Indian Motorcycle 2003 Chief Vintage, Service Manual

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Check each fork for squareness before installation. Place
a carpenter’s square against the fork as pictured. Shifting
forks can become bent from an accident or excessively
hard shifts. Bent forks should be replaced to avoid
damage to mating parts.
Figure 510 — Check each fork for squareness
Measure the fork width where it fits into the gear
groove. Minimum thickness is 0.165". If you find worn
or damaged shift forks, check the mating gear groove
for wear or damage.
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Identify shift forks with the pins facing you as follows:
The 1st and 2nd gear fork (shown in middle) has the pin
in the middle.
The 3rd and 5th gear fork (shown at right) has the pin
offset to the left.
The 4th gear fork (shown at left) has the 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 mainshaft.
Lubricate the shift shaft with transmission oil. Slide the
shaft through the hole in the trapdoor while aligning the
shift forks to it.
Slide the gears with the forks checking the movements.
There should be no binding of any component.
Apply blue threadlock on the shift shaft retaining plug.
Run the plug inward until below flush with the case
face, using a 1/4" hex bit socket.
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Orient the shift drum to have the cam plunger to the
trapdoor side of the transmission.
Lift the shift pawl upward and place the shift drum
under it.
Figure 512 — Lift shift pawl upward