Indian Motorcycle 2003 Chief Vintage, Service Manual

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Item Standard Fit Wear Limits
Cylinder head displacement range
•
Pre #1800 engine
• Post #1800 engine
82–83 cc
86–87 cc —
—
Cylinder head flatness (gasket surface) 0.003 in. 0.005 in.
Valve guide-to-cylinder head (press fit) 0.0028–0.0018 in. Less than 0.0018 in.
Valve seat insert-to-cylinder head (press fit) 0.0050–0.0030 in. Less than 0.0030 in.
Valve seats
• Intake lead angle 60 deg —
• Intake seat angle 45 deg —
• Intake trail angle 30 deg —
• Intake seat width 0.041–0.063 in. —
• Exhaust lead angle 52 deg —
• Exhaust seat angle 45 deg —
• Exhaust trail angle 30 deg —
• Exhaust seat width 0.048–0.070 in. —
Valve stem diameter 0.3100–0.3102 in. —
Valve stem-to-face runout 0.002 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 Standard Fit Wear Limits
Cylinder bore 3.8750–3.8755 in. 0.002 in. max. Taper
0.003 in. max. out-of-round
Piston-to-cylinder 0.0015–0.0025 in. Exceeds 0.0050 in.
Piston rings
• Compression rings
Gap 0.018–0.025 in. Exceeds 0.040 in.
Side clearance (top) 0.001–0.003 in. Exceeds 0.0045 in.
Side clearance (2nd) 0.0023–0.0033 in. Exceeds 0.0045 in.
• Oil control ring
Side clearance 0.003–0.006 in. Exceeds 0.0065 in.
Wrist pin-to-piston 0.0005–0.0007 in. Exceeds 0.001 in.
Wrist pin-to-connecting rod 0.0015–0.0020 in. Exceeds 0.0020 in.