Indian Motorcycle Indian Challenger 2020 Owner'S Manual Download Page 119

Page: 119 / 178

MEECCHHAANNIICCAALL CCLLUUTTCCHH LLEEVVEERR LLUUBBRRIICCAATTIIOONN

1. The clutch cable adjuster nut is located on the bottom of the

clutch cover on the engine. Loosen the lock nut.

2. Turn the cable adjuster completely inward to provide maximum

lever freeplay.

3. Remove the clutch lever c-clip

and pin

. Disconnect the

clutch cable from the clutch lever.

4. Remove any old grease and dirt from the lever and housing.

Lubricate the clutch lever and pin with moly assembly grease
or all-purpose grease.

NOTICE

During installation of the lever, be aware of the internal clutch

switch. Improper assembly can cause damage to the switch.

5. Reconnect the clutch cable. Reinstall the lever C-clip and pin.

6. Adjust clutch lever freeplay. See page 116.

7. Tighten the adjuster nut and slide the protective cover over the

adjuster.

MEECCHHAANNIICCAALL CCLLUUTTCCHH CCAABBLLEE LLUUBBRRIICCAATTIIOONN

Lubricate control cable barrel ends at the intervals recommended
in the Periodic Maintenance table.

NOTICE

External casings are factory-lubricated. Additional lubrication

could be detrimental to cable performance.

Verify proper routing and smooth movement. Inspect for damage
to the external casing, and inspect exposed cable wire for fraying,
kinks or corrosion. Replace any damaged, sticky or sluggish
cable.

117

MAINTENANCE

Summary of Contents for Indian Challenger 2020

Page 2: ...o minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels F...

Page 3: ...2020 Rider s Manual Indian Challenger ...

Page 4: ...n to make the same or similar changes to motorcycles previously built Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited INDIAN INDIAN MOTORCYCLE and INDIAN CHALLENGER are trademarks of Indian Motorcycle Company iPhone iPod iPod nano and iPod touch are trademarks of Apple Inc registered in the U S and other countries The Bl...

Page 5: ...ny years to come We hope you will take as much pride in riding your new motorcycle as our team did in building it for you We urge you to read this rider s manual thoroughly It contains information essential to safe riding and proper maintenance of your motorcycle Your authorized INDIAN MOTORCYCLE dealer knows your motorcycle best and should be consulted for service and assistance Skilled technicia...

Page 6: ...ARNING WARNING indicates a hazardous situation that if not avoided may result in death to the operator bystanders or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage IMPORT...

Page 7: ...ety 9 Reporting Safety Defects 19 Instruments Features and Controls 25 Pre Ride Inspections 57 Operation 67 Maintenance 79 Cleaning and Storage 145 Specifications 151 Warranty 157 Maintenance Log 169 5 TABLE OF CONTENTS ...

Page 8: ...6 ...

Page 9: ... Be sure you have the required technical skills and tools that are needed before you attempt ANY service on your motorcycle Please contact your authorized dealer before attempting any service work that is beyond your level of technical knowledge or experience or if the work requires specialized equipment O OP PE ER RA AT TI IN NG G M MO OT TO OR RC CY YC CL LE E O OU UT TS SI ID DE E T TH HE E U U...

Page 10: ...U UM MB BE ER R The engine number q is stamped into the right crankcase beneath the balance shaft cover The engine number is positioned behind the right floorboard with the engine installed in the frame Record the number in the space provided on page 7 8 INTRODUCTION ...

Page 11: ...of the motorcycle and should remain with the motorcycle when ownership changes S SA AF FE E R RI ID DI IN NG G P PR RA AC CT TI IC CE ES S WARNING Improper use of a motorcycle can result in serious injury or death to you your passenger and others To minimize the risk of injury read and understand the information contained in this section before operating the motorcycle This section contains safety...

Page 12: ...nd in different weather conditions Know your skills and limits and ride within them Allow only licensed experienced operators to ride your motorcycle and then only after they have become familiar with its controls and operation Make sure all riders read and understand this rider s manual before riding Do not ride when you re fatigued ill or under the influence of alcohol prescription drugs over th...

Page 13: ...ke the motorcycle hard to handle Retract the sidestand fully before riding If the sidestand is not fully retracted it could contact the road surface and cause loss of control To maximize braking effectiveness use the front and rear brakes together Be aware of the following braking facts and practices The rear brake provides 40 of the motorcycle s stopping power at most Use the front and rear brake...

Page 14: ...s such as VESC 8 V 8 Z87 1 or CE Make sure protective eyewear is kept clean All riders should wear bright or light colored and or reflective clothing to improve visibility to other motorists A motorist s failure to see or recognize a motorcycle is the leading cause of automobile motorcycle accidents Wear gloves a jacket heavy boots and long pants to prevent or reduce injury from abrasions lacerati...

Page 15: ...an accessory failure that could cause loss of control Always obey posted speed limits Do not attach anything to the motorcycle unless specifically designed for that purpose by INDIAN MOTORCYCLE S SA AD DD DL LE EB BA AG GS S A AN ND D O OT TH HE ER R S ST TO OR RA AG GE E Whenever operating a motorcycle equipped with cargo storage features such as saddlebags racks glove boxes or other storage comp...

Page 16: ...ving any equipment or by adding equipment not approved by the manufacturer may void your warranty Such modifications could make the motorcycle unsafe to ride and could result in severe injury to operator or passenger as well as damage to the motorcycle Some modifications may not be legal in your area of operation If in doubt contact your authorized INDIAN MOTORCYCLE dealer P PA AR RK KI IN NG G T ...

Page 17: ...l gasoline If you swallow gasoline inhale more than a few breaths of gasoline vapor or get gasoline in your eyes see a physician immediately If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exhaust gases contain carbon monoxide a colorless odorless gas that can cause loss of consciousness or death in a short time Never start the engine or ...

Page 18: ...nsport the motorcycle Use a truck or trailer Do not tow the motorcycle with another vehicle as towing will impair the motorcycle s steering and handling Position and restrain the motorcycle in an upright position Do not restrain the motorcycle using the handlebars Loop tiedown straps from the front up and over the lower triple clamp using care to not interfere with wiring and brake lines Place tie...

Page 19: ...lable at the following internet address https www polaris com en us radio conformity Technical Information Frquency band 433 05 434 70 MHz Maximum output power 10 mW Manufacturer and Address Marquardt GmbH Schloss Str 16 78604 Rietheim Weilheim GERMANY WARNING This product contains a lithium button cell If the button cell is swallowed severe internal burns can occur within a mere two hours and lea...

Page 20: ...eil ne doit pas produire de brouillage et 2 l appareil doit accepter tout brouillage radioélectrique subi même si le brouillage est susceptible d en compromettre le fonctionnement F FO OR R M ME EX XI IC CO O C CO OM MP PL LI IA AN NC CE E Model SK1 RLVPOSK19 1418 Model SE1 RLVPOSE19 1419 G GR RO OS SS S V VE EH HI IC CL LE E W WE EI IG GH HT T R RA AT TI IN NG G G GV VW WR R WARNING Exceeding the...

Page 21: ... it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your INDIAN MOTORCYCLE dealer or Indian Motorcycle Company To contact NHTSA or obtain other information about motor vehicle safety you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 visit the NHTSA web site at www safercar gov or write to ADM...

Page 22: ...I I The Vehicle Emission Control Information VECI label w is located on the left hand side of the motorcycle N NO OI IS SE E E EM MI IS SS SI IO ON N C CO ON NT TR RO OL L I IN NF FO OR RM MA AT TI IO ON N The Noise Emission Control Information label e is located on the left hand side of the motorcycle 20 SAFETY ...

Page 23: ...g use follow all safety precautions Always wear an approved helmet eye protection and protective clothing If your Owner s Manual is missing contact an Indian Motorcycle dealer for a replacement Never overfill fuel tank Fuel level should not rise into fill neck funnel Overfilling may result in degraded performance of engine and evaporative emission control system PREMIUM UNLEADED FUEL RECOMMENDED 9...

Page 24: ...25 4 425 500 5 C CA AR RG GO O L LI IM MI IT T W WA AR RN NI IN NG G The Cargo Limit warning label y is located inside the saddlebag WARNING CARGO LIMIT 10kg 22 0 lbs Including optional lid rack cargo Lid rack cargo limit 2 2 kg 5 0 lbs Including any optional accessory Distribute weight evenly on both sides of the vehicle Total weight of rider passenger accessories and cargo must not exceed gross ...

Page 25: ...eflectors will not protect the rider in a collision Dark Smoked wind deflectors will reduce visibility in low light riding conditions CAUTION Brake fluid and alcohol will permanently damage the polycarbonate windshield Do not clean the windshield wind deflector with glass cleaners or rain protective products CLEANING Clean windshield or wind deflector with a soft cloth and plenty of warm water Dry...

Page 26: ...24 ...

Page 27: ... C CO ON NS SO OL LE E q Power Switch Security Light w Ride Command Display e Speedometer Fuel Gauge r Tachometer t Clutch Lever y Front Brake Lever u Heated Grip Switch if equipped i Saddlebag Fuel Cap Lock Switch o USB Terminal a Fuel Cap s Air Duct Doors 25 INSTRUMENTS FEATURES AND CONTROLS ...

Page 28: ...Horn w Hi Beam e Low Beam Flash to Pass r Turn Signal Hazard Signal t Screen List Select y Audio Control Switch R RI IG GH HT T C CO ON NT TR RO OL L u Engine Stop Switch i Engine Start Run Switch o Cruise Control Switch a Windscreen Control Switch 26 INSTRUMENTS FEATURES AND CONTROLS ...

Page 29: ...light beam switch activates the low headlight beam Press down momentarily to activate Flash to Pass See page 31 Turn Signal Switch Move the switch to the left to activate the left turn signals Move the switch to the right to activate the right turn signals A signal will deactivate automatically when speed or distance reach predetermined levels To cancel a signal manually move the switch to the cen...

Page 30: ... menus decline dialog boxes hang up phone calls and toggle through display screens See page 27 Right Hand Trigger Switch Use the right hand switch to navigate through menus or accept dialog boxes on Ride Command display S SW WI IT TC CH HE ES S P PO OW WE ER R S SW WI IT TC CH H The power switch is located on the dash Press and release the power switch to enable or disable all electrical power to ...

Page 31: ... activate the flashers Press the switch again to cancel the flashers E EN NG GI IN NE E S ST TO OP P R RU UN N S SW WI IT TC CH H Use the engine stop run switch to turn the engine off quickly Press the top of the switch STOP q to interrupt the circuits and stop the engine The engine should not start or run when the switch is in the STOP position Press the bottom of the switch RUN w to complete the...

Page 32: ... RA AT TI IO ON N After starting the engine the Wireless Control Module WCM will verify that the key fob is within range again when shifting from neutral into gear The security light may turn on during this check The WCM will not search for the key fob again after the vehicle has moved If the key fob is lost during riding the PIN will be needed to restart the vehicle If the key fob is not detected...

Page 33: ... H The headlights automatically come on when the engine is started See page 46 The high low headlight beam switch toggles the headlight between high beam and low beam To activate the high beam press the upper portion of the switch To activate the low beam press the lower portion of the switch To momentarily flash headlights Flash to Pass press and hold the lower portion of the switch C CR RU UI IS...

Page 34: ...en using the console lock switch the key fob must be within range If the key fob is not detected the security light and or power switch will flash The system will not perform the lock or unlock command I IN NS ST TR RU UM ME EN NT T C CL LU US ST TE ER R q Speedometer w Indicator Lamps e Multi function Display r Tachometer 32 INSTRUMENTS FEATURES AND CONTROLS ...

Page 35: ...de is selected speed displays in kilometers per hour High Beam The headlight switch is set to high beam This indicator will flash if there is a problem with the low or high beam light LAMP INDICATES CONDITION Neutral The transmission is in neutral and the power switch is ON Low Fuel This lamp illuminates when approximately one gallon 3 8 liters of fuel remains in the fuel tank The LCD Display will...

Page 36: ... LAMP INDICATES CONDITION Check Engine This lamp illuminates briefly when the power switch is turned ON This indicates proper function If this lamp illuminates while the engine is running see an authorized dealer promptly The light will remain on if the tilt sensor shuts down the engine If abnormal sensor or engine operation is detected the light will remain on as long as the fault condition exist...

Page 37: ...ning is activated All segments including the fuel icon will flash Refuel promptly R RE EA AR R C CY YL LI IN ND DE ER R D DE EA AC CT TI IV VA AT TI IO ON N I IF F E EQ QU UI IP PP PE ED D Designed as an aid to reduce engine and exhaust heat to the rider Rear Cylinder Deactivation turns off the rear cylinder when the engine gets hot The following condition must be met for Rear Cylinder Deactivatio...

Page 38: ...ongly recommend that you use extreme caution when using any device that may take your focus off the road Your primary responsibility is the safe operation of your vehicle We recommend against the use of any hand held device while driving and encourage the use of voice operated systems when possible Make sure you are aware of all applicable local laws that may affect the use of electronic devices w...

Page 39: ...ce may not cause interference 2 This device must accept any interference including interference that may cause undesired operation of the device CAUTION This equipment complies with part 15 of the Federal Communications Commission FCC rules These requirements are intended to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and c...

Page 40: ...ress the Device Manger button to pair a phone or headset to the Ride Command display Audio Press the Audio Button to change the audio source adjust volume level and set radio presets R RI ID DE ER R S SC CR RE EE EN N The Rider Screen is a customizable split screen menu system that provides unique access to ride data vehicle status and vehicle information The Rider Screen also provides easy access...

Page 41: ... contact list key pad and messages The display will only show messages received while smart phone is paired via Bluetooth A AU UD DI IO O S SC CR RE EE EN N The Audio screen allows you to access music stored on your smart phone or other music device You can pair your device using Bluetooth or by connecting it to the display s USB port USB audio playback is only available on flash drives formatted ...

Page 42: ...witch q to do the following Press center to mute Press up down to increase decrease volume Press left right to move to previous next track S SE EL LE EC CT T S SW WI IT TC CH H Use the 3 way select switch w to do the following Press up and down to navigate display screen Press center to select 40 INSTRUMENTS FEATURES AND CONTROLS ...

Page 43: ...m selection Press the left trigger switch to back out of menu screens R RI ID DE E C CO OM MM MA AN ND D R RI ID DE E M MO OD DE ES S You can choose between three ride modes Rain Standard or Sport for an experience customized to your riding style The throttle map for each ride mode was designed with a specific application in mind resulting in one motorcycle with three distinct personalities 41 INS...

Page 44: ...tion S ST TA AN ND DA AR RD D Standard mode features a crisp throttle response and well balanced power delivery for responsive passing power and predictable slow speed handling S SP PO OR RT T Sport mode is designed for situations when instant response is needed Sport mode quickens the throttle response and has a more aggressive power delivery for increased acceleration T TR RA AC CT TI IO ON N C ...

Page 45: ... OR RM MA AT TI IO ON N From the Information settings menu you can view the following Vehicle Identification Number VIN Mileage Installed Software Version Oil Change Interval G GE EN NE ER RA AL L S SE ET TT TI IN NG GS S From the General settings menu you can do the following Themes Day Night Auto Manage Bluetooth Devices Change the Language Set the Speed Units of Measure MPH or KPH Set the Tempe...

Page 46: ...onnected service status and to renew go to http ridecommand indianmotorcycle com U UP PD DA AT TE E S SO OF FT TW WA AR RE E A AN ND D M MA AP PS S For the latest software and maps for the Ride Command display go to https ridecommand indianmotorcycle com The display software and maps can be updated by connecting a USB stick containing the latest software version to the USB port located in the righ...

Page 47: ...ndicator lamp will continue to flash until the ignition switch has been moved to the off position Restarting the engine will clear the flashing indicator and restore fuel to both cylinders If another misfire occurs the check engine indicator lamp will resume flashing and fuel will once again be cut to the affected cylinder s After the 3rd misfire P0314 misfire fault is determined set the check eng...

Page 48: ...n as visible as possible at all times To aid in this the headlight must be on at all times Do not modify the ignition headlight wiring to circumvent the automatic headlight feature The headlights operate only when the engine is running You can use the high low headlight beam switch to override this function and allow the headlights to operate when the engine is not running Turn the power switch on...

Page 49: ...e engine speed and power and cancel cruise control The control grip is spring loaded When you release the grip the throttle returns to the idle position C CL LU UT TC CH H L LE EV VE ER R The clutch lever q is located on the left handlebar Disengage the clutch before shifting gears For smooth clutch operation pull the lever quickly and release it in a brisk but controlled manner To disengage the c...

Page 50: ...n the Ride Command display If dashes display instead of a pressure value while traveling above 15 MPH 24 km h the system may not be functioning properly See your dealer for service The TPMS warning indicator will illuminate if low tire pressure is detected Always correct low tire pressure promptly Always inspect tire pressure and condition before each ride See page 61 The TPMS display may indicate...

Page 51: ...ag lids 3 Disconnect the saddlebag lock wiring near the seat q 4 Press the lid latch release button and lift the lid 5 Remove the saddlebag fastener bolts w 6 Tilt the saddlebag away from the frame of the vehicle to remove it 7 To reinstall place the hard bag in a fully seated position on the muffler 8 Insert saddlebag fastener bolts and torque to specification TORQUE 18 ft lbs 24 Nm 49 INSTRUMENT...

Page 52: ...otorcycle To park the motorcycle swing the end of the sidestand downward and away from the motorcycle until it is fully extended Always turn the handlebars to the left for maximum stability Lean the motorcycle to the left until the sidestand firmly supports the motorcycle CAUTION If the motorcycle weight is not resting on the sidestand it will not lock In this situation any movement of the motorcy...

Page 53: ...ndshield TORQUE Windshield Screws 36 in lbs 4 W WI IN ND DS SH HI IE EL LD D A AD DJ JU US ST TM ME EN NT T Use the windshield switch q to adjust windshield height for the best wind deflection Press up on the switch to adjust the windshield upward Press down on the switch to adjust the windshield downward Double tap up or down on the switch to auto adjust the windshield all the way up or down If t...

Page 54: ... brake effectiveness apply the front brake lever and the rear brake pedal together A AN NT TI I L LO OC CK K B BR RA AK KE E S SY YS ST TE EM M A AB BS S The anti lock brake system automatically adjusts brake pressure as needed to provide optimum braking control reducing the chance of wheel lock up during hard braking events or when braking on rough uneven slippery or loose surfaces See page 14 1 ...

Page 55: ...s adhere to all safe motorcycle riding practices as recommended It is not unusual to leave tire marks on the road surface during a hard braking event The anti lock brake system does not compensate for or reduce the risks associated with excessive speed reduced traction on rough uneven or loose surfaces poor judgment improper operation F FR RO ON NT T B BR RA AK KE E L LE EV VE ER R The front brake...

Page 56: ...ear brake pedal q is located on the right side of the motorcycle Press downward on the rear brake pedal to apply the rear brake WARNING Resting your foot on the brake pedal will cause excessive and premature wear of brake pads and reduced braking efficiency which could result in severe injury or death See page 74 for braking procedures F FU UE EL L C CA AP P The fuel filler cap q is located on the...

Page 57: ...eling instructions 4 To close press fuel cap downward until it clicks M MA AN NU UA AL L O OV VE ER RR RI ID DE E NOTE The manual override process should only be used in case of system lock issues or loss of bike electric power You should use the electric unlock process detailed on page 54 or have a authorize dealer repair the system if it does not work The manual override process shows you how to...

Page 58: ...ap and push forward to release front mount from keyway 4 Lift console up and out away from the fuel tank to complete removal 5 Use a small narrow tool to push the lock solenoid at the front of fuel cap under the latch to the left position 6 Reinstall console NOTE Console cannot be re installed with fuel door open It is recommended that the console be re installed prior to opening the fuel cap 7 Re...

Page 59: ... can assist WARNING Read the entire Instruments Features and Controls section of this manual before riding your motorcycle A complete understanding of the features and capabilities of your motorcycle is essential to its safe operation Anything less may result in serious injury or death You must be familiar with all instruments and controls to perform the pre ride inspections TIP During the pre rid...

Page 60: ...cancel the signal Verify that the signals and the indicator light stop flashing Repeat the procedure for the right turn signals Emer gency Flashers Press and hold the turn signal switch in for 1 second to activate flashers Verify that all four turn signals flash as well as the lamps on the indicator panel Turn the flashers off Verify that all signals and indicator lamps stop flashing ITEM INSPECTI...

Page 61: ...ely closed E EN NG GI IN NE E O OI IL L L LE EV VE EL L With the semi dry sump lubrication system the engine oil level on the dipstick will fluctuate depending on the motorcycle s position and engine temperature when checked To ensure a proper reading of the engine oil level follow all inspection procedures closely WARNING Operating with insufficient deteriorated or contaminated engine oil will ca...

Page 62: ...range anywhere between the two marks on the dipstick If the oil level on the dipstick is anywhere in the safe range do not add oil Oil should be added only if the proper oil check procedure is followed and the level is below safe mark NOTICE Oil should be added only if the proper oil check procedure is followed and the level is below the safe mark TIP The approximate volume between the FULL w and ...

Page 63: ...re and condition before each ride Check tire pressure before riding when the tires are cold This will provide the most accurate reading as riding warms the tires and increases tire air pressure Tires remain warm for at least 3 hours after a ride Do not adjust tire pressure immediately after riding As tires cool the pressure will drop and result in underinflation Always check and adjust tire pressu...

Page 64: ...ry See page 120 F FR RO ON NT T B BR RA AK KE E L LE EV VE ER R 1 Pull the front brake lever toward the handlebar and hold it The lever should move freely and smoothly The lever should feel firm and continue to feel firm until released 2 Release the lever It should return to its rest position quickly when released 3 If the front brake lever fails to perform as stated service the brake lever before...

Page 65: ...ns from leaking or dried fluid Tighten any leaking connections to the proper torque values and replace components as necessary See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer or other qualified dealer WARNING Brake fluid leaks or low brake fluid levels could cause brake system failure which could result in serious injury or death Do not operate the vehicle with l...

Page 66: ...n of the clutch safety switch S SI ID DE E S ST TA AN ND D 1 On level ground straddle the motorcycle and bring it to the fully upright position 2 Move the side stand up to the stored position and down to the fully extended position several times It should move smoothly and quietly Make sure the return spring holds the side stand tightly in place when the side stand is in the stored position Adjust...

Page 67: ...t interfere with smooth steering R RE EA AR R S SU US SP PE EN NS SI IO ON N Check the rear shock absorber mounting and inspect for leaks See your dealer for service if you discover leaks or malfunction of any kind See page 110 WARNING Inadequate ground clearance could result in components contacting the ground causing loss of control and serious injury or death Always ensure ground clearance is a...

Page 68: ...le and bring it to the upright position before turning it on The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel promptly 66 PRE RIDE INSPECTIONS ...

Page 69: ...nd follow all break in procedures to ensure the long term performance and durability of your engine NOTICE Failure to properly follow the engine break in procedures outlined in this manual can result in serious damage to the engine Avoid full throttle operation and other conditions that may place an excessive load on the engine during the break in period The more cautiously you treat your motorcyc...

Page 70: ...tening and an engine oil and filter change Performing break in maintenance at the required odometer reading helps ensure peak engine performance minimal exhaust emissions and maximum service life of the engine F FU UE EL LI IN NG G Always dismount the motorcycle and refuel on level ground with the sidestand down Review the fuel warnings Use only the recommended fuel See page 155 Hold the nozzle wh...

Page 71: ... filler neck 4 Add fuel to the tank until it crests the circular shaped opening in the filler neck column The tank is full at this level Do not overfill the fuel tank Fuel level should not rise into the fill neck Overfilling may result in degraded performance of engine and evaporative emissions control system 5 Always securely close the fuel cap before remounting the motorcycle 69 OPERATION ...

Page 72: ...ith the clutch disengaged clutch lever pulled in The engine should NEVER start in any gear except neutral if the sidestand is down See page 50 TIP If the motorcycle runs out of fuel prime the system before attempting to restart the engine 1 Perform the Pre Ride Inspections See page 57 Properly secure any cargo 2 Straddle the motorcycle and bring it to the fully upright position Retract the sidesta...

Page 73: ...can overheat the catalytic converter which could result in catalytic converter damage and loss of emission control DO NOT OPERATE the motorcycle if a misfire or non firing cylinder exists 9 Leave the throttle closed and allow the engine to idle Idle speed will gradually slow to normal as the engine warms to operating temperature TIP Do not rev the engine or put the transmission in gear immediately...

Page 74: ...wly To shift from first gear to neutral gently lift the toe lever a half stroke TIP The transmission is in neutral if you can move the motorcycle forward or rearward freely without disengaging the clutch If the power switch is ON the neutral indicator illuminates when the transmission is in neutral S SH HI IF FT TI IN NG G G GE EA AR RS S W WH HI IL LE E S ST TA AT TI IO ON NA AR RY Y To locate ne...

Page 75: ...r and open the throttle in one smooth motion TIP Within the recommended speed ranges see Recommended Shift Points chart you can downshift to slow the motorcycle or to increase power You may want to downshift when climbing a hill or passing Downshifting also helps to decrease speed when combined with closing the throttle 8 To shift to a lower gear downshift simultaneously pull the clutch lever towa...

Page 76: ...ont brake than rear brake generally provides the best braking performance 1 To slow the motorcycle with the brakes close the throttle and apply the front and rear brakes evenly and gradually TIP If the anti lock brakes engage during a braking event the rider will feel pulsing at the brake levers Continue to apply steady pressure to the brakes for the best stopping performance 2 As the motorcycle s...

Page 77: ... clutch WARNING Stopping the engine with the transmission in gear while the motorcycle is moving could cause loss of rear wheel traction or engine and transmission damage which could cause loss of control and serious injury or death Always stop the engine after the motorcycle is fully stopped and the transmission is in neutral If the engine stops unexpectedly while the motorcycle is moving guide t...

Page 78: ...ave been activated at least once since the engine was started for the cruise control to function S SE ET T S SP PE EE ED D 1 Press and release the center of the cruise control switch q The amber cruise control indicator will illuminate in the instrument cluster Cruise control is enabled but not set 2 Accelerate to the desired speed and press left on the cruise control switch to activate cruise con...

Page 79: ...orts the motorcycle 5 Turn the power switch off and ensure the run stop switch on the right hand control is in the off position P PA AR RK KI IN NG G O ON N A A S SL LO OP PE E If parking on a slope is unavoidable park with the front wheel uphill from the rear wheel Place the transmission in first gear and position the motorcycle so that it is stable when it rests on the sidestand P PA AR RK KI IN...

Page 80: ...78 ...

Page 81: ...rmation in the Safety Maintenance section Before beginning any maintenance procedure read the instructions for the entire procedure Always position the motorcycle on a firm level surface before performing service Make sure the motorcycle will not tip or fall while elevated or while on the sidestand See the Elevating the Vehicle section for details Hot engine and exhaust components can cause burns ...

Page 82: ...lp ensure optimum engine performance for the entire service life of the engine Your dealer will change engine oil inspect all fluids and serviceable components ensure that all fasteners are tightened and make other adjustments as needed P PE ER RI IO OD DI IC C M MA AI IN NT TE EN NA AN NC CE E Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for repla...

Page 83: ...ntrol System Service California International 5 50 00 0 M MI IL LE E 8 80 00 0 K KM M S SE ER RV VI IC CE E ITEM REMARKS D Crankcase Ventilation System Inspect tighten clean adjust D Drive Belt Inspect tighten clean adjust Damper Cushion Drive Visual inspection for cracks or deformation is required whenever the rear wheel is removed Replace if damage is found D Engine Mount Fasteners Inspect tight...

Page 84: ...proper lubricant as directed D Front Fork Oil Inspect D Front Forks and Front Axle Inspect adjust if necessary D Gear Shift Pedal Inspect adjust if necessary D Head Light Inspect adjust if necessary D Rear Brake Pedal Inspect adjust if necessary D Rear Shock Absorber Inspect adjust if necessary D Rear Wheel Alignment Inspect adjust if necessary Road Test Perform Road Test D Sidestand Lubricate wit...

Page 85: ...t clean D Oil Lines Oil System Inspection Inspect clean adjust if necessary Battery Check terminals clean test D Brake Fluid Change every two years DOT 4 XU D Brake Pads Inspect pad wear replace if worn beyond service limit D Clutch Cable Freeplay Inspect adjust if necessary D Fasteners Inspect tighten if necessary D Front Brake Lever Inspect adjust if necessary lubricate with proper lubricant as ...

Page 86: ...r Filter Inspect clean D Crankcase Ventilation System Inspect tighten clean adjust Damper Cushion Drive Visual inspection for cracks or deformation is required whenever the rear wheel is removed Replace if damage is found D Drive Belt Inspect tighten clean adjust XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants E Evaporative Emission Control System Inspect clean ...

Page 87: ...il Replace at specified interval or every 2 years D Front Forks and Front Axle Inspect adjust if necessary D Gear Shift Pedal Inspect adjust if necessary D Rear Brake Pedal Inspect adjust if necessary D Rear Shock Absorber Inspect adjust if necessary D Rear Wheel Alignment Inspect adjust if necessary Road Test Perform Road Test D Sidestand Inspect adjust if necessary lubricate with proper lubrican...

Page 88: ...s E Evaporative Emission Control System Inspect clean E Exhaust System Inspect tighten adjust D Fuel System Inspect clean D Oil Lines Oil System Inspection Inspect clean adjust if necessary D E Spark Plugs Inspect torque to specification Battery Check terminals clean test D Brake Fluid Replace DOT 4 XU D Brake Pads Inspect pad wear replace if worn beyond service limit D Clutch Lever Lubricate with...

Page 89: ...Test Perform Road Test D Sidestand Lubricate with proper lubricant as directed D Steering Bearings Inspect D Suspension Linkage Rear Inspect D Swing Arm and Rear Axle Inspect D Tires Wheels Inspect tread depth sidewall cracking wear patterns 1 15 5 0 00 00 0 M MI IL LE E 2 24 4 0 00 00 0 K KM M S SE ER RV VI IC CE E ITEM REMARKS XU Air Filter Inspect Clean D Crankcase Ventilation System Inspect ti...

Page 90: ...ect adjust if necessary D Clutch Cable Freeplay Inspect adjust if necessary D Control Cable Ends Inspect adjust if necessary D Fasteners Inspect tighten if necessary D Front Brake Lever Adjust if necessary lubricate with proper lubricant as directed D Front Fork Oil Replace D Front Forks and Front Axle Inspect adjust if necessary D Gear Shift Pedal Inspect adjust if necessary D Rear Brake Pedal In...

Page 91: ... deformation is required whenever the rear wheel is removed Replace if damage is found D Drive Belt Inspect tighten clean adjust D Engine Compression Inspect correct if necessary XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants E Evaporative Emission Control System Inspect clean E Exhaust System Inspect tighten adjust D Fuel System Inspect clean Key Fob Battery R...

Page 92: ...l Inspect D Front Forks and Front Axle Inspect adjust if necessary D Gear Shift Pedal Inspect adjust if necessary D Gear Position Switch Inspect clean D Head Light Inspect adjust if necessary D Rear Brake Pedal Inspect adjust if necessary D Rear Shock Absorber Inspect adjust if necessary D Rear Wheel Alignment Inspect adjust if necessary Road Test Perform Road Test D Sidestand Lubricate with prope...

Page 93: ...l System Inspect clean E Exhaust System Inspect tighten adjust D Fuel System Inspect clean D Oil Lines Oil System Inspection Inspect clean adjust if necessary Battery Check terminals clean test D Brake Fluid Change every two years DOT 4 XU D Brake Pads Inspect pad wear replace if worn beyond service limit D Clutch Lever Inspect adjust if necessary D Clutch Cable Freeplay Inspect adjust if necessar...

Page 94: ...eels Inspect tread depth sidewall cracking wear patterns 3 30 0 0 00 00 0 M MI IL LE E 4 48 8 0 00 00 0 K KM M S SE ER RV VI IC CE E ITEM REMARKS XU Air Filter Replace D Crankcase Ventilation System Inspect tighten clean adjust Damper Cushion Drive Visual inspection for cracks or deformation is required whenever the rear wheel is removed Replace if damage is found D Drive Belt Replace D Engine Com...

Page 95: ...ubricate with proper lubricant as directed D Fasteners Inspect tighten if necessary D Front Brake Lever Lubricate with proper lubricant as directed D Front Fork Oil Replace D Front Forks and Front Axle Inspect adjust if necessary D Gear Shift Pedal Inspect adjust if necessary D Gear Position Switch Inspect clean D Head Light Inspect adjust if necessary D Rear Brake Pedal Inspect adjust if necessar...

Page 96: ...henever the rear wheel is removed Replace if damage is found D Drive Belt Inspect tighten clean adjust XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants E Evaporative Emission Control System Inspect clean E Exhaust System Inspect tighten adjust D Fuel System Inspect clean D Oil Lines Oil System Inspection Inspect clean adjust if necessary Battery Check terminals c...

Page 97: ...ar Wheel Alignment Inspect adjust if necessary Road Test Perform Road Test D Sidestand Lubricate with proper lubricant as directed D Steering Bearings Inspect D Suspension Linkage Rear Inspect D Swing Arm and Rear Axle Inspect D Tires Wheels Inspect tread depth sidewall cracking wear patterns 4 40 0 0 00 00 0 M MI IL LE E 6 64 4 0 00 00 0 K KM M S SE ER RV VI IC CE E ITEM REMARKS XU Air Filter Rep...

Page 98: ... to specification Battery Check terminals clean test D Brake Fluid Replace DOT 4 XU D Brake Pads Inspect pad wear replace if worn beyond service limit D Clutch Lever Lubricate with proper lubricant as directed D Clutch Cable Freeplay Inspect adjust if necessary D Control Cable Ends Lubricate with proper lubricant as directed D Fasteners Inspect tighten if necessary D Front Brake Lever Adjust if ne...

Page 99: ...epth sidewall cracking wear patterns 4 45 5 0 00 00 0 M MI IL LE E 7 72 2 0 00 00 0 K KM M S SE ER RV VI IC CE E ITEM REMARKS XU Air Filter Inspect clean D Crankcase Ventilation System Inspect tighten clean adjust Damper Cushion Drive Visual inspection for cracks or deformation is required whenever the rear wheel is removed Replace if damage is found D Drive Belt Inspect tighten clean adjust XU En...

Page 100: ...spect tighten if necessary D Front Brake Lever Lubricate with proper lubricant as directed D Front Fork Oil Replace D Front Forks and Front Axle Inspect adjust if necessary D Gear Shift Pedal Inspect adjust if necessary D Rear Brake Pedal Inspect adjust if necessary D Rear Shock Absorber Inspect adjust if necessary D Rear Wheel Alignment Inspect adjust if necessary Road Test Perform Road Test D Si...

Page 101: ...nt Replace Coolant XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants E Evaporative Emission Control System Inspect clean E Exhaust System Inspect tighten adjust D Fuel System Replace D Oil Lines Oil System Inspection Inspect clean adjust if necessary D E Spark Plugs Inspect torque to specification Battery Check terminals clean test D Brake Fluid Replace DOT 4 XU D...

Page 102: ...pect adjust if necessary D Rear Brake Pedal Inspect adjust if necessary D Rear Shock Absorber Replace D Rear Wheel Alignment Inspect adjust if necessary Road Test Perform Road Test D Sidestand Lubricate with proper lubricant as directed D Steering Bearings Inspect D Suspension Linkage Rear Inspect D Swing Arm and Rear Axle Inspect D Tires Wheels Inspect tread depth sidewall cracking wear patterns ...

Page 103: ... NOTICE After an oil change the low oil pressure indicator may illuminate when the engine is started If this occurs do not increase RPM above idle speed until the indicator turns off Operating above idle speed could result in damage to the engine 1 Change the oil and filter when the engine is warm If the engine is cold start the engine and allow it to run at idle for at least 5 minutes 2 Park the ...

Page 104: ...se by hand until the filter gasket contacts the sealing surface then turn it an additional 3 4 to one full turn 11 Remove the dipstick Add only 4 qts 3 8 l of the recommended oil at this step Do not overfill 12 Reinstall the dipstick securely 13 With the motorcycle in an upright centered position start the engine and idle for approximately 30 seconds 14 Stop the engine and add an additional 1 qts ...

Page 105: ... Tank See page 114 2 Remove the zip ties from harness retention as well as the the brake line retention clips Remove the wiring harness q and the brake lines w from airbox filter cover retention features 3 Remove the airbox filter cover fasteners e and remove from the unit 4 Installation of new filter is performed by reversing the removal procedure TORQUE Airbox Filter Cover Fastener 84 in lbs 10 ...

Page 106: ... antifreeze is already premixed and ready to use Do not dilute with water To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every five 5 years or 50 000 miles whichever comes first Please see your dealer for this service CAUTION Allow the vehicle to cool before performing any maintenance on the cooling system Failure to do so ...

Page 107: ...R R D DR RI IV VE E B BE EL LT T C CL LE EA AN NI IN NG G TIP Do not inspect or adjust drive belt tension when the belt or drive system is wet or hot Improper adjustment will result Cleaning the drive belt will maximize belt and sprocket life and minimize drive line noise Clean the belt at every tire change Clean the belt more often if riding in dirty dusty or high debris environments 1 Mix a few ...

Page 108: ...f the vehicle has been run at operating temperature within the last four hours Allow the vehicle to cool down to ambient temperature before measuring belt tension Replace the drive belt and both sprockets as a set if the drive belt has over 5 000 miles 8 000 km of service at the time of damage or failure R RE EA AR R D DR RI IV VE E B BE EL LT T W WE EA AR R A AN NA AL LY YS SI IS S WEAR ANALYSIS ...

Page 109: ...NT Perform this procedure to achieve proper belt tension and alignment Belt tension should be set before performing the alignment procedure B BE EL LT T T TE EN NS SI IO ON N WARNING A drive belt that is not properly tensioned can cause drive line noise and damage the drive belt causing possible belt failure and loss of control of the motorcycle NOTICE Marks q and w are used as a reference for ini...

Page 110: ...note of adjuster locations q and w 4 Raise the rear of the motorcycle so the rear tire can be freely rotated 5 Loosen axle nut e 6 Turn the RIGHT SIDE adjuster nut r to achieve proper belt tension BELT DEFLECTION Model Deflection 10 lbs force Challenger 0 6 15 mm New Belt 0 79 20 mm Belt with 1000 miles 108 MAINTENANCE ...

Page 111: ...tation IMPORTANT The belt should track to the center of the sprocket tooth surface when properly aligned t Sprocket teeth should be visible on both sides of the drive belt 2 Rotate the wheel in the FORWARD direction and verify that sprocket teeth are still visible on both sides of the drive belt t 3 If necessary loosen the axle nut and LEFT SIDE adjuster until belt just moves off the right flange ...

Page 112: ...H HO OC CK K P PR RE EL LO OA AD D A AD DJ JU US ST TM ME EN NT T To adjust the shock preload perform the following procedure 1 Remove left hand side cover See page 127 2 Look up suspension setting for the specific loading according to chart decal applied to the inside of the left hand upper body panel 3 Use the 10 mm speed wrench and extension provided in the tool kit to set adjuster to proper se...

Page 113: ... swingarm or in the axle area see your dealer for service 4 With the transmission in neutral slowly rotate the rear wheel If the wheel does not rotate smoothly see your dealer for service F FR RO ON NT T F FO OR RK K S SU US SP PE EN NS SI IO ON N I IN NS SP PE EC CT TI IO ON N 1 Place the motorcycle on the sidestand and inspect the front forks If fork oil is present on the outer tube do not ride ...

Page 114: ...re the motorcycle is stable when elevated Injury may occur if the motorcycle tips or falls 2 Turn the handlebars from stop to stop The action should be smooth but not loose Make sure wires hoses and control cables do not interfere with smooth steering 3 Position the front wheel straight ahead Grasp the front forks near the front axle and attempt to move the wheel front to back If there is front to...

Page 115: ...y are secure The vent line coming from the tank should be connected to the port marked TANK the purge line should be connected to the port marked PURGE and the Atmospheric vent line should be conntected to the port marked AIR F FU UE EL L S SY YS ST TE EM M C CO OM MP PO ON NE EN NT TS S 1 Inspect fuel hoses for cracks or damage 2 Inspect hose connections at the fuel tank q and at the fuel rail fo...

Page 116: ...d exhaust to cool completely before disconnecting fuel line or removing tank Protect fuel tank finish when removing storing and installing tank 1 Remove seat See page 128 2 Remove left hand v cover by removing its fasteners q 3 Disconnect fuel feed line w 114 MAINTENANCE ...

Page 117: ... EVAP canister on the right hand side of the fuel tank 5 Remove fuel tank fastener t 6 Lift rear of tank upward and pull rearward to remove Place the fuel tank in a secure location with a drain pan positioned to catch any fuel that may leak or drip from disconnected hoses or fittings IMPORTANT Disconnect the fuel feed line from the bottom of the fuel tank during removal 115 MAINTENANCE ...

Page 118: ...N NI IC CA AL L C CL LU UT TC CH H L LE EV VE ER R F FR RE EE EP PL LA AY Y 1 Position the handlebars in the straight ahead position before measuring clutch lever freeplay 2 The clutch cable adjuster nut is located on the bottom of the clutch cover on the engine Loosen the lock nut 3 Turn the cable adjuster inward or outward until clutch lever freeplay is 0 5 1 5 mm as measured at the clutch perch...

Page 119: ...f the internal clutch switch Improper assembly can cause damage to the switch 5 Reconnect the clutch cable Reinstall the lever C clip and pin 6 Adjust clutch lever freeplay See page 116 7 Tighten the adjuster nut and slide the protective cover over the adjuster M ME EC CH HA AN NI IC CA AL L C CL LU UT TC CH H C CA AB BL LE E L LU UB BR RI IC CA AT TI IO ON N Lubricate control cable barrel ends at...

Page 120: ... purpose grease 2 Inspect brake pads as outlined in the Brake Pads section B BR RA AK KE E F FL LU UI ID D P PR RE EC CA AU UT TI IO ON NS S WARNING Using the wrong fluid or allowing air or contaminants into the fluid system can damage the system seals or result in a malfunction that could lead to serious injury or death Use only DOT 4 brake fluid from a sealed container Do not operate the front b...

Page 121: ... from the right side of the vehicle 3 Wipe the fluid container and the area around the reservoir cover with a clean cloth 4 If the fluid level is low inspect brake pads as outlined on page 122 If pads are not worn beyond the service limit inspect the brake system for leaks 5 Remove the cover and diaphragm The fluid level should be above the minimum indicator mark w on the reservoir body q Add brak...

Page 122: ... attempt to change the anti lock brake system fluid Please see your dealer for this service Always add brake fluid from a new unopened container Always use the recommended fluid See page 155 1 Position the motorcycle on level ground in the fully upright position Position the handlebars so that the fluid reservoir is level Wipe the fluid container and the area around the reservoir cover with a clea...

Page 123: ...eterioration of hoses B BR RA AK KE E D DI IS SC C I IN NS SP PE EC CT TI IO ON N C CL LE EA AN NI IN NG G CAUTION Allow brake components to cool before inspecting or performing maintenance Failure to do so can result in burn to skin 1 Inspect brake discs q for nicks scratches cracks or other damage Inspect the thickness of each brake disc at four or more locations around the disc If any disc is w...

Page 124: ...ly During this time brake performance will be less effective Avoid using brakes harshly unless in an emergency Brake efficiency will gradually increase during this seating period Inspect each front brake pad on both sides of the front disc Inspect each rear brake pad on both sides of the rear disc Replace brake pads when the thinnest point of the friction material w has worn to 1 0 mm Please see y...

Page 125: ...se an inspection mirror positioned at the front side of the caliper to view the friction material W WH HE EE EL L I IN NS SP PE EC CT TI IO ON N Inspect both wheels for cracks or damage and replace damaged wheels promptly Do not operate the motorcycle if wheels are damaged or cracked See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer can assist W WH HE EE EL L A AL ...

Page 126: ...ed by INDIAN MOTORCYCLE for your vehicle Always maintain proper tire pressure as recommended in the rider s manual and on safety labels T TI IR RE E R RE EP PL LA AC CE EM ME EN NT T NOTICE On models equipped with a TPMS the sensors are located 180 from the valve stem Use caution when servicing tires To avoid damaging a sensor break the bead at the valve stem then at 90 and 270 from the valve stem...

Page 127: ...ure the depth of the center tire tread on both front and rear tires T TI IR RE E P PR RE ES SS SU UR RE E Always check and adjust tire pressure when tires are cold Do not adjust tire pressure immediately after riding Wait at least 3 hours after riding to check pressure If pressure checked and adjusted while tires are warm the pressure will drop as tires cool and result in under inflation Adjust ti...

Page 128: ...park Plug Torque 7 4 ft lbs 10 Nm 1 Make sure the engine has cooled to room temperature 2 Turn the power switch off 3 Pull upward on the spark plug boots not the wires to remove the boots 4 To prevent debris from entering the spark plug holes use compressed air to clean the area around the plugs before removing them Tool 14 mm plug socket CAUTION Wear eye and face protection when using pressurized...

Page 129: ...HT T S SI ID DE E C CO OV VE ER R R RE EM MO OV VA AL L 1 Gently grasp front edge of right side cover and pull away from vehicle to release three grommet pins Use caution to prevent damage to painted surfaces L LE EF FT T S SI ID DE E C CO OV VE ER R R RE EM MO OV VA AL L 1 Gently grasp front lower corner left side cover and pull away from vehicle to release three grommet pins Use caution to preve...

Page 130: ...mounting tab from rear to front into the mount on the top of the frame 2 Rotate the rear of the seat downward and position the side mount seat brackets onto the frame Do not allow the seat mount brackets to contact the rear fender 3 On each side thread the seat mount bolt through the seat mount bracket and into the frame Torque seat bolts to specification TORQUE 18 ft lbs 24 Nm 4 Reinstall side co...

Page 131: ...rear suspension ride height preload is at specification 3 Position the motorcycle on a level surface with the headlight 32 ft 10 in 10 m from a wall 4 With the operator and passenger if applicable on board bring the motorcycle to the fully upright position 5 Start the engine and switch the headlight to low beam Observe the headlight aim on the wall 6 Make any necessary adjustments to headlight aim...

Page 132: ...D T TU UR RN N S SI IG GN NA AL L R RE EP PL LA AC CE EM ME EN NT T The LED turn signal lights are not serviceable If the turn signal becomes damaged or inoperable the entire light assembly must be replaced See your authorized INDIAN MOTORCYCLE dealer or other authorized dealer B BA AT TT TE ER RY Y The motorcycle battery is a sealed maintenance free battery Do not remove the battery cap strip for...

Page 133: ... removing its fasteners q 2 Remove battery bracket my removing its fastener w and sliding the bracket out of its retention feature 3 Disconnect negative battery terminal CAUTION Be careful not to cross battery terminals 4 Disconnect positive battery terminal 5 Remove battery from battery box 131 MAINTENANCE ...

Page 134: ...s 1 Carefully install battery into battery box 2 Connect the positive battery terminal and torque fastener to specification TORQUE Battery Terminal 48 in lbs 5 4 Nm 3 Connect the negative battery terminal and torque fastener to specification TORQUE Battery Terminal 48 in lbs 5 4 Nm 4 Install battery bracket and fastener w TORQUE Battery Bracket Fastener 84 in lbs 10 Nm 132 MAINTENANCE ...

Page 135: ... TT TE ER RY Y C CH HA AR RG GI IN NG G If your motorcycle will not be used for a period of four 4 weeks or longer a maintenance charger should be connected to the battery using the 12V Battery Charge Port The Battery Charge Port is taped to the main harness A maintenance charger can be purchased through your authorized INDIAN MOTORCYCLE dealer 133 MAINTENANCE ...

Page 136: ...Both Battery Light and Security Light are illuminated Key Fob performance can be affected by the following conditions Close proximity of ferrous materials e g money clip or pocket knife Key Fob stuck to saddlebag speaker magnet Key Fob held in ferrous container metal cup holder or glasses case Cold temperatures Key Fob should be kept above 45 F 7 C To replace the kep fob battery do the following 1...

Page 137: ...GI IN NG G R RE EC CO OM MM ME EN ND DA AT TI IO ON NS S L LO OW W C CH HA AR RG GE E The nominal voltage for an Indian Motorcycle battery is 12 8 Volts when fully charged The battery will self discharge when disconnected from a vehicle and will discharge at a faster rate when connected If the battery voltage falls below 12 5V it should be charged immediately using the recommended battery charger ...

Page 138: ...harged battery negative 4 Proceed with charging both batteries to full capacity Listed in the table below are the approximate charging times for deeply discharged batteries Always use the recommended automatic battery charger and wait for the charger to complete the charge cycle before disconnecting it The recommended automatic charger will indicate when the battery is fully charged on its display...

Page 139: ...nal brush will help maximize battery life Wash terminals with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly 4 Battery connections should be tightened to the correct torque during installation This will reduce voltage drop and ensure a reliable connection between th...

Page 140: ...odule and anti lock brake system This fuse box is located next to the battery box Fuse application and size are provided on a label on the fuse box cover E EL LE EC CT TR RI IC CA AL L P PR RE EC CA AU UT TI IO ON NS S Be aware of the following precautions regarding the electrical system to avoid disruption of electrical signals and possible system malfunction DO use ONLY genuine INDIAN MOTORCYCLE...

Page 141: ...If a key fob is not available your rider PIN can be entered using the Ride Command display to unlock the security system C CH HA AN NG GI IN NG G Y YO OU UR R S SE EC CU UR RI IT TY Y S SY YS ST TE EM M P PI IN N To change your PIN you must have either the key fob or your existing valid PIN available to gain access to the security system If the key fob is not detected or is not available and you c...

Page 142: ... AU US ST T S SY YS ST TE EM M I IN NS SP PE EC CT TI IO ON N Check the exhaust system for stains from leaking exhaust gasses Replace damaged or leaking exhaust gaskets Check all exhaust system fasteners Tighten loose clamps and fasteners Do not overtighten See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer can assist E EL LE EV VA AT TI IN NG G T TH HE E M MO OT TO...

Page 143: ... REMEDY ACTION Low Fuel Verify fuel level Fuel Pump Inoperative Turn engine STOP switch to RUN Turn the power switch on The fuel pump should run momentarily and then stop Check the fuel pump ignition circuit breaker POSSIBLE CAUSE POSSIBLE REMEDY ACTION Battery Voltage Too Low Fully charge the battery Spark Plug s Fouled Inspect spark plugs Spark Plug Wire s Disconnected or Loose Be sure spark plu...

Page 144: ... Cable Not Adjusted Properly Please see your dealer for inspection and adjustment Shift Linkage Not Adjusted Properly Please see your dealer for inspection and adjustment B BA AT TT TE ER RY Y C CH HA AR RG GI IN NG G R RA AT TE E L LO OW W O OR R B BA AT TT TE ER RY Y D DI IS SC CH HA AR RG GE ES S POSSIBLE CAUSE POSSIBLE REMEDY ACTION Loose Corroded Charging Circuit Connection Check clean batter...

Page 145: ...A AT TE ES S I IN NT TE ER RM MI IT TT TE EN NT TL LY Y POSSIBLE CAUSE POSSIBLE REMEDY ACTION Blown fuse Check the fuses See page 137 Debris lodged in components Inspect wheel speed sensor for debris Damage caused by debris Inspect wheel speed sensor for cracked housing Damaged components See service manual or authorized dealer 143 MAINTENANCE ...

Page 146: ...144 ...

Page 147: ... or for answers to your cleaning and detailing questions please see your INDIAN MOTORCYCLE dealer W WA AS SH HI IN NG G T TH HE E M MO OT TO OR RC CY YC CL LE E NOTICE Do not use pressurized water to wash the motorcycle Water may seep in and deteriorate wheel bearings brake caliper assemblies brake master cylinders electrical connectors steering head bearings and transmission seals Do not direct a...

Page 148: ...d NOTICE Never use a polishing buffing wax or any sponge that has an abrasive surface when cleaning a matte finish These products will buff the matte surface of the finish and result in a glossy finish Never clean matte finishes with a pressure washer as this will further imbed contaminants into the clear coat and may damage labels and decals G GL LO OS SS S C CL LE EA AR R C CO OA AT T F FI IN NI...

Page 149: ...uchscreen Wash and dry with a lint free cloth Do not expose to brake fluid Do not expose to gasoline Do not expose to DEET S ST TO OR RA AG GE E A AR RE EA A P PR RE EP PA AR RA AT TI IO ON N If you will not operate the motorcycle for more than 60 days store the motorcycle to prevent damage to the fuel system and the battery and to protect components from corrosion or deterioration During storage ...

Page 150: ...h a wire brush to remove any loose deposits 3 Wash the posts and the ends of the battery cables with a solution of one part baking soda to 16 parts water Rinse with clean water and wipe dry 4 Apply a thin film of dielectric grease to the posts and cable connectors 5 Clean the outside of the battery with a solution of mild detergent and warm water 6 Store the battery in a dry area with a temperatur...

Page 151: ...to prevent moisture from building up on the motorcycle which can cause oxidation of metal surfaces R RE EM MO OV VA AL L F FR RO OM M S ST TO OR RA AG GE E 1 Install a fully charged battery 2 Check the oil level If the motorcycle was stored in an area subject to wide swings in temperature and humidity such as outdoors change the engine oil before starting the engine NOTICE During storage temperatu...

Page 152: ...150 ...

Page 153: ...m Overall Height 56 2 in 1428 5 mm Unladen Seat Height 26 5 in 672 mm Wheelbase 65 7 in 1667 8 mm Ground Clearance 5 4 in 137 3 mm Rake Frame Trail 25 Degrees WEIGHT Dry Weight without Fuel Fluids 796 lbs 361 kg 805 lbs 365 kg Wet Weight with Fuel Fluids 831 lbs 377 kg 840 lbs 381 kg Gross Vehicle Weight Rating GVWR 1385 lbs 628 kg CAPACITIES Radiator Coolant 2 4 qts 2 3 L 151 SPECIFICATIONS ...

Page 154: ...ler CruiseTec Rear Tire Type Size 180 60R16 80H Metzeler CruiseTec Tire Pressures Front 36 psi 248 kPa Rear 41 psi 283 kPa CHASSIS Front Suspension Type Travel Inverted Telescopic Fork 5 1 in 130 mm Front Suspension Diameter 43 mm Rear Suspension Type Travel Single shock with hydraulic adjuster 4 5 114 mm Front Brakes Dual 320 mm Semi floating Rotor 4 Piston Caliper Rear Brakes Single 298 mm Float...

Page 155: ...uel System Throttle Body Bore Closed loop fuel injection 52 mm dual bore Exhaust System Two O2 sensors one each bank single three way catayst Rev Limit 6500 RPM Idle RPM 900 RPM 50 RPM Lubrication System Semi Dry Sump Spark Plug Gap NGK LZMAR8AI 10 0 039 in 1 0 mm DRIVETRAIN Primary drive Gear Drive Wet Clutch Clutch Type Wet Multi Plate Assist Primary Reduction Ratio 1 564 1 153 SPECIFICATIONS ...

Page 156: ... 1 385 1 4th Gear Ratio 1 103 1 5th Gear Ratio 0 943 1 6th Gear Ratio 0 811 1 Gear Shift Pattern 1 Down 5 Up Final Drive Type Belt Drive 152 Tooth Final Drive Ratio 2 379 1 Overall Gear Ratio 1st Gear 10 169 1 2nd Gear 6 933 1 3rd Gear 5 151 1 4th Gear 4 105 1 5th Gear 3 508 1 6th Gear 3 017 1 154 SPECIFICATIONS ...

Page 157: ...d the use of INDIAN MOTORCYCLE Full Synthetic 15W 60 Engine Oil for your motorcycle This oil is formulated with synthetic based oil and premium engine additive which have physical properties that meet API SM and ILSAC GF 4 specifications Do not blend oil additives with engine oil If oil must be added in an emergency and the recommended oil is not available choose only a high quality 15W 60 motorcy...

Page 158: ...156 ...

Page 159: ...and submitted to INDIAN MOTORCYCLE within ten days of purchase Upon receipt of this registration INDIAN MOTORCYCLE will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact ...

Page 160: ... snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect i...

Page 161: ...IS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE o...

Page 162: ...r country be sure to contact INDIAN MOTORCYCLE Customer Assistance and the customs department of the destination country before you move Vehicle importation rules vary considerably from country to country You may be required to present documentation of your move to INDIAN MOTORCYCLE in order to continue your warranty coverage You may also be required to obtain documentation from INDIAN MOTORCYCLE ...

Page 163: ...egistered outside of the country where it was purchased and you have not followed the procedure set above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the Li...

Page 164: ...t which conducts exhaust gasses Removal or puncturing of any part of the intake system Lack of proper maintenance Replacing any moving part of the vehicle or parts of the exhaust system or intake system with parts other than those specified by the manufacturer This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use Otherwise the owne...

Page 165: ...e parts such as the fuel injection system the ignition system catalytic converter and engine computer Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists INDIAN MOTORCYCLE will repair your motorcycle at no cost to you including diagnosis parts and labor M MA AN NU UF FA AC CT TU UR RE ER R S S W WA AR RR RA AN NT TY Y C CO OV VE ER...

Page 166: ...rnia Air Resources Board P O Box 8001 9528 Telstar Avenue El Monte CA 91734 8001 INDIAN MOTORCYCLE COMPANY hereinafter INDIAN MOTORCYCLE warrants that each new 2015 and later INDIAN motorcycle that includes as standard equipment a headlight taillight and stoplight and is street legal A is designed built and equipped so as to conform at the time of initial retail purchases with all applicable regul...

Page 167: ...gs if failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related parts may vary from model to model certain models may not contain all of these parts and certain models may contain functionally equivalent parts In the State of California only Emission Control System emergency repairs as provided for in the Califo...

Page 168: ...roperly installed Use of replacement parts or accessories not conforming to INDIAN MOTORCYCLE specifications which adversely affect performance and or Use in competitive racing or related events B Inspections replacement of parts and other services and adjustments necessary for required maintenance C Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be rea...

Page 169: ...THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU B NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY INDIAN MOTORCYCLE EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CO...

Page 170: ... part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However INDIAN MOTORCYCLE is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins on the date the motorcycle is delivered to an ...

Page 171: ...M MA AI IN NT TE EN NA AN NC CE E L LO OG G M MA AI IN NT TE EN NA AN NC CE E L LO OG G MAINTENANCE PERFORMED MILES KM NOTES PERFORMED BY 169 MAINTENANCE LOG ...

Page 172: ...170 ...

Page 173: ... Connections 118 Brake Light Replacement 130 Brake Pads 122 Brakes 52 Front Brake Lever 53 Rear Brake Pedal 54 Braking 74 Break In Maintenance 80 C Cargo Limit Warning 22 Carrying a Passenger 12 Carrying Cargo 12 Changing Your Security System PIN 139 Clean and Protect the Motorcycle 148 Cleaning Products 145 Clutch Lever 47 Compliance Statement 37 Console 25 Control Left Control 26 Right Control 2...

Page 174: ... Coat Finish Care 146 Gross Vehicle Weight Rating 18 GVWR 18 H Headlight Aim Inspection 128 Headlight Aim Adjustment 129 Headlight Beam Switch 31 Headlights 46 Heated Grips Setting 45 High Current Fuses 138 I Identification Number Records 7 Indicator Lamps 33 Infotainment Care 147 Instrument Cluster 32 35 45 Speedometer 35 K Key Fob Battery Life 134 Keyless Ignition 30 L LUBRICANTS AND FLUIDS 159 ...

Page 175: ...aning 105 Rear Drive Belt Condition 106 Rear Drive Belt Wear Analysis 106 Removal From Storage 149 Reporting Safety Defects 19 Ride Command 36 Buttons 38 Settings 43 Update Software 44 Ride Modes 41 Rider Screen 38 Road Test 140 Road Tests 80 Rodents 148 S Saddlebag Lock Switch 32 Saddlebags 48 Saddlebags and Other Storage 13 Safe Riding Practices 9 Follow These General Safe Riding Practices 10 Mo...

Page 176: ...e Condition 125 Tire Inflation 148 Tire Pressure 125 Tire Pressure Chart 125 Tire Pressure Monitoring System 48 Tire Replacement 124 Tire Tread Depth 125 Tires 124 Toggle Switches 27 Traction Control 42 Transporting the Motorcycle 16 Trigger Switches 41 Troubleshooting 141 143 Turn Signal Replacement 130 U USB Port 45 W Warranty 157 Warranty Information 7 Washing the Motorcycle 145 Wheel Alignment...

Page 177: ......

Page 178: ...To locate your nearest dealer visit www indianmotorcycle com Part No 9931163 Rev 02 Printed in USA Indian Motorcycle Company 2100 Highway 55 Medina MN 55340 Phone 1 877 204 3697 French 1 800 268 6334 ...

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