Indian Motorcycle Indian Scout Rider'S Manual Download Page 86

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Maintenance

Headlight Aim Adjustment

1. To adjust the headlamp vertically, loosen the housing mount

fastener and pivot the housing upward or downward. Tighten the

fastener.

Torque: 35 ft-lbs (47.5 Nm)

2. To adjust the headlamp horizontally, loosen the headlight mounting

bolt and pivot the headlight to the left or right. Tighten the bolt.

Torque: 18 ft-lbs (24.4 Nm)

Headlight Housing

Mount Fastener

(Vertical Adjustment)

Headlight Mounting Bolt

(Horizontal Adjustment)

Summary of Contents for Indian Scout

Page 1: ...2015 Rider s M ual ...

Page 2: ...California Proposition 65 Warning This product contains or emits chemicals known to the state of California to cause cancer and birth defects or other reproductive harm ...

Page 3: ...1 2015 Rider s Manual Indian Scout ...

Page 4: ...ation are intended for reference use only No liability can be accepted for omissions or inaccuracies Indian Motorcycle Company reserves the right to make changes at any time without notice and without incurring obligation 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 expre...

Page 5: ... Safety 5 Reporting Safety Defects 16 Component Identification 18 Instruments Features Controls 22 Pre Ride Inspections 34 Operation 43 Maintenance 53 Cleaning and Storage 94 Specifications 98 Warranty 104 Maintenance Log 115 Index 117 ...

Page 6: ...r repairs and service your motorcycle may require INDIAN motorcycles comply with all federal state and local safety and emission regulations for the area of intended sale Service and Warranty Information Some procedures are beyond the scope of this manual See your dealer to purchase an INDIAN MOTORCYCLE Service Manual Some procedures provided in the service manual require specialized knowledge equ...

Page 7: ...e Following the precautions and procedures in the manual will add to your enjoyment and help keep you safe If you lose or damage this manual please purchase a new one through any authorized INDIAN MOTORCYCLE dealer This rider s manual should be considered part of the motorcycle and should remain with the motorcycle when ownership changes Safety Symbols and Signal Words The following signal words a...

Page 8: ... courses in your area call 1 800 446 9227 or visit www msf usa org Read and understand all information in this rider s manual Observe all maintenance requirements specified in this manual See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer Design characteristics affect how you should ride the motorcycle The motorcycle is designed for on road use with one rider and on...

Page 9: ...so affect your awareness and judgment If your motorcycle operates abnormally correct the problem immediately See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer Ride defensively as if you are invisible to other motorists even in broad daylight A motorist s failure to see or recognize a motorcycle is the leading cause of automobile motorcycle accidents Ride where you ...

Page 10: ...se loss of control Do not tow a trailer Towing a trailer can make 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 m...

Page 11: ...ssenger footrests Do not carry a passenger who cannot place both feet firmly on the passenger footrests A passenger who is not holding on properly or who cannot reach the passenger footrests can shift their body erratically which can make the motorcycle hard to handle and cause loss of control Before riding be sure your passenger knows safe riding procedures Discuss any safety information unfamili...

Page 12: ...at you wear approved Personal Protective Equipment PPE bearing markings 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 bo...

Page 13: ...cle is either leaned or in a vertical position limit suspension or steering travel or your ability to operate controls displace you from your normal riding position obscure lights or reflectors Bulky heavy or large accessories can cause instability due to the lifting or buffeting effects of wind and loss of control Do not install electrical accessories that exceed the capacity of the motorcycle s ...

Page 14: ...Do not park near a flammable source such as a kerosene heater or an open flame where hot components could ignite combustible materials Park the motorcycle on a firm level surface Sloped or soft surfaces may not support the motorcycle If you must park on a slope or soft surface follow the precautions outlined on page 52 Saddlebags Whenever operating with saddlebags or while carrying cargo Never rid...

Page 15: ...t distribution or sudden shifting of accessories or cargo while you re riding may cause difficult handling loss of control and driving hazards for other motorists if cargo falls from the motorcycle For riding comfort and to ensure proper ground clearance adjust rear shock preload See page 68 Do not attach large or heavy cargo such as sleeping bags duffel bags or tents to the handlebars front fork ...

Page 16: ...ine is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine before refueling Always refuel outdoors or in a well ventilated area Open the fuel cap slowly Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gaso...

Page 17: ...ead condition and wheel and tire balance Inspect tires regularly and replace worn or damaged tires promptly Use only approved replacement tires See the Specifications section beginning on page 98 Always ensure proper steering head bearing adjustment Regularly inspect the rear shock absorber and the front forks for fluid leaks or damage Make any necessary repairs promptly See page 71 Clean the moto...

Page 18: ...riders apparel and items in or on apparel weight of any accessories and their contents weight of any additional cargo on the motorcycle Reporting Safety Defects If you believe that your vehicle has a defect that could result in a crash or cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying INDIAN MOTORCYCLE in writin...

Page 19: ...nd market specific Your motorcycle may not contain all of the labels shown 1 Vehicle Identification Number VIN on side of steering head 2 Vehicle Emission Control Information VECI 3 Noise Emission Control Information NECI 4 Operator Warning Fuel Recommendation 1 4 2 3 ...

Page 20: ...n Signal 6 Headlight 7 Front Fork 8 Rear Brake Pedal 9 Driver s Footrest 10 Mufflers 11 Right Rear Turn Signal 12 Taillight 13 Left Front Turn Signal 14 Ignition Switch 15 Battery under seat 16 Left Rear Turn Signal 17 Coolant Recovery Bottle 18 Sidestand 19 Gear Shifter 20 Radiator 6 5 9 8 12 11 4 1 3 7 2 10 ...

Page 21: ...19 Component Identification 19 18 13 9 15 7 14 17 4 16 20 ...

Page 22: ...se near the sidestand Record the number in the space provided on page 103 Key Identification Number The key identification number is stamped on the metal key tag attached to the key ring If it becomes necessary to replace the ignition key for any reason provide the key number to your INDIAN dealer Engine Number Key Number ...

Page 23: ...21 Component Identification Console 1 Clutch Lever 2 Instrument Cluster 3 Front Brake Master Cylinder 4 Throttle Control Grip 5 Front Brake Lever 6 Fuel Cap 1 6 5 4 3 2 ...

Page 24: ...truments Features and Controls Switches Turn Signal Switch Hazard Warning Flashers Switch High Low Light Switch Horn Switch Engine Starter Switch Engine Stop Run Switch Left Control Right Control Mode Button ...

Page 25: ... signal will deactivate automatically when speed or distance reach predetermined levels To cancel a signal manually move the switch to the center position and push it inward Momentary Feature Move the turn signal switch left or right and hold it in that position for at least one second The momentary feature will activate and the signal will then cancel when the switch is released Tip If a bulb fai...

Page 26: ...ront side of the left handlebar controls With the ignition switch on use the MODE button to toggle through the modes of the multi function display Use the MODE button to set the display units to either standard or metric units of measurement See page 28 Engine Stop Run Switch Use the engine stop run switch to turn the engine off quickly Turn the key off after the engine stops Press the top of the ...

Page 27: ...ht must be on at all times while operating The headlights automatically operate when the engine is running Do not modify the ignition light switch wiring to circumvent the automatic headlight feature The ignition light key switch controls the electrical functions of the motorcycle The switch is located on the ignition cover on the left side of the motorcycle Before starting the engine read the ins...

Page 28: ...High Beam The lamp illuminates when the headlight switch is set to high beam Turn Signal The turn signal indicator flashes when the left right or both turn signals hazard warning flashers are active If there is a problem in the signal system the lamps will flash at twice the normal rate Check Engine If this lamp illuminates while the engine is running see your dealer promptly The light will remain...

Page 29: ...raveled Trip Odometer The trip odometer displays total distance traveled since being reset To reset toggle to the trip odometer then press and hold the MODE button until the trip odometer resets to zero Engine Speed Engine speed displays in revolutions per minute RPM Engine Coolant Temperature The temperature area displays the temperature of the engine coolant Modes Available Odometer Engine Coola...

Page 30: ...aining display settings Clock Tip The clock must be reset any time the battery has been disconnected or discharged 1 Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the switch 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes ...

Page 31: ...rting the engine If the CHECK ENGINE indicator lamp illuminates retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 See an authoriz...

Page 32: ...fe operating pressure Stop the engine as soon as safely possible and check the oil level If the oil level is sufficient but LO OIL continues to display after restarting the engine stop the engine immediately Condition Indicates Action Required Engine coolant temperature approaches unsafe operating condition while the engine is running Engine coolant temperature is above a safe operating temperatur...

Page 33: ...er The clutch lever 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 clutch pull the lever toward the handlebar To engage the clutch release the lever in a brisk but controlled manner Mirrors Your vehicle is equipped with convex mirrors Objects seen in a mi...

Page 34: ... 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 motorcycle could cause the sidestand to retract slightly If the sidestand is not in the ...

Page 35: ...kes The front brakes should be applied simultaneously with the rear brakes To apply the front brake pull the lever toward the handlebar See page 51 for braking procedures Rear Brake Pedal The rear brake pedal 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 w...

Page 36: ... service 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 ride i...

Page 37: ... rear left turn signals flash as well as the corresponding light on the indicator panel Move the switch to the center position and push it inward to cancel the signal Verify that the signals and the indicator light stop flashing Repeat the procedure for the right turn signals Hazard Warning Flashers Press and hold the hazard warning flashers switch for 1 2 seconds to activate the hazard warning fl...

Page 38: ... Brake Fluid Levels Check front and rear brake fluid levels Brake Components Inspect hoses and connections Throttle Inspect hand grip and throttle movement Clutch Check lever operation and freeplay Front Suspension Check for leaks debris and damage Steering Check for smooth operation by turning handlebars full left and full right Rear Suspension Check mounting and inspect for leaks Rear Drive Belt...

Page 39: ...e oil fill dipstick is located on the right side of the motorcycle Always use the recommended oil See page 102 1 Position the motorcycle on level ground in the fully upright and centered position 2 Start the engine from cold and allow it to idle for 30 seconds Stop the engine 3 Remove the dipstick and wipe it clean 4 Reinstall the dipstick until fully seated 5 Remove the dipstick and view the oil ...

Page 40: ...e 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 pressure when tires are cold...

Page 41: ... brake fluid if necessary See page 77 Front Brake Lever 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 riding ...

Page 42: ...or low brake fluid levels could cause brake system failure which could result in serious injury or death Do not operate the vehicle with low brake fluid levels or when leaks are evident dampness or stains from dried fluid See your authorized INDIAN MOTORCYCLE dealer Mechanical Clutch 1 Squeeze the clutch lever toward the handlebar and release it It should move freely and smoothly and it should ret...

Page 43: ...equate ground clearance could result in components contacting the ground causing loss of control and serious injury or death Always ensure ground clearance is at specification Rear Drive Belt 1 Check drive belt tension See pages 66 67 Tip The drive belt system must be cool clean and dry to accurately measure belt tension deflection Do not measure belt tension when the belt or drive system is wet o...

Page 44: ... sidestand is in the stored position Adjust or replace a loose spring 3 Inspect the sidestand pivot bolt for looseness or wear Tighten or replace a loose or worn bolt Fasteners 1 Inspect the entire motorcycle chassis and engine for loose damaged or missing fasteners 2 Tighten loose fasteners to the proper torque See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer 3 A...

Page 45: ...anual can result in serious damage to the engine Follow all break in procedures carefully 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 motorcycle during the break in period the more satisfied you will be with its performance later on Overloading the engine at low RPM and or running th...

Page 46: ...frequently 301 500 484 800 Do not operate for extended periods above 3 4 throttle At 500 At 800 Perform the break in maintenance outlined in the maintenance section of this manual Break in maintenance should be performed by an authorized INDIAN MOTORCYCLE dealer Break in maintenance must include inspection adjustments fastener tightening and an engine oil and filter change Performing break in main...

Page 47: ...e key in this position while lifting the cap 2 Insert the fuel nozzle into the fuel tank filler neck 3 Hold the nozzle while filling Do not rest the weight of the nozzle and hose on the filler neck Do not leave the nozzle unattended 4 Add fuel to the tank until it touches the bottom edge of the filler neck The tank is full at this level 5 Always close and lock the fuel cap before remounting the mo...

Page 48: ...ition 8 Start the engine See page 46 Starting the Engine The starter interlock system allows the engine to be started only when the transmission is in neutral or when the transmission is in gear with the clutch disengaged clutch lever pulled in 1 Perform the Pre Ride Inspections See page 34 Properly secure any cargo 2 Straddle the motorcycle and bring it to the fully upright position Retract the s...

Page 49: ...display information on page 30 NOTICE Operating an engine with a misfire or non firing cylinder 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 10 Leave the throttle closed and allow the engine to idle Idle speed will gradually slow to normal as the engine war...

Page 50: ...ip The transmission is in neutral if you can move the motorcycle forward or rearward freely without disengaging the clutch If the ignition switch is in the ON position the neutral indicator illuminates when the transmission is in neutral Shifting Gears While Stationary To locate neutral when the motorcycle is stationary use one of the following techniques to load and unload the transmission shift ...

Page 51: ... 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 toward th...

Page 52: ...Decelerating Gear Change Recommended Speed Gear Change Recommended Speed 1 to 2 17 MPH 27 km h 6 to 5 40 MPH 65 km h 2 to 3 24 MPH 38 km h 5 to 4 35 MPH 56 km h 3 to 4 35 MPH 57 km h 4 to 3 29 MPH 47 km h 4 to 5 41 MPH 66 km h 3 to 2 20 MPH 33 km h 5 to 6 50 MPH 81 km h 2 to 1 10 MPH 16 km h ...

Page 53: ...nded speed for upshifting shift up one gear WARNING Accelerating abruptly could cause your body to shift rearward suddenly which could result in loss of control Accelerating abruptly could also cause loss of control on low traction surfaces Loss of control could result in serious injury or death Always accelerate gradually especially on wet slippery or other low traction surfaces Stopping the Engi...

Page 54: ...ing on a slope If the front wheel is downhill from the rear wheel the sidestand could retract and cause a tipover Parking on a Soft Surface If parking on a soft surface is unavoidable place a sidestand footrest under the foot of the sidestand to provide a firm surface The sidestand footrest must be strong enough and large enough to support the motorcycle s weight without sinking into the parking s...

Page 55: ...n page 15 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 page 90 Hot engine and exhaust components can cause burns to skin and can ignite a fire if exposed to flammable materials Always...

Page 56: ... operation of all serviced components Make any corrections or additional adjustments necessary to ensure safe vehicle performance Break In Maintenance Perform the break in maintenance procedures when the motorcycle s odometer registers 500 miles 800 km Please see your authorized dealer for this service Performing the break in maintenance will help ensure optimum engine performance for the entire s...

Page 57: ...ricants and components can result in damage to the motorcycle Damage resulting from the use of non recommended products is not covered by warranty Perform maintenance at the intervals specified in the periodic maintenance table beginning on page 56 Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition high speed operation for extended periods low spe...

Page 58: ... I R I Chassis Battery Connections 86 I I I I I I I I I I I I Brake Fluid 76 77 I I I R I R I R I R I R Brake Lines Brake Pads 78 I I I I I I I I I I I I Clutch Cable 74 I I L I L I L I L I L Clutch Lever Mechanical 73 74 L I L I L I L I L I L Diagnostic Codes See dealer I I I I I I I I I I I I Drive Belt Rear 41 67 I I I I I I I R I I I I Drive Belt Tension Adjustment See dealer I I See dealer or...

Page 59: ...ler I I I I I I I I I I I I Headlamp 83 I I I I I I I Rear Suspension Rocker See dealer I I I I L I I L I I L I Rear Shock Unit 41 68 I I I I I I I I I I I R Rear Wheel Alignment 79 I I I I I I I I I I I I Rear Brake Pedal 75 I I I I I I I I I I I I Road Test 90 P P P P P P P P P P P P Sidestand 42 72 L I L I I I I I I I I I Steering Bearings 71 I I I I I I I I I I I I Suspension Linkage Rear See ...

Page 60: ...ot 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 five 5 minutes 2 Park the motorcycle with the sidestand down on a firm level surface For proper oil drain use a service lift to ensure the mo...

Page 61: ... 3 8 l of the recommended oil Reinstall the dipstick securely 13 With the motorcycle in an upright centered position start the engine and allow it to idle for 30 seconds Stop the engine 14 Add the recommended oil as needed to bring the level to the FULL mark on the dipstick Verify the level on the dipstick Tip The approximate volume between the ADD and FULL marks on the dipstick is 16 oz 45 l 15 R...

Page 62: ...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 Coolant Level Inspection Tip A flashlight is required for viewing the coolant level 1 Allow the engine to cool before checking coolant level 2 Position the mot...

Page 63: ...removed 3 Loosen the six 6 captive air filter screws and remove the air filter 4 Inspect the air filter Do not attempt to clean the air filter Replace a soiled or damaged filter with a new filter 5 Reinstall the air filter or install a new air filter 6 Torque screws to specification Torque 24 in lbs 2 7 Nm 7 Reinstall the fuel tank See pages 64 65 8 Reinstall the seat See page 82 Fuel Filter The f...

Page 64: ...e 82 2 Lift the rear of the fuel tank filler pad to access the fuel tank bolts 3 Remove the four 4 rear fuel tank bolts Set hardware aside for reassembly 4 Locate the rubber elbow and the straight rubber coupler exiting the rear of the tank mounting bracket 5 Gently pull the elbow free of the tube to disconnect the fuel tank vent line 6 Gently pull the straight rubber coupler free of the tube to d...

Page 65: ...abs on both sides of the fitting 12 Install the fuel tank fitting plug tool onto the fuel pump fitting to protect the fitting and prevent fuel from seeping out of the tank 13 Lift the rear of the fuel tank and carefully slide it rearward to release it from the front isolators 14 Lift the tank up and away from the frame Reinstall the front isolators if they become dislodged 15 Place the fuel tank o...

Page 66: ... fuel tank onto the frame of the motorcycle Slide the tank forward to make sure it s fully seated on the isolators 4 Pivot the rear of the tank upward to access the tank bottom Support the rear of the tank in this position 5 Remove the plug tool from the fuel pump fitting 6 Reconnect the fuel supply line connector to the fuel pump Make sure you hear a click to indicate proper engagement Test the c...

Page 67: ...e fuel cap recess drain line 11 Connect the fuel tank vent line 12 Reinstall the fuel tank filler pad 13 Reinstall the four 4 rear fuel tank bolts Torque 18 ft lbs 24 4 Nm 14 Prime the fuel pump See page 46 15 Check for leaks 16 Reinstall the seat See page 82 Step 11 Step 10 California Models Step 11 Step 10 Step 12 Step 13 ...

Page 68: ...or high debris environments 1 Mix a few drops of mild dish soap with a cup of warm water 2 Use a soft nylon brush to clean the belt and sprocket teeth with the soapy water Clean well in corner areas where road debris and belt dust can collect 3 Rinse the belt with clear water then dry thoroughly Tip Do not inspect or adjust drive belt tension when the belt or drive system is wet or hot Improper ad...

Page 69: ...d or if 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 Rear Drive Belt Wear Analysis Internal tooth cracks hairline OK to run but monitor condi...

Page 70: ...g your riding gear bring the motorcycle to the upright position and sit on the operator s seat If you plan to carry a passenger have the passenger with riding gear sit on the passenger seat WARNING Do not carry a passenger unless the motorcycle is equipped with passenger seat and passenger footrests 3 Measure shock preload from upper mount bolt center to lower mount bolt center eye to eye Perform ...

Page 71: ...tand 3 Loosen the lock nut by turning it counter clockwise as viewed from the top of shock with the spanner wrench The upper spanner nut on the shock is the lock nut The lower spanner nut is the adjuster nut 4 Spray a light lubricant on the adjuster nut where it contacts the spring DO NOT allow spray to contact the drive belt 5 Adjust shock preload by rotating the adjuster nut clockwise as viewed ...

Page 72: ...otorcycle on the sidestand and inspect the front forks If fork oil is present on the outer tube do not ride the motorcycle See your dealer for service before operating If fork oil is present around the fork seals or inner tubes replace the fork seals 2 Clean the fork tubes to remove bugs tar or buildup which may cause seal wear or leakage Inspect the outer surfaces of the inner fork tubes for scra...

Page 73: ...ur dealer for service 4 If steering binds feels rough or uneven or if movement is detected at the steering stem see your dealer for service 5 Rotate the front wheel and inspect for smooth rotation of front wheel bearings If roughness or unusual sounds are present see your dealer for service 6 Turn handle bars full right or left and hold against the fork stop Attempt to move front wheel side to sid...

Page 74: ...ecting and servicing the fuel system See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer Throttle Control Inspection 1 With the engine OFF rotate the throttle control grip fully open and then release it It should rotate smoothly from the rest position to the completely open position It should return to the rest position quickly when released 2 Repeat the twist and re...

Page 75: ...able adjuster inward or outward until clutch lever freeplay is 0 5 1 5 mm 3 While holding the cable tighten the adjuster lock nut securely 4 Verify that the safety switch activates properly The engine should not start in gear with the clutch lever released Tip The starter interlock switch is dependent on the clutch lever freeplay being set correctly to ensure activation of the clutch safety switch...

Page 76: ...Lubricate control cable barrel ends at the intervals recommended in the periodic maintenance table beginning on page 56 NOTICE The clutch cable is factory lubricated Additional lubrication could be detrimental to cable performance Replace the clutch cable assembly if binding or sticking occurs DO NOT lubricate between the cable and sheath Verify proper routing and smooth movement Inspect for damag...

Page 77: ...s 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 brake with the reservoir cover removed Fluid could overflow from the reservoir and allow air to enter the system Air in the brake system could cause...

Page 78: ...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 78 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 on the reservoir body Add brake fluid as needed Do not o...

Page 79: ...t position Position the handlebars so that the fluid reservoir is level Wipe the fluid container and the area around the reservoir cover with a clean cloth 2 If the fluid level is low inspect brake pads as outlined on page 78 If pads are not worn beyond the service limit inspect the brake system for leaks 3 To add fluid remove the reservoir cover screws Remove the cover and diaphragm 4 The fluid l...

Page 80: ...riving conditions not highway cruising to allow pads to mate with new rotors Brakes should be used frequently 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 Brake Disc Inspection Cleaning 1 Inspect brake discs for nicks scratches cracks or other damage Inspect the thickn...

Page 81: ...nt at regular service intervals whenever the rear wheel is removed and when the rear drive belt is adjusted Please see your dealer for this service Front Wheel Installation If the front wheel is removed for any reason it must be reinstalled in the correct rotating direction Clean all wheel components before installation Apply a light coat of all purpose grease to the axle and both spacers Axle Bol...

Page 82: ...equipped with innertubes innertubes MUST be replaced with new innertubes when tires are replaced Use only the proper size innertubes WARNING Mismatched tires rims and air valves may result in damage to the tire bead during mounting or may allow the tire to slip off the rim possibly resulting in tire failure Tire Condition Inspect the tire sidewalls road contact surface and tread base for cuts punc...

Page 83: ...e as recommended for the total weight of your intended load see chart below For more information refer to the manufacturing information label located on the front frame downtube See page 17 WARNING Do not exceed the maximum recommended inflation pressure to seat the bead Tire or rim failure may result Location Size Brand Type Recommended Pressure Loads up to 200 lbs 91 kg Loads up to vehicle s max...

Page 84: ...rcycle 3 To fully remove the seat remove the lanyard bolt from the bottom of the seat and disconnect the lanyard from the seat base 4 To reinstall the seat reinstall the lanyard making sure it s routed between the guides on the seat base 5 Make sure the seat base engages the rear retainer then press downward firmly at the front edge of the seat to engage the stud to the seat base grommet WARNING I...

Page 85: ... that rear suspension ride height preload is at specification See page 68 3 Position the motorcycle on a level surface with the headlight 25 feet 7 6 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 headlamp to high beam Observe the headlight aim on the wall 6 Make any necessary adjustments t...

Page 86: ...sing upward or downward Tighten the fastener Torque 35 ft lbs 47 5 Nm 2 To adjust the headlamp horizontally loosen the headlight mounting bolt and pivot the headlight to the left or right Tighten the bolt Torque 18 ft lbs 24 4 Nm Headlight Housing Mount Fastener Vertical Adjustment Headlight Mounting Bolt Horizontal Adjustment ...

Page 87: ...hing a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp If a lamp is touched clean it thoroughly with denatured alcohol 6 Install the new bulb and secure the retainer 7 Reinstall the rubber boot making sure it seals around the bulb and headlight 8 Connect the wire harness 9 Reinstall the headlight to the base and tighten t...

Page 88: ...OUT OF REACH OF CHILDREN Battery Removal 1 Remove the seat See page 82 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 2 Remove the fuse box from the frame of the motorcycle U...

Page 89: ...erpendicular to the long side of the battery Connect the positive cable to the positive battery terminal Torque 45 in lbs 5 Nm 5 Install the negative ground cable last Torque 45 in lbs 5 Nm 6 Reinstall the battery hold down strap Torque 96 in lbs 10 8 Nm 7 Reinstall the seat See page 82 Battery Charging If your motorcycle will not be used for a period of four 4 weeks or longer a maintenance charge...

Page 90: ... with the recommended amperage to avoid damage to the electrical system 1 Remove the seat See page 82 2 Press the fuse box release tab inward and slide the fuse box rearward to remove it from the bracket Use care to avoid pulling or stretching the wires 3 Bend the cover clips slightly away from the cover to remove the cover Tip Use the fuse puller provided in the tool kit to remove a fuse 4 After ...

Page 91: ...that does not use one of the previously mentioned power jacks connect to the hot side of the starter solenoid with an inline fuse and connect the ground wire to the chassis ground located at the left rear section of the frame under the seat DO NOT splice or cut any wires DO NOT tap in to any power or ground on the motorcycle unless specifically directed to do so by the INDIAN MOTORCYCLE instructio...

Page 92: ...30 cm square DO NOT attempt to lift the motorcycle without proper equipment Always secure the motorcycle properly before lifting so it cannot tip or fall when elevated Road Test Before returning the motorcycle to regular use perform a road test in a safe area Pay special attention to the proper fit and operation of all serviced components Make any corrections or additional adjustments promptly to ...

Page 93: ...mp doesn t operate Turn engine STOP switch to RUN Turn the ignition key on The fuel pump should run momentarily and then stop Check the fuel pump ignition circuit breaker See page 88 Battery voltage is too low Fully charge the battery See page 87 Fouled spark plug s Please see your dealer Low compression Please see your dealer for an engine compression test Possible Cause Possible Remedy Action En...

Page 94: ...rect or wrong oil type Inspect level and quality of oil See page 37 Loose broken shorted ignition coil wires Inspect coil primary wires Please see your dealer Air intake restricted Inspect air filter See page 61 Intake leaks Inspect air box crankcase breather hoses throttle body and intake boot joints Possible Cause Possible Remedy Action Shift linkage bushings dry or worn Lubricate shift linkage ...

Page 95: ...r Low coolant Allow the engine to cool before checking coolant level See page 60 Air in cooling system Please see your dealer Possible Cause Possible Remedy Action Loose Corroded Charging Circuit Connection Check clean battery cable connections Check clean charging circuit connections Please see your dealer Accessory Load Exceeds Charge Rate Limit accessory operation when the engine is off Imprope...

Page 96: ...surized water to wash the motorcycle High pressure water will damage radiator fins 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 any water stream at air intakes exhaust outlets or electrical connectors Electrical components may be damaged by water Do not allow water ...

Page 97: ...e the motorcycle to prevent damage to the fuel system and the battery and to protect components from corrosion or deterioration During storage preparation you might use products that are potentially hazardous such as fuel stabilizer When using any of these products follow the instructions and warnings on the product packaging Storage Area Preparation Choose a dry well ventilated storage location i...

Page 98: ...ge the engine oil See page 58 Cooling System Check the coolant level and maintain as recommended by adding coolant to the recovery bottle See page 60 Battery Care 1 Remove the battery See page 86 2 Clean the battery terminals first with 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 ...

Page 99: ...Cover the motorcycle with a cover made from a durable breathable material designed for storage Covering the motorcycle helps protect it from dust and other airborne materials The cover must be of a breathable material to prevent moisture from building up on the motorcycle which can cause oxidation of metal surfaces Removal From Storage 1 Install a fully charged battery 2 Check the oil level If the...

Page 100: ...ame Trail 29 4 7 in 119 9 mm Weight Dry Weight without fuel fluids 520 lbs 236 kg Wet Weight with fuel fluids 550 lbs 250 kg Gross Vehicle Weight Rating GVWR 988 lbs 449 kg Gross Axle Weight Rating GAWR Front 337 lbs 153 kg Rear 651 lbs 296 kg Maximum Load Capacity riders cargo accessories 448 lbs 204 kg Capacities Engine Oil 3 4 qts 2 8 3 8 l with filter at oil change 4 5 qts 4 25 l total for new...

Page 101: ... Body Bore Closed Loop Fuel Injection 60 mm Exhaust System Split Dual Exhaust w Crossover Rev Limit 8750 RPM Idle RPM 1100 50 RPM Fully Warm Lubrication System Semi Dry Sump Spark Plug Gap NGK MR7F 030 inch 0 80 mm Chassis Front Suspension Type Travel Telescopic Fork 4 7 in 120 mm Front Fork Tube Diameter 41 mm Rear Suspension Type Travel Dual Shocks 3 in 76 mm Swingarm Cast Aluminum Front Brakes ...

Page 102: ...ed Sliding Mesh Foot Shift 1st Gear Ratio 2 769 1 2nd Gear Ratio 1 882 1 3rd Gear Ratio 1 500 1 4th Gear Ratio 1 273 1 5th Gear Ratio 1 125 1 6th Gear Ratio 1 036 1 Gear Shift Pattern 1 Down 5 Up Final Drive Type Belt Drive 141 Tooth Transmission 28 Tooth Rear Wheel 66 Tooth Ratio 2 357 1 Overall Gear Ratio 1st Gear 10 926 1 2nd Gear 7 427 1 3rd Gear 5 918 1 4th Gear 5 022 1 5th Gear 4 439 1 6th G...

Page 103: ...e Size Kenda K673 150 80 16 71H Electrical Alternator 460W 3000 RPM Battery 12 volt 12 amp hour 210 CCA cold cranking amps Maintenance Free AGM Voltage Regulator 14 5 volts 35 amp Lamps all bulbs are 12 volt Headlight Osram HB2 12V 60 55W LL Tail Brake Light Non serviceable LED Turn Signal RY10W License Plate Non Serviceable LED Speedometer Non Serviceable LED Indicator Lights Non Serviceable LED ...

Page 104: ...n as possible Engine Oil Recommendation We recommend the use of INDIAN MOTORCYCLE Synthetic Blend 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...

Page 105: ...pecifications Identification Number Record Record important identification numbers below Vehicle Identification Number VIN see page 17 Engine Identification Number see page 20 Ignition Key Number see page 20 ...

Page 106: ... based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer 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...

Page 107: ...on 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...

Page 108: ... PERSON FOR BREACH OF THIS WARRANTY INDIAN MOTORCYCLE SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIV...

Page 109: ...the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another 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 ...

Page 110: ...cle is registered 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 b...

Page 111: ...pes or any other component 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 throu...

Page 112: ... provided there has been no abuse neglect or improper maintenance of your motorcycle Your emission control system may include 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 cos...

Page 113: ...ifornia 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 2014 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 re...

Page 114: ...densers and spark plugs 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 provi...

Page 115: ... replacements improperly 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 mile...

Page 116: ...BILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU C No dealer is authorized to modify this INDIAN MOTORCYCLE Lim...

Page 117: ...115 Maintenance Log Maintenance Performed Miles Km Notes Performed by ...

Page 118: ...116 Maintenance Log Maintenance Performed Miles Km Notes Performed by ...

Page 119: ... Rear Brake Pedal 33 Braking 51 Break In Maintenance 54 Break in Procedure 44 Break In Engine 43 44 Breather Hose Inspection 71 C Cargo Distribution 13 Cargo Safety 13 Check Engine Indicator 29 Cleaning Products 94 Clock Resetting 28 Clutch Cable Lubrication Mechanical 74 Clutch Inspection Mechanical 40 Clutch Lever 31 Clutch Lever Freeplay Mechanical 73 Clutch Lever Lubrication Mechanical 74 Comp...

Page 120: ... Shifting 48 50 Gross Vehicle Weight Rating 16 GVWR 16 H Hazard Warning Flashers Switch 24 Headlight Aim Adjustment 84 Headlight Aim Inspection 83 Headlight Lamp Replacement 85 High Low Headlight Beam Switch 25 I Identification Number Record 103 Indicator Lamps 26 Instrument Cluster 26 30 K Key Identification Number 20 L Labels Information 17 Labels Safety 17 Leather Care 95 M Maintenance Break In...

Page 121: ...k Oil 102 Speedometer 26 Steering Head Inspection 71 Steering Inspection 41 Storage Battery Care 96 Clean Protect the Motorcycle 96 Engine Protection 96 Fuel Stabilizer 96 Maintenance During 96 Motorcycle Cover 97 Removal From 97 Rodents 97 Storage Area 95 Tire Inflation 96 Suspension Inspection Front 41 70 Suspension Inspection Rear 41 Swing Arm Inspection 70 Switches 22 25 Engine Starter Switch ...

Page 122: ...To locate your nearest dealer visit www indianmotorcycle com Indian Motorcycle Company 2100 Highway 55 Medina MN 55340 Phone 877 204 3697 Part No 9925953 Rev 01 Printed in USA ...

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