Indian Motorcycle 2003 Chief Vintage, Service Manual

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Clamping the assembly in a vise at any point other
than the axle end can bend, distort or otherwise
permanently damage the fork tube or slider.
With the assembly securely clamped in the vise, remove
the damping tube retainer screw and washer, using a
6 mm hex bit. Remove the assembly from the vise.
Remove the fork slider-to-fork tube dust cap
(with garter spring) by prying, using a flat-blade
screwdriver.
Remove the snap ring from its groove at the inside top
of the fork slider. Then, remove the upper fork tube,
bushings, preload spacer, washer and oil seal together
from the fork slider.
Note:
The bushings, preload spacer, washer and oil
seal are removed together by carefully using the upper
fork tube in a “slide hammer” manner.
Remove the fork spring, damping tube, top out spring
and bottoming cone from the fork slider.
Repeat the procedure for the other fork tube assembly.
Use care to keep all component parts for each fork
assembly together. DO NOT interchange components
between the left and right assemblies.
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Thoroughly clean and then inspect all parts of the front
fork tube assemblies.
Check the upper fork tube and damping tube to make
sure they are not bent. This can be done by placing the
parts in V-blocks and while rotating them, using a dial
indicator to check for variations.
Inspect the slide surface of the fork tube for scoring,
blemishes and any other damage that would prevent a
good seal.
Make sure that the damping tube seal is in good
condition.
Inspect the plug O-ring and the fork slider oil seal for
wear or damage.
Inspect the fork tube and slider bushings for wear,
scoring or other damage.
Inspect the fork tube-to-fork slider outer seal for wear,
stretched or missing gater spring or other damage.
Make sure that the copper washers for the drain plug
and damping tube retainer bolt are in good condition to
properly seal and prevent oil leakage.
Prior to assembly, replace all parts found to be worn or
damaged during the inspection process.
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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 to the bottom. Use care in this
process to make sure the tapered end of the damping
tube is properly aligned and passes through the opening
at the bottom of the upper fork tube.
Insert the progressive-rate fork spring into the upper
fork tube so that it is seated on top of the damping tube.
Make sure that the fork spring is inserted with the end
having the closely spaced coils against the damping
tube.
Insert the preload spacer and washer into the upper fork
tube on top of the fork spring.
Check that the O-ring is positioned properly in its
groove on the fork tube plug. Push down on the spacer
to compress the spring and using a 21 mm wrench,
install the plug and washer. Tighten the plug to
specification.
If removed, install the bushing on the lower end of the
upper fork tube.
Slip the bottoming cone onto the tapered end of the
damping tube protruding from the bottom of the upper
fork tube.
With the lower bushing and bottoming cone in place,
insert the assembled upper fork tube into the fork slider
until it bottoms. Use care to ensure that the bottoming
cone remains in position at the bottom of the damping
tube.
Clamp the axle end of the slider in a soft-jawed vise. DO
NOT clamp the assembly at any other point on the fork
tube or slider.
Clamping the assembly in a vise at any point other
than the axle end can bend, distort or otherwise
permanently damage the fork tube or slider.
With the assembly securely clamped in the vise, check
that the bottoming cone and damping tube are properly
aligned with the hole at the bottom of the slider. When
aligned, have an assistant push the fork tube into the
slider to hold the bottoming cone and damping tube in
position for installation of the retainer screw.