Indian Motorcycle Indian Challenger 2020 Owner's Manual
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Indian Motorcycle Indian Challenger 2020 Owner's Manual

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For Maintenance and Safety
INDIAN CHALLENGER
TM
OWNER'S MANUAL
2020
BE LEGENDARY
®
©2019
Indian Motorcycle Inc.
All Rights Reserved.

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  • Page 1 For Maintenance and Safety INDIAN CHALLENGER OWNER’S MANUAL 2020 BE LEGENDARY ® ©2019 Indian Motorcycle Inc. All Rights Reserved.
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING Operating, servicing, and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 2020 Rider’s Manual Indian Challenger™...
  • Page 4 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 expressly prohibited.
  • Page 5 CONGRATULATIONS! Congratulations on your purchase of a new INDIAN motorcycle. You have joined an elite family of motorcycle riders who have acquired a celebrated piece of American history by choosing to own an INDIAN motorcycle. Your new motorcycle is the end result of true dedication and craftsmanship by our engineering, design and assembly teams. It was designed and manufactured to meet our goal of providing you with a high quality motorcycle that you can ride trouble-free for many years to come.
  • Page 6 SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual. Your safety and the safety of others is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction......... . 7 Safety .

  • Page 9: Introduction

    S S E E R R V V I I C C E E A A N N D D W W A A R R R R A A N N T T Y Y I I N N F F O O R R M M A A T T I I O O N N 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, equipment, and training.
  • Page 10 INTRODUCTION E E N N G G I I N N E E I I D D E E N N T T I I F F I I C C A A T T I I O O N N N N U U M M B B E E R R The engine number is stamped into the right crankcase beneath the balance shaft cover.

  • Page 11: Safety

    This section contains safety information specific to the INDIAN motorcycle, as well as information about general motorcycle safety. Anyone who rides All references to RIGHT, LEFT, FRONT or REAR are from the the motorcycle (operators and passengers) must follow these operator’s perspective when seated in a normal riding position.
  • Page 12 • If your motorcycle operates abnormally, correct the problem make handling difficult, which could cause loss of control. immediately. See the INDIAN MOTORCYCLE Service Manual or • During the first 500 miles (800 km) of operation, follow all an authorized INDIAN MOTORCYCLE dealer.
  • Page 13 SAFETY • Do not move or operate the motorcycle with the steering locked • To maximize braking effectiveness, use the front and rear brakes (if equipped), as the severely restricted steering could result in together. Be aware of the following braking facts and practices: loss of control.
  • Page 14 SAFETY P P R R O O T T E E C C T T I I V V E E A A P P P P A A R R E E L L • Wear gloves, a jacket, heavy boots and long pants to prevent or reduce injury from abrasions, lacerations or burns should the Wear protective apparel to decrease the risk of injury and increase motorcycle fall.
  • Page 15 • Do not exceed the maximum cargo weight limit of any accessory (see accessory instructions and labels). Do not attach cargo to Because INDIAN MOTORCYCLE cannot test and make specific an accessory not designed for that purpose. Either circumstance recommendations concerning every accessory or combination of...
  • Page 16 A A N N T T I I - - L L O O C C K K B B R R A A K K E E S S Y Y S S T T E E M M R R E E S S P P O O N N S S E E • Use only genuine INDIAN MOTORCYCLE accessories designed for your model.
  • Page 17 SAFETY F F U U E E L L A A N N D D E E X X H H A A U U S S T T S S A A F F E E T T Y Y WARNING Always heed these fuel safety warnings when refueling or servicing the fuel system.
  • Page 18 SAFETY • Before each ride, perform the Pre-Ride Inspections on page 57. • Loop tiedown straps (from the front) up and over the lower triple clamp, using care to not interfere with wiring and brake lines. • Perform all periodic maintenance at the recommended intervals Place tiedowns as wide apart as possible on the truck or trailer outlined in the Periodic Maintenance section.
  • Page 19 SAFETY The full text of the EU declaration of conformity is available at the Technical Information following internet address: Frquency band: 433.05 – 434.70 MHz https://www.polaris.com/en-us/radio-conformity/ Maximum output power: < 10 mW F F O O R R E E U U C C O O M M P P L L I I A A N N C C E E Manufacturer and Address: SE1 (WCM): Marquardt GmbH...
  • Page 20 SAFETY F F O O R R M M E E X X I I C C O O C C O O M M P P L L I I A A N N C C E E Changes or modifications made to this equipment not expressly approved by Marquardt GmbH may void the FCC authorization to Model SK1: operate this equipment.
  • Page 21 National Highway Traffic Safety Administration (NHTSA) in addition to notifying INDIAN MOTORCYCLE in writing. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 22 SAFETY V V E E H H I I C C L L E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L I I N N F F O O R R M M A A T T I I O O N N N N O O I I S S E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L I I N N F F O O R R M M A A T T I I O O N N ( ( V V E E C C I I ) ) The Noise Emission Control Information label...
  • Page 23 • 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.
  • Page 24 SAFETY S S H H O O C C K K P P R R E E S S S S U U R R E E W W A A R R N N I I N N G G C C A A R R G G O O L L I I M M I I T T W W A A R R N N I I N N G G The Shock Pressure Warning is located under the side cover.
  • Page 25 SAFETY W W I I N N D D S S H H I I E E L L D D W W A A R R N N I I N N G G ATTENTION: This item to be removed by customer only. WARNING The windshield warning label is located on the vehicle’s...

  • Page 27: Instruments, Features And Controls

    INSTRUMENTS, FEATURES AND CONTROLS I I N N S S T T R R U U M M E E N N T T S S , , F F E E A A T T U U R R E E S S A A N N D D C C O O N N T T R R O O L L S S C C O O N N S S O O L L E E Power Switch/Security Light Ride Command Display...
  • Page 28 INSTRUMENTS, FEATURES AND CONTROLS S S W W I I T T C C H H L L O O C C A A T T I I O O N N S S L L E E F F T T C C O O N N T T R R O O L L R R I I G G H H T T C C O O N N T T R R O O L L Horn Engine Stop Switch...
  • Page 29 INSTRUMENTS, FEATURES AND CONTROLS S S W W I I T T C C H H S S Y Y M M B B O O L L S S T T O O G G G G L L E E S S W W I I T T C C H H E E S S All models are equipped with toggle switches on the front side of SYMBOL SWITCH...
  • Page 30 INSTRUMENTS, FEATURES AND CONTROLS S S W W I I T T C C H H E E S S SYMBOL SWITCH DESCRIPTION P P O O W W E E R R S S W W I I T T C C H H Audio Control The Audio Control Switch allows users to control Switch...
  • Page 31 INSTRUMENTS, FEATURES AND CONTROLS H H A A Z Z A A R R D D S S W W I I T T C C H H E E N N G G I I N N E E S S T T O O P P / / R R U U N N S S W W I I T T C C H H The power switch must be ON to activate the flashers, but once Use the engine stop/run switch to turn the engine off quickly.
  • Page 32 INSTRUMENTS, FEATURES AND CONTROLS K K E E Y Y L L E E S S S S I I G G N N I I T T I I O O N N A A U U D D I I O O C C O O N N T T R R O O L L S S W W I I T T C C H H S S T T A A R R T T I I N N G G K K E E Y Y F F O O B B O O P P E E R R A A T T I I O O N N : : The Audio Control Switch allows users to control the audio...
  • Page 33 INSTRUMENTS, FEATURES AND CONTROLS C C R R U U I I S S E E C C O O N N T T R R O O L L S S W W I I T T C C H H NOTE Cruise control can be activated and adjusted from the right control When using a bluetooth audio device, pushing down on the audio...
  • Page 34 INSTRUMENTS, FEATURES AND CONTROLS I I N N S S T T R R U U M M E E N N T T C C L L U U S S T T E E R R S S A A D D D D L L E E B B A A G G L L O O C C K K S S W W I I T T C C H H Use the key fob or the lock switch on the console to lock and unlock the electric saddlebag locks.
  • Page 35 INSTRUMENTS, FEATURES AND CONTROLS I I N N D D I I C C A A T T O O R R L L A A M M P P S S LAMP INDICATES CONDITION LAMP INDICATES CONDITION Neutral The transmission is in neutral and the power switch is ON.
  • Page 36 INSTRUMENTS, FEATURES AND CONTROLS LAMP INDICATES CONDITION LAMP INDICATES CONDITION Tire Pressure The TPMS indicator illuminates if low Check Engine This lamp illuminates briefly when Monitoring System tire pressure is detected. It will also the power switch is turned ON. This (TPMS) illuminate along with the Low Battery indicates proper function.
  • Page 37 INSTRUMENTS, FEATURES AND CONTROLS S S P P E E E E D D O O M M E E T T E E R R R R E E A A R R C C Y Y L L I I N N D D E E R R D D E E A A C C T T I I V V A A T T I I O O N N ( ( I I F F E E Q Q U U I I P P P P E E D D ) ) The speedometer displays forward vehicle speed in either miles Designed as an aid to reduce engine and exhaust heat to the rider, per hour or kilometers per hour.
  • Page 38 INSTRUMENTS, FEATURES AND CONTROLS R R I I D D E E C C O O M M M M A A N N D D WARNING O O V V E E R R V V I I E E W W Do not enter information while operating your vehicle.
  • Page 39 INSTRUMENTS, FEATURES AND CONTROLS T T O O U U C C H H S S C C R R E E E E N N D D I I S S P P L L A A Y Y C C O O M M P P L L I I A A N N C C E E CAUTION S S T T A A T T E E M M E E N N T T This equipment complies with part 15 of the Federal...
  • Page 40 INSTRUMENTS, FEATURES AND CONTROLS R R I I D D E E C C O O M M M M A A N N D D B B U U T T T T O O N N S S R R I I D D E E R R S S C C R R E E E E N N The Rider Screen is a customizable BUTTON...
  • Page 41 INSTRUMENTS, FEATURES AND CONTROLS C C O O N N T T R R O O L L P P A A N N E E L L D D E E V V I I C C E E M M A A N N A A G G E E R R The Device Manager screen displays recent calls, contact list, key pad, and messages.
  • Page 42 INSTRUMENTS, FEATURES AND CONTROLS R R I I D D E E C C O O M M M M A A N N D D H H A A N N D D C C O O N N T T R R O O L L S S S S E E L L E E C C T T S S W W I I T T C C H H M M E E D D I I A A S S W W I I T T C C H H Use the 3–way select switch...
  • Page 43 INSTRUMENTS, FEATURES AND CONTROLS R R I I D D E E C C O O M M M M A A N N D D R R I I D D E E M M O O D D E E S S T T R R I I G G G G E E R R S S W W I I T T C C H H E E S S There are trigger switches located on the reverse side of both the You can choose between three ride modes, Rain, Standard, or...
  • Page 44 INSTRUMENTS, FEATURES AND CONTROLS T T R R A A C C T T I I O O N N C C O O N N T T R R O O L L NOTE To disable the Traction Control, do the following: For the ride mode to change the throttle must be fully disengaged.
  • Page 45 INSTRUMENTS, FEATURES AND CONTROLS G G E E N N E E R R A A L L S S E E T T T T I I N N G G S S 3. A prompt will appear asking you to confirm that you want to disable the Traction Control.
  • Page 46 INSTRUMENTS, FEATURES AND CONTROLS B B L L U U E E T T O O O O T T H H P P A A I I R R I I N N G G U U P P D D A A T T E E S S O O F F T T W W A A R R E E A A N N D D M M A A P P S S The Ride Command touchscreen display can be connected to a For the latest software and maps for the Ride Command display, go smart-phone and a headset simultaneously.
  • Page 47 INSTRUMENTS, FEATURES AND CONTROLS M M I I S S F F I I R R E E D D E E T T E E C C T T I I O O N N U U S S B B P P O O R R T T The USB Port makes it easy to power devices, such as phones, If a misfire is detected, the check engine indicator lamp will begin audio sources, or GPS units, in addition to allowing you to stream...
  • Page 48 INSTRUMENTS, FEATURES AND CONTROLS B B A A T T T T E E R R Y Y C C H H A A R R G G E E P P O O R R T T / / H H E E A A T T E E D D G G E E A A R R H H E E A A D D L L I I G G H H T T S S P P L L U U G G The headlights automatically come on when the engine is started.
  • Page 49 INSTRUMENTS, FEATURES AND CONTROLS T T H H R R O O T T T T L L E E C C O O N N T T R R O O L L G G R R I I P P C C L L U U T T C C H H L L E E V V E E R R The throttle control grip is located on the right handlebar.
  • Page 50 INSTRUMENTS, FEATURES AND CONTROLS G G E E A A R R S S H H I I F F T T L L E E V V E E R R T T I I R R E E P P R R E E S S S S U U R R E E M M O O N N I I T T O O R R I I N N G G S S Y Y S S T T E E M M The gear shift lever is located on the left side of the motorcycle.
  • Page 51 INSTRUMENTS, FEATURES AND CONTROLS H H A A R R D D B B A A G G R R E E M M O O V V A A L L 5. Remove the saddlebag fastener bolts 1. Remove the side cover. See page 127. 2.
  • Page 52 INSTRUMENTS, FEATURES AND CONTROLS 9. Reconnect the electrical wiring. CAUTION If the motorcycle weight is not resting on the sidestand, it will not 10. Reinstall the side panel, using care to avoid damaging lock. In this situation, any movement of the motorcycle could electrical wires.
  • Page 53 INSTRUMENTS, FEATURES AND CONTROLS W W I I N N D D S S H H I I E E L L D D W W I I N N D D S S H H I I E E L L D D A A D D J J U U S S T T M M E E N N T T W W I I N N D D S S H H I I E E L L D D R R E E M M O O V V A A L L Use the windshield switch to adjust windshield height for the...
  • Page 54 INSTRUMENTS, FEATURES AND CONTROLS W W I I N N D D S S H H I I E E L L D D C C A A R R E E A A N N T T I I - - L L O O C C K K B B R R A A K K E E S S Y Y S S T T E E M M ( ( A A B B S S ) ) Clean the windshield with a soft cloth and plenty of warm water.
  • Page 55 MPH (10 km/h), the ABS system is not functioning. See your The front brake lever is located on the right handlebar. This lever INDIAN MOTORCYCLE dealer or other dealer promptly for controls only the front brakes. The front brakes should be applied service.
  • Page 56 INSTRUMENTS, FEATURES AND CONTROLS 1. Gently push and hold the lever away from the hand grip. The WARNING adjuster wheel is located on top of the lever. Resting your foot on the brake pedal will cause excessive and 2. To increase reach distance, rotate the adjuster to a lower premature wear of brake pads and reduced braking efficiency, number.
  • Page 57 INSTRUMENTS, FEATURES AND CONTROLS NOTE 3. See page 68 for fueling instructions. The fuel cap automatically locks when you start the engine. 4. To close, press fuel cap downward until it clicks. M M A A N N U U A A L L O O V V E E R R R R I I D D E E 1.
  • Page 58 INSTRUMENTS, FEATURES AND CONTROLS 1. Ensure engine is not running before attempting to manually 5. Use a small, narrow tool to push the lock solenoid at the front of unlock fuel cap fuel cap (under the latch) to the left position. NOTE Cap will automatically lock/re-lock if closed and engine is running.

  • Page 59: Pre-Ride Inspections

    • refer to the maintenance section of this manual ( page 79) • refer to the INDIAN MOTORCYCLE Service Manual WARNING • or see your authorized INDIAN MOTORCYCLE dealer or other Failure to perform the recommended pre-ride inspections could dealer result in component failure while riding, which could result in serious injury or death.
  • Page 60 PRE-RIDE INSPECTIONS E E L L E E C C T T R R I I C C A A L L I I N N S S P P E E C C T T I I O O N N S S ITEM INSPECTION PROCEDURE Horn...
  • Page 61 PRE-RIDE INSPECTIONS E E N N G G I I N N E E O O I I L L L L E E V V E E L L ITEM INSPECTION PROCEDURE Brake Inspect hoses and connections. With the semi-dry sump lubrication system, the engine oil level on Components the dipstick will fluctuate, depending on the motorcycle’s position and engine temperature when checked.
  • Page 62 PRE-RIDE INSPECTIONS 3. Remove the dipstick and wipe it clean. 6. Add the recommended oil as needed to bring the level within the safe operating 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.
  • Page 63 Always use the correct size Operating the motorcycle with incorrect tires, incorrect tire and type of tires specified by INDIAN MOTORCYCLE for your pressure or excessively worn tires could cause loss of control or vehicle.
  • Page 64 PRE-RIDE INSPECTIONS F F R R O O N N T T B B R R A A K K E E F F L L U U I I D D L L E E V V E E L L 4.
  • Page 65 View the reservoir level from the right side of the vehicle. 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.
  • Page 66 PRE-RIDE INSPECTIONS M M E E C C H H A A N N I I C C A A L L C C L L U U T T C C H H The starter interlock switch is dependent on the clutch lever 1.
  • Page 67 2. Make sure wires, hoses and control cables do not interfere with 3. Inspect drive belt condition. See page 106. If you discover smooth steering. cracks, broken teeth or frayed edges, replace the drive belt before riding. See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer can assist.
  • Page 68 PRE-RIDE INSPECTIONS F F U U E E L L L L E E V V E E L L For the most accurate reading, sit on the motorcycle 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.

  • Page 69: Operation

    OPERATION O O P P E E R R A A T T I I O O N N O O V V E E R R V V I I E E W W NOTICE The operation section of this manual describes how to ensure Failure to properly follow the engine break-in procedures maximum performance and longevity through the proper care and outlined in this manual can result in serious damage to the...
  • Page 70 OPERATION O O P P E E R R A A T T I I N N G G S S P P E E E E D D S S A A N N D D G G E E A A R R S S F F U U E E L L I I N N G G Always dismount the motorcycle and refuel on level ground with ODOMETER...
  • Page 71 OPERATION 1. Press the center of the fuel cap unlock button located on the lower right fairing 3. Insert the fuel nozzle into the fuel tank filler neck. 4. Add fuel to the tank until it crests the circular-shaped opening in the filler neck column.
  • Page 72 OPERATION NOTICE Fuel can damage painted surfaces and plastic parts. If gasoline If the motorcycle runs out of fuel, prime the system before spills on the any part of the motorcycle, immediately rinse it off attempting to restart the engine. with water or wipe it dry with a clean cloth.
  • Page 73 OPERATION 7. If starting a COOL engine, DO NOT open the throttle while NOTICE starting. Idle speed is computer controlled and idle speed will Do not run the engine at high RPM with the clutch disengaged or adjust automatically depending on engine temperature and air the transmission in neutral.
  • Page 74 OPERATION S S H H I I F F T T I I N N G G G G E E A A R R S S This motorcycle is equipped with a six-speed transmission. Neutral is located between first and second gear. WARNING Press downward on the toe lever to shift to a lower gear.
  • Page 75 OPERATION S S H H I I F F T T I I N N G G G G E E A A R R S S W W H H I I L L E E D D R R I I V V I I N N G G 8.
  • Page 76 OPERATION B B R R A A K K I I N N G G R R E E C C O O M M M M E E N N D D E E D D S S H H I I F F T T P P O O I I N N T T S S U U P P S S H H I I F F T T I I N N G G ( ( A A C C C C E E L L E E R R A A T T I I N N G G ) ) Always allow sufficient stopping distance so that brakes can be applied gradually.
  • Page 77 OPERATION A A C C C C E E L L E E R R A A T T I I N N G G 1. When fully stopped, shift into neutral. Accelerate by opening the throttle (rolling the throttle control grip 2.
  • Page 78 OPERATION S S E E T T S S P P E E E E D D Toggle Position Function 1. Press and release the center of the cruise control switch . The Left Set/Decelerate amber cruise control indicator will illuminate in the instrument Center Off/On cluster.
  • Page 79 OPERATION P P A A R R K K I I N N G G O O N N A A S S L L O O P P E E D D E E C C E E L L E E R R A A T T E E While cruise control is engaged, tap and release left on the cruise If parking on a slope is unavoidable, park with the front wheel control switch to decrease speed in approximately 1 MPH (1-2 km/...

  • Page 81: Maintenance

    MAINTENANCE M M A A I I N N T T E E N N A A N N C C E E S S A A F F E E T T Y Y D D U U R R I I N N G G S S E E R R V V I I C C E E P P R R O O C C E E D D U U R R E E S S WARNING Failure to follow all recommended precautions and procedures could result in severe injury or death.
  • Page 82 When inspection reveals the need for replacement parts, use the proper fit and operation of all serviced components. Make any genuine INDIAN MOTORCYCLE parts available from your dealer. corrections or additional adjustments necessary to ensure safe Record service and maintenance information on page 169.
  • Page 83 K K E E Y Y XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Indian Motorcycle dealer perform these services. E - Emission Control System Service (California / International) 5 5 0 0 0 0 M M I I L L E E ( ( 8 8 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E...
  • Page 84 MAINTENANCE ITEM REMARKS Change every two years (DOT 4) Brake Fluid Inspect pad wear; replace if worn beyond service limit XU / D Brake Pads Lubricate with proper lubricant as directed Clutch Lever Clutch Cable Freeplay Inspect; adjust if necessary Inspect;...
  • Page 85 MAINTENANCE 2 2 , , 5 5 0 0 0 0 M M I I L L E E ( ( 4 4 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM REMARKS Inspect;...
  • Page 86 MAINTENANCE ITEM REMARKS Rear Wheel Alignment Inspect; adjust if necessary Road Test Perform Road Test Inspect; adjust if necessary, lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 5 5 , , 0 0 0 0 0 0 M M I I L L E E ( ( 8 8 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM...
  • Page 87 MAINTENANCE ITEM REMARKS Inspect pad wear; replace if worn beyond service limit XU / D Brake Pads Inspect; adjust if necessary Clutch Lever Clutch Cable Freeplay Inspect; adjust if necessary Inspect; lubricate with proper lubricant as directed Control Cable Ends Inspect;...
  • Page 88 MAINTENANCE 1 1 0 0 , , 0 0 0 0 0 0 M M I I L L E E ( ( 1 1 6 6 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM REMARKS Replace...
  • Page 89 MAINTENANCE ITEM REMARKS Replace at specified interval or every 2 years Front Fork Oil Inspect; adjust if necessary Front Forks and Front Axle Inspect; adjust if necessary Gear Shift Pedal Inspect; clean. Gear Position Switch Head Light Inspect; adjust if necessary Inspect;...
  • Page 90 MAINTENANCE ITEM REMARKS Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants Evaporative Emission Control System Inspect; clean Exhaust System Inspect; tighten, adjust Fuel System Inspect; clean Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary Battery Check terminals;...
  • Page 91 MAINTENANCE ITEM REMARKS Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 2 2 0 0 , , 0 0 0 0 0 0 M M I I L L E E ( ( 3 3 2 2 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM REMARKS Replace...
  • Page 92 MAINTENANCE ITEM REMARKS Inspect pad wear; replace if worn beyond service limit XU / D Brake Pads Lubricate with proper lubricant as directed Clutch Lever Clutch Cable Freeplay Inspect; adjust if necessary Lubricate with proper lubricant as directed Control Cable Ends Inspect;...
  • Page 93 MAINTENANCE 2 2 5 5 , , 0 0 0 0 0 0 M M I I L L E E ( ( 4 4 0 0 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM REMARKS Inspect;...
  • Page 94 MAINTENANCE ITEM REMARKS Inspect; adjust if necessary Gear Shift Pedal Inspect; adjust if necessary Rear Brake Pedal Inspect; adjust if necessary Rear Shock Absorber Rear Wheel Alignment Inspect; adjust if necessary Road Test Perform Road Test Inspect; adjust if necessary, lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect...
  • Page 95 MAINTENANCE ITEM REMARKS Fuel System Inspect; clean Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary Spark Plugs Replace D / E Battery Check terminals; clean; test Replace (DOT 4) Brake Fluid Inspect pad wear; replace if worn beyond service limit XU / D Brake Pads Lubricate with proper lubricant as directed...
  • Page 96 MAINTENANCE ITEM REMARKS Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 3 3 5 5 , , 0 0 0 0 0 0 M M I I L L E E ( ( 5 5 2 2 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM REMARKS Inspect;...
  • Page 97 MAINTENANCE ITEM REMARKS Inspect; adjust if necessary Control Cable Ends Inspect; tighten if necessary Fasteners Adjust if necessary, lubricate with proper lubricant as directed Front Brake Lever Inspect Front Fork Oil Inspect; adjust if necessary Front Forks and Front Axle Inspect;...
  • Page 98 MAINTENANCE ITEM REMARKS Inspect; tighten, clean, adjust Drive Belt Engine Compression Inspect; correct if necessary Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants Evaporative Emission Control System Inspect; clean Exhaust System Inspect; tighten, adjust Fuel System Inspect;...
  • Page 99 MAINTENANCE ITEM REMARKS Head Light Inspect; adjust if necessary Inspect; adjust if necessary Rear Brake Pedal Inspect; adjust if necessary Rear Shock Absorber Rear Wheel Alignment Inspect; adjust if necessary Road Test Perform Road Test Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect...
  • Page 100 MAINTENANCE ITEM REMARKS Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary Battery Check terminals; clean; test Change every two years (DOT 4) Brake Fluid Inspect pad wear; replace if worn beyond service limit XU / D Brake Pads Lubricate with proper lubricant as directed Clutch Lever Clutch Cable Freeplay...
  • Page 101 MAINTENANCE 5 5 0 0 , , 0 0 0 0 0 0 M M I I L L E E ( ( 8 8 0 0 , , 0 0 0 0 0 0 K K M M ) ) S S E E R R V V I I C C E E ITEM REMARKS Replace...
  • Page 102 MAINTENANCE ITEM REMARKS Inspect; tighten if necessary Fasteners Adjust if necessary, lubricate with proper lubricant as directed Front Brake Lever Inspect Front Fork Oil Inspect; adjust if necessary Front Forks and Front Axle Inspect; adjust if necessary Gear Shift Pedal Inspect;...
  • Page 103 MAINTENANCE E E N N G G I I N N E E O O I I L L / / F F I I L L T T E E R R C C H H A A N N G G E E 3.
  • Page 104 MAINTENANCE 5. Install new sealing washer and o-ring on the drain plug. The 13. With the motorcycle in an upright, centered position, start the sealing surfaces on drain plug and engine should be clean and engine and idle for approximately 30 seconds. free of burrs, nicks or scratches.
  • Page 105 MAINTENANCE A A I I R R F F I I L L T T E E R R 3. Remove the airbox filter cover fasteners and remove from the unit. NOTICE If the motorcycle is operated in wet or dusty conditions, more frequent servicing is required.
  • Page 106 MAINTENANCE C C O O O O L L I I N N G G S S Y Y S S T T E E M M C C O O O O L L A A N N T T L L E E V V E E L L I I N N S S P P E E C C T T I I O O N N The engine coolant level is controlled by the recovery system.
  • Page 107 MAINTENANCE A A D D D D I I N N G G C C O O O O L L A A N N T T CAUTION To add coolant, do the following: Do not fill the coolant bottle to full. 0.3 L of air must remain in the bottle to account for thermal expansion.
  • Page 108 Replace belt broken teeth. No matter its condition, the drive belt should be replaced at periodic intervals. See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer can assist. Chipping (not serious): DO NOT attempt to check belt tension if the belt has been exposed...
  • Page 109 MAINTENANCE B B E E L L T T T T E E N N S S I I O O N N WEAR ANALYSIS BELT CONDITION Stone damage: WARNING Replace belt if damage is on A drive belt that is not properly tensioned can cause drive line edge noise and damage the drive belt, causing possible belt failure and loss of control of the motorcycle.
  • Page 110 MAINTENANCE 1. Place the motorcycle in an upright position with the front wheel 6. Turn the RIGHT SIDE adjuster nut to achieve proper belt clamped in a wheel vise. tension 2. Remove saddlebags. 3. Make note of adjuster locations 4. Raise the rear of the motorcycle so the rear tire can be freely rotated.
  • Page 111 MAINTENANCE B B E E L L T T A A L L I I G G N N M M E E N N T T 2. Rotate the wheel in the FORWARD direction and verify that sprocket teeth are still visible on both sides of the drive belt WARNING A drive belt that is not properly aligned can cause drive line noise and damage the drive belt, causing possible belt failure...
  • Page 112 MAINTENANCE 4. Rear wheel alignment is satisfactory when the drive belt remains centered on driven sprocket during forward and backward wheel rotation. Sprocket teeth should be visible from both sides of the drive belt. 5. Verify that drive belt tension is still within specification. 6.
  • Page 113 MAINTENANCE S S W W I I N N G G A A R R M M / / R R E E A A R R A A X X L L E E I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T F F O O R R K K / / S S U U S S P P E E N N S S I I O O N N I I N N S S P P E E C C T T I I O O N N 1.
  • Page 114 6. Turn handle bars full right or left and hold against the fork stop. the recommended intervals. Special tools are required to Attempt to move front wheel side-to-side. If movement is perform this procedure. See the INDIAN MOTORCYCLE Service observed, see your dealer for service. Manual or an authorized INDIAN MOTORCYCLE dealer can assist.
  • Page 115 MAINTENANCE E E V V A A P P O O R R A A T T I I V V E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L S S Y Y S S T T E E M M F F U U E E L L S S Y Y S S T T E E M M C C O O M M P P O O N N E E N N T T S S ( ( C C A A L L I I F F O O R R N N I I A A A A N N D D I I N N T T E E R R N N A A T T I I O O N N A A L L M M O O D D E E L L S S ) ) 1.
  • Page 116 MAINTENANCE F F U U E E L L T T A A N N K K R R E E M M O O V V A A L L 3. Disconnect fuel feed line WARNING Allow engine and exhaust to cool completely before disconnecting fuel line or removing tank.
  • Page 117 MAINTENANCE 4. At the rear of the tank, disconnect the fuel vent line and the 5. Remove fuel tank fastener fuel pump electrical connector 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 IMPORTANT catch any fuel that may leak or drip from disconnected hoses or On models equipped with an EVAP system, remove the EVAP...
  • Page 118 MAINTENANCE T T H H R R O O T T T T L L E E C C O O N N T T R R O O L L I I N N S S P P E E C C T T I I O O N N S S I I D D E E S S T T A A N N D D L L U U B B R R I I C C A A T T I I O O N N Periodically lubricate the sidestand bushing.
  • Page 119 MAINTENANCE M M E E C C H H A A N N I I C C A A L L C C L L U U T T C C H H L L E E V V E E R R L L U U B B R R I I C C A A T T I I O O N N 4.
  • Page 120 Fluid could overflow from the reservoir and allow air to enter the replace components as necessary. See the INDIAN MOTORCYCLE system. Air in the brake system could cause the brakes to Service Manual or an authorized INDIAN MOTORCYCLE dealer can malfunction. assist.
  • Page 121 MAINTENANCE R R E E A A R R B B R R A A K K E E F F L L U U I I D D 5. Remove the cover and diaphragm. The fluid level should be above the minimum indicator mark on the reservoir body Change the brake fluid at the intervals recommended in the...
  • Page 122 MAINTENANCE F F R R O O N N T T B B R R A A K K E E L L E E V V E E R R F F R R O O N N T T B B R R A A K K E E F F L L U U I I D D Change the brake fluid at the intervals recommended in the 1.
  • Page 123 MAINTENANCE B B R R A A K K E E D D I I S S C C I I N N S S P P E E C C T T I I O O N N / / C C L L E E A A N N I I N N G G 4.
  • Page 124 MAINTENANCE 2. Clean discs if minor squeaks develop due to dirt or dust. Apply brake cleaner to a clean shop towel and wipe the discs. DO NOT allow brake cleaner to contact painted or plastic parts. Read all precautions on the label. NOTE Minimum Thickness Front: 4.5mm;...
  • Page 125 See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer can assist. W W H H E E E E L L A A L L I I G G N N M M E E N N T T...
  • Page 126 Under-inflation can cause a tire to overheat and result in a tire failure. Always use the correct size and type of tires specified by INDIAN MOTORCYCLE for your vehicle. Always maintain proper tire pressure as recommended in the rider’s manual and on safety labels.
  • Page 127 Inspect the tire sidewalls, road contact surface, and tread base for cuts, punctures, and cracking. Replace damaged tires immediately. See the INDIAN MOTORCYCLE Service Manual or an WARNING authorized INDIAN MOTORCYCLE dealer can assist.
  • Page 128 MAINTENANCE S S P P A A R R K K P P L L U U G G S S 3. Pull upward on the spark plug boots (not the wires) to remove the boots. Inspect spark plugs after the break-in period and every 15,000 miles (24,000 km) thereafter.
  • Page 129 MAINTENANCE S S I I D D E E C C O O V V E E R R S S L L E E F F T T S S I I D D E E C C O O V V E E R R R R E E M M O O V V A A L L Remove the left side cover to access the shock fitting, fuse box, 1.
  • Page 130 MAINTENANCE S S E E A A T T R R E E M M O O V V A A L L S S E E A A T T I I N N S S T T A A L L L L A A T T I I O O N N Remove the seat to access the battery.
  • Page 131 MAINTENANCE 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. H H E E A A D D L L I I G G H H T T A A I I M M A A D D J J U U S S T T M M E E N N T T NOTE Adjust headlight aim when there is a change in load (rider, cargo,...
  • Page 132 The LED turn signal lights are not serviceable. If the turn signal • KEEP OUT OF REACH OF CHILDREN. becomes damaged or inoperable, the entire light assembly must be replaced. See your authorized INDIAN MOTORCYCLE dealer or other authorized dealer.
  • Page 133 MAINTENANCE B B A A T T T T E E R R Y Y R R E E M M O O V V A A L L 2. Remove battery bracket my removing its fastener sliding the bracket out of its retention feature. To remove the battery, do the following: 3.
  • Page 134 MAINTENANCE B B A A T T T T E E R R Y Y I I N N S S T T A A L L L L A A T T I I O O N N 4. Install battery bracket and fastener NOTICE Be sure cable ends and battery terminals are clean.
  • Page 135 6. Install chin faring and fasteners battery using the 12V Battery Charge Port. The Battery Charge Port is taped to the main harness. A maintenance charger can be TORQUE purchased through your authorized INDIAN MOTORCYCLE dealer. Chin Fairing Fastener: 36 in-lbs (4 Nm)
  • Page 136 MAINTENANCE 1. Following the charger manufacturer’s instructions, use a battery • Key Fob held in ferrous container (metal cup holder or glasses charger designed for use with 12-volt batteries. The charger case) should have a maximum charging rate of 1.8 amps. Charge the •...
  • Page 137 L L O O W W C C H H A A R R G G E E IMPORTANT The nominal voltage for an Indian Motorcycle battery is 12.8 Volts Read and follow the safety precautions listed on the battery and when fully charged.
  • Page 138 MAINTENANCE A A G G M M B B A A T T T T E E R R Y Y C C H H A A R R G G I I N N G G R R E E C C O O M M M M E E N N D D A A T T I I O O N N S S 1.
  • Page 139 MAINTENANCE A A G G M M B B A A T T T T E E R R Y Y M M A A I I N N T T E E N N A A N N C C E E T T I I P P S S S S T T A A N N D D A A R R D D F F U U S S E E S S The standard fuse box is located under the left side cover.
  • Page 140 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 parts and accessories designed for your model, and follow the instructions provided. • DO use the accessory power jack provided (if equipped).
  • Page 141 • DO NOT back-probe electrical connectors on the vehicle unless key fob is detected or until the valid, current PIN is entered. directed to do so by the INDIAN MOTORCYCLE Service Manual. 2. Push or hold the turn signal CANCEL switch for 10 seconds •...
  • Page 142 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. If the 4-digit PIN is NOT successfully entered within 20 seconds,...
  • Page 143 Spark Plug(s) Fouled Inspect spark plugs. damaged or missing fasteners. Tighten loose fasteners to the proper torque. See the INDIAN MOTORCYCLE Service Manual or Spark Plug Wire(s) Be sure spark plug wires are securely an authorized INDIAN MOTORCYCLE dealer can assist.
  • Page 144 MAINTENANCE B B A A T T T T E E R R Y Y C C H H A A R R G G I I N N G G R R A A T T E E L L O O W W O O R R B B A A T T T T E E R R Y Y POSSIBLE CAUSE POSSIBLE REMEDY/ACTION D D I I S S C C H H A A R R G G E E S S...
  • Page 145 MAINTENANCE A A N N T T I I - - L L O O C C K K B B R R A A K K E E L L I I G G H H T T R R E E M M A A I I N N S S I I L L L L U U M M I I - - N N A A T T E E D D O O R R I I L L L L U U M M I I N N A A T T E E S S I I N N T T E E R R M M I I T T T T E E N N T T L L Y Y POSSIBLE CAUSE POSSIBLE REMEDY/ACTION...

  • Page 147: Cleaning And Storage

    This section provides tips on the very best way to clean, polish and NOTICE preserve every surface of your beautiful new INDIAN motorcycle. Do not use pressurized water to wash the motorcycle. Water may We recommend the use of our new INDIAN MOTORCYCLE...
  • Page 148 CLEANING AND STORAGE 5. After washing, remove the rubber bands and plastic bags from NOTICE the exhaust pipes. Start the engine and let it idle for a few Never use a polishing/buffing wax or any sponge that has an minutes. abrasive surface when cleaning a matte finish.
  • Page 149 CLEANING AND STORAGE S S T T O O R R A A G G E E A A R R E E A A P P R R E E P P A A R R A A T T I I O O N N •...
  • Page 150 CLEANING AND STORAGE C C L L E E A A N N A A N N D D P P R R O O T T E E C C T T T T H H E E M M O O T T O O R R C C Y Y C C L L E E 4.
  • Page 151 CLEANING AND STORAGE P P A A R R K K A A N N D D C C O O V V E E R R T T H H E E M M O O T T O O R R C C Y Y C C L L E E R R E E M M O O V V A A L L F F R R O O M M S S T T O O R R A A G G E E 1.

  • Page 153: Specifications

    SPECIFICATIONS S S P P E E C C I I F F I I C C A A T T I I O O N N S S S S P P E E C C I I F F I I C C A A T T I I O O N N S S MODEL 2020 BASE DARK HORSE...
  • Page 154 SPECIFICATIONS Engine Oil 5.0 qt (4.7 l) Fuel 6.0 gal (22.7 l) Fuel Reserve (fuel light on) 1.0 gal (3.8 l) Fork oil 6.4 oz (485 ml) per fork leg WHEELS / TIRES Front Wheel Size / Type 19” x 3.5” Cast Rear Wheel Size / Type 16”...
  • Page 155 SPECIFICATIONS MODEL 2020 ALL MODELS ENGINE Engine Type Powerplus Displacement 108 cid (1768 cc) Compression Ratio 11.0:1 Valve Train 4 Valves per cylinder, SOHC, Hydraulic lifters Bore and Stroke 108 mm x 96.5 mm Fuel System / Throttle Body Closed loop fuel injection / 52 mm dual bore Bore Exhaust System Two O2 sensors, one each bank, single three-way catayst...
  • Page 156 SPECIFICATIONS Transmission Type 6 Speed / Constant Mesh / Foot Shift 1st Gear Ratio 2.733:1 2nd Gear Ratio 1.864:1 3rd Gear Ratio 1.385:1 4th Gear Ratio 1.103:1 5th Gear Ratio 0.943:1 6th Gear Ratio 0.811:1 1 Down / 5 Up Gear Shift Pattern Final Drive Type Belt Drive , 152 Tooth...
  • Page 157 F F O O R R K K O O I I L L We recommend the use of INDIAN MOTORCYCLE Fork Oil for your motorcycle. B B R R A A K K E E F F L L U U I I D D We recommend the use of INDIAN MOTORCYCLE DOT 4 Brake Fluid for both brake master cylinders.

  • Page 159: Warranty

    R R E E G G I I S S T T R R A A T T I I O O N N 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.
  • Page 160 L L I I M M I I T T A A T T I I O O N N S S O O F F W W A A R R R R A A N N T T I I E E S S A A N N D D R R E E M M E E D D I I E E S S This INDIAN MOTORCYCLE limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN.
  • Page 161 The exclusive remedy for breach of this warranty shall be, at INDIAN MOTORCYCLE’s option, repair or replacement of any defective materials, components, or products.
  • Page 162 I I F F Y Y O O U U P P U U R R C C H H A A S S E E F F R R O O M M A A P P R R I I V V A A T T E E P P A A R R T T Y Y : : If you purchase an INDIAN motorcycle from a private party, to be kept and used outside of the country in which the motorcycle was originally purchased, all warranty coverage will be denied.
  • Page 163 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from INDIAN MOTORCYCLE. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized...
  • Page 164 N N O O I I S S E E E E M M I I S S S S I I O O N N W W A A R R R R A A N N T T Y Y INDIAN MOTORCYCLE warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
  • Page 165 Class III motorcycles (280cc and larger): for a period of use of five (5) years or 30,000 kilometers (18,641 miles), whichever first occurs. If an emission-related part on your motorcycle is defective, the part will be repaired or replaced by INDIAN MOTORCYCLE. This is your emission control system DEFECTS WARRANTY.
  • Page 166 You are responsible for presenting your motorcycle to an INDIAN MOTORCYCLE dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
  • Page 167 In the State of California only, Emission Control System emergency repairs, as provided for in the California Administrative Code, may be performed by other than an authorized INDIAN MOTORCYCLE dealer. An emergency situation occurs when an authorized INDIAN MOTORCYCLE dealer is not reasonably available, a part is not available within 30 days or a repair is not complete within 30 days. Any replacement part can be used in an emergency repair.
  • Page 168 • Accident • Misuse • Repairs improperly performed or 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...
  • Page 169 I I I I I I . . L L I I M M I I T T E E D D L L I I A A B B I I L L I I T T Y Y The liability of INDIAN MOTORCYCLE under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized INDIAN MOTORCYCLE dealer at its place of business during customary business hours.
  • Page 170 Any replacement 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.

  • Page 171: Maintenance Log

    MAINTENANCE LOG M M A A I I N N T T E E N N A A N N C C E E L L O O G G M M A A I I N N T T E E N N A A N N C C E E L L O O G G PERFORMED MAINTENANCE PERFORMED MILES/KM...

  • Page 173: Drive Belt

    INDEX Belt Coolant Level Inspection ....104 Adjustment ........107 Cooling System .

  • Page 174: Fuel Tank

    INDEX Engine Oil/Filter Change ....101 Keyless Ignition ....... . . 30 Engine Protection.
  • Page 175 INDEX Tire Condition ....... . 61 Tire Pressure ........61 Operating Motorcycle Outside the U.
  • Page 176 INDEX Steering Head Inspection ....112 Stopping the Engine ......75 USB Port .
  • Page 178 To locate your nearest dealer, visit www.indianmotorcycle.com Indian Motorcycle Company 2100 Highway 55 Medina, MN 55340 Phone: 1-877-204-3697 French: 1-800-268-6334 Part No. 9931163 Rev 02 Printed in USA...

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