 05 002 Spark plug 1 12 01 159 Keepers 4 ...

Page 291: ...282 44 3 8 4 7 5 4 37 6 Figure 577 Cylinder head installation Item Part Number Part Description Qty 6 01 170 Head bolt long 2 7 01 171 Head bolt short 2 ...

Page 292: ...er left 1 7 01 260 O ring small 1 9 96 296 Screw socket head 1 4 20 x 7 8 5 11 96 297 Screw socket head 5 16 x 18 x 1 3 4 2 13 01 259 O ring large 1 14 97 121 Screw socket head 1 4 20 x 3 4 4 15 96 201 Washer flat 4 16 01 924 Washer vulcanized 4 18 96 298 Screw socket head 5 16 18 x 2 2 01 201 Rocker box front does not include rockers shafts or girdles 1 ...

Page 293: ... left 1 7 01 260 O ring small 1 9 96 296 Screw socket head 1 4 20 x 7 8 5 11 96 297 Screw socket head 5 16 18 x 1 3 4 2 13 01 259 O ring large 1 14 97 121 Screw socket head 1 4 20 x 3 4 4 15 96 201 Washer flat 4 16 01 924 Washer vulcanized 4 18 96 298 Screw socket head 5 16 18 x 2 2 01 205 Rocker box rear does not include rocker arms shafts or girdles 1 ...

Page 294: ...linder exhaust rear cylinder intake 2 2 01 152 Rocker arm assembly front cylinder intake rear cylinder exhaust 2 12 96 298 Screw socket head 5 16 18 x 2 2 13 96 297 Screw socket head 5 16 18 x 1 3 4 2 20 01 142 Dowel pin 1 4 x 5 8 6 21 01 199 Shaft rocker arm 4 01 909 Girdle left rocker arm 1 01 910 Girdle right rocker arm 1 ...

Page 295: ...37 6 Figure 581 Rocker covers Item Part Number Part Description Qty 8 01 290 Gasket breather housing 2 10 01 321 Seal O ring 4 17 01 325 Plug stainless 2 18 01 318 Valve umbrella 2 19 96 965 Screw socket head 10 24 x 1 6 ...

Page 296: ... 7 5 4 37 6 44 3 8 4 287 Figure 582 Engine assembly ...

Page 297: ...on gear nut socket 94555 55A Piston spiral lock ring tool Driver Requires modification 96780 58A 2 Collar Requires modification 96781 72 2 Piston ring compressor set 1236 Piston ring expander tool 1235 Race and bearing install tool handle use with 97272 60 33416 80 1 Rod alignment tool 1010 Shaft installer 2189 Sprocket locker 2260 Sprocket shaft bearing installation tool 97225 55 set Main body 97...

Page 298: ...T The following drawings provide dimensions for fabricating a cam cover puller and modifying JIMS piston lock ring tools Figure 583 Cam cover puller dimensions Figure 584 Modification to JIMS piston lock ring tools 96780 58A 2 and 96781 72 2 ...

Page 299: ...290 05 4 7 5 4 37 6 ...

Page 300: ...STRATIONS 120 CARBURETOR MAINTENANCE 118 CARBURETOR REMOVAL AND INSTALLATION 116 CARBURETOR SERVICE 114 CARBURETOR TROUBLESHOOTING 17 CASE NEEDLE BEARING INSPECTION AND REPLACEMENT 212 CHANGING THE OIL 200 CHARGING SYSTEM SERVICE 234 CHARGING SYSTEM TESTS 26 CHASSIS FAIRING REMOVAL AND INSTALLATION 86 CHASSIS SPECIFICATIONS AND TORQUE VALUES 246 CHASSIS TROUBLESHOOTING 9 CHASSIS VIN 4 CHASSIS WIRI...

Page 301: ...NG 182 EVAPORATIVE SYSTEM 131 EVAPORATIVE SYSTEM CHECKS 12 EXHAUST HEADER REMOVAL AND INSTALLATION 134 EXHAUST SYSTEM SERVICE 134 FEATURES OF THE 2003 INDIAN CHIEF VINTAGE MOTORCYCLE 1 FENDER REMOVAL AND INSTALLATION 84 FENDER TIPS AND RAIL 94 FENDER MOUNTED LIGHT PROCEDURES 90 FITS AND TOLERANCES 249 FLOAT LEVEL ADJUSTMENT 118 FLOORBOARD AND BUDDY PEG REMOVAL AND INSTALLATION 91 FLYWHEEL AND CRAN...

Page 302: ...NITION COIL WIRES AND SPARK PLUGS OPERATIONAL CHECK 14 IGNITION COVER TRIGGER PLATE CHECK 13 IGNITION COVER HOUSING ROTOR REMOVAL AND INSTALLATION 125 162 IGNITION MODULE OPERATIONAL CHECK 15 IGNITION MODULE REPLACEMENT 125 IGNITION SYSTEM DIAGRAM 262 IGNITION SYSTEM SERVICE 124 IGNITION SYSTEM TROUBLESHOOTING 12 IGNITION TIMING CHECK AND ADJUSTMENT 125 INDIAN 5 SPEED TRANSMISSION 264 INDIAN CHIEF...

Page 303: ...5 REAR WHEEL SPROCKET 61 RECTIFIER REGULATOR CURRENT LEAK TEST 26 REMOVING CHASSIS COMPONENTS AND ENGINE ACCESSORIES 135 RENEWAL SERVICE 8 REPAIR 101 REPLACING A SWITCH AND HARNESS ASSEMBLY 243 REPLACING A SWITCH ONLY 241 REPLACING BRAKE FLUID AND BLEEDING THE HYDRAULIC SYSTEM 81 REPLACING THE MAIN CIRCUIT BREAKER 240 RESISTANCE TESTS 30 RIGHT HANDLEBAR SWITCHES 239 ROAD LIGHT REPLACEMENT 241 ROCK...

Page 304: ... CIRCUIT 114 THROTTLE CABLE ADJUSTMENT 110 THROTTLE CABLE LUBRICATION 108 THROTTLE CONTROL INSPECTION AND MAINTENANCE 108 TIGHTENING LOOSE SPOKES FRONT AND REAR WHEELS 61 TIRE AND TUBE REPLACEMENT 63 TIRE INSPECTION AND PRESSURE CHECK 62 TIRE INSTALLATION 64 TIRE REMOVAL 64 TOOL DRAWINGS 289 TRANSMISSION 20 TRANSMISSION AND DRIVE TROUBLESHOOTING 20 TRANSMISSION DISASSEMBLY 207 TRANSMISSION INSTALL...

Page 305: ...296 05 4 7 5 4 37 6 ...

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