Indian Motorcycle FTR 1200 2019 Service Manual

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2019 FTR 1200

Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most

recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer

technicians in a properly equipped shop and should be kept available for reference. All references to left and

right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar

with the service procedures before starting any repair. Certain procedures require the use of special tools. Use

only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures

outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more

useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit

feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature

Question'.

Consumers, please provide your feedback in writing to: Indian Motorcycle Company ATTN: Service Publications

Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed December 2018 (PN 9929391 R01)

to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the

information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for

omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

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Summary of Contents for Indian Motorcycle FTR 1200 2019

Page 1 The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer ®...
Page 2 IMPORTANT IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS INDIAN MOTORCYCLE ACKNOWLEDGES THE FOLLOWING PRODUCTS THAT MAY BE MENTIONED IN THIS MANUAL: LOCTITE®, is a registered trademark of the Henkel Corporation. DUNLOP®, is a registered trademark of the Dunlop Tire Corporation.
Page 3 FEEDBACK FORM - SERVICE MANUAL (9929391) A feedback form has been created for the technician or consumer to provide Indian Motorcycle with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile device by scanning the QR code or by clicking HERE if viewing this document electronically.
Page 4 2019 FTR 1200 Service Manual Chapter Summary CHAPTER 1: GENERAL / SPECIFICATIONS CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING / EXHAUST CHAPTER 4: FUEL DELIVERY / EFI CHAPTER 5: CLUTCH / PRIMARY / SHIFT CHAPTER 6: TRANSMISSION / CRANKSHAFT CHAPTER 7: FRAME / BODY CHAPTER 8:...
Page 5 GENERAL / SPECIFICATIONS CHAPTER 1 GENERAL / SPECIFICATIONS VEHICLE INFORMATION................1.2 .
Page 6 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E I I N N F F O O R R M M A A T T I I O O N N M M O O D D E E L L N N U U M M B B E E R R D D E E S S I I G G N N A A T T I I O O N N Example: N19RTA22AA TYPE MODEL...
Page 7 GENERAL / SPECIFICATIONS V V E E H H I I C C L L 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 ( ( V V I I N N ) ) D D E E S S I I G G N N A A T T I I O O N N Example: 56KTCAAA0E3000024 Vehicle Descriptors...
Page 8 GENERAL / SPECIFICATIONS G G E E N N E E R R A A L L 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 2 2 0 0 1 1 9 9 F F T T R R 1 1 2 2 0 0 0 0 YEAR / MODEL PAINT COLOR / CODE...
Page 9 GENERAL / SPECIFICATIONS MODEL YEAR 49 State with ABS 50 State with ABS International / China 2019 DIMENSIONS Overall Length 90 in. (2287 mm) Overall Width 33.5 in. (850 mm) Overall Height 51.1 in. (1297 mm) Unladen Seat Height 33.6 in. (853 mm) Wheelbase 60 in.
Page 10 GENERAL / SPECIFICATIONS MODEL YEAR ALL MODELS 2019 ENGINE Engine Type Liquid Cooled V-Twin (60 Degrees) Displacement 73 Cid (1203 cc) Compression Ratio 12.5 : 1 Valve Train DOHC, 4 Valves Per Cylinder, Graded Buckets Bore and Stroke 102 x 73.6 Fuel System/Throttle Body Bore Closed Loop Fuel Injection / Dual 60 mm Bore Exhaust System...
Page 11 GENERAL / SPECIFICATIONS MODEL YEAR ALL MODELS 2019 ELECTRICAL Alternator 460W @ 3000 RPM Battery 12 Volt, 12AH, 240CCA, Maintenance Free AGM Voltage Regulator 14.5 Volts / 32 Amp Headlight Non-Serviceable LED Tail/Brake Light Non-Serviceable LED Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Speedometer...
Page 12 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E L L O O A A D D I I N N G G G G R R O O S S S S V V E E H H I I C C L L E E W W E E I I G G H H T T R R A A T T I I N N G G ( ( G G V V W W R R ) ) WARNING Exceeding the gross vehicle weight rating of your motorcycle can reduce stability and handling and...
Page 13 P P U U B B L L I I C C A A T T I I O O N N P P A A R R T T N N U U M M B B E E R R S S Some Indian Motorcycle publications, such as Owner’s Manuals and Parts Books may be available on-line at the Indian Motorcycle website;...
Page 14 GENERAL / SPECIFICATIONS E E M M I I S S S S I I O O N N I I N N F F O O R R M M A A T T I I O O N N 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 S S 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 Tampering with Noise Control Systems is Prohibited.
Page 15 GENERAL / SPECIFICATIONS C C R R A A N N K K C C A A 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 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 The crankcase emission control system is comprised California and International models are equipped with...
Page 16 GENERAL / SPECIFICATIONS S S P P E E C C I I A A L L T T O O O O L L S S U U S S I I N N G G S S P P E E C C I I A A L L T T O O O O L L S S How To Use This Book Special tools have been designed exclusively for The Special Tools Index located in this chapter...
Page 17 Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Indian Motorcycle recommends use of the Special Tools referenced in the chapters of this service manual when servicing any Indian Motorcycle product.
Page 18 GENERAL / SPECIFICATIONS S S P P E E C C I I A A L L T T O O O O L L S S I I N N D D E E X X MultiLink XP Battery Tester Relay Bypass Tool PU-52792 PU-50296...
Page 19 GENERAL / SPECIFICATIONS Brake Lever Reserve Tool Steering Head Adjustment Socket Front Axle Adapter PV-50104 (Commercially available)(See PV-43508 example below) Chain Breaker Tool Shock Preload Spanner Wrench Swingarm Bushing Tool (Commercially available) 2884176 PF-51237 (KM500R) Swingarm Lock Ring Tool Swingarm Adjuster Tool Fork Spring Compressor PF-52737 PF-52738...
Page 20 GENERAL / SPECIFICATIONS Fork Cap Wrench Fork Seal Guide Inverted Fork Seal Installer PF-52744 PV–47037 PV-47035 Cartridge Holder Crankshaft Locking Pin Oil Filter Wrench PF-52745 PF-51235-A PU-50105 Engine Transmission Lock Tool Flywheel Puller Output Shaft Seal Tool PF-51612 PA-49316–A PF-51243 Water Pump Seal Installation Tool Bearing Removal Kit Engine Stand Adapter Plate...
Page 21 GENERAL / SPECIFICATIONS Engine Stand Adapter Crankcase Separator Tool Cup Adapter PF-51609 PF-51234-A PF-51665 Engine Case Assembly Cup Mainshaft / Crankcase Installer Crankcase Installation Adapter PF-51663 PV-45030 (5/16) PV-47429 Fork spring compressor adapter Main Bearing Tool Main Bearing Tool PV–49464 PF-52726 1 PF-52726 2 Wireless Vehicle Link...
Page 22 GENERAL / SPECIFICATIONS R R E E F F E E R R E E N N C C E E M M A A S S T T E E R R T T O O R R Q Q U U E E T T A A B B L L E E - - F F T T R R 1 1 2 2 0 0 0 0 TORQUE 36 in-lbs (4 N·m) ITEM...
Page 23 GENERAL / SPECIFICATIONS Coolant Temperature Exhaust Clamp (Front 17 ft-lbs (23 N·m) Sensor Headpipe to Rear 144 in-lbs (16 N·m) Headpipe) Cooling Fan Fastener 96 in-lbs (11 N·m) (M6 1.0x14) Exhaust Clamp (Front 144 in-lbs (16 N·m) Headpipe to Resonator) Cooling Fan Fastener 96 in-lbs (11 N·m) (M6 1.0x16)
Page 24 GENERAL / SPECIFICATIONS Oil Scavenge Pump Sight Glass Fastener 44 in-lbs (5 N·m) 88 in-lbs (10 N·m) Fastener Spark Plug 106 in-lbs (12 N·m) Oil Drain Plug 15 ft-lbs (20 N·m) 125 ft-lbs (170 N·m) Stake Nut, Clutch Oil Pump to Crankcase 88 in-lbs (10 N·m) 88 in-lbs (10 N·m) Starter Motor Fastener...
Page 25 GENERAL / SPECIFICATIONS STEP 1: TIGHTEN Footpeg Bracket 17 ft-lbs (23 N·m) Fasteners (Passenger) FASTENER TO 129 ft- lbs (175 N·m) Flywheel Fastener Fuel Pump Fastener 88 in-lbs (10 N·m) STEP 2: BACK OUT FASTENER 180° AND Fuel Feed Line Retainer RE-TORQUE TO SPEC 48 in-lbs (5 N·m) Fastener...
Page 26 GENERAL / SPECIFICATIONS Footpeg Bracket Axle (front) 55 ft-lbs (75 N·m) 17 ft-lbs (23 N·m) Fasteners (Passenger) Axle Nut (rear) 88 ft-lbs (119 N·m) Footpeg Shoulder 50 ft-lbs (68 N·m) 14 ft-lbs (19 N·m) Axle Pinch Fasteners Fasteners 22 ft-lbs (30 N·m) 88 in-lbs (10 N·m) Brake Disc Fasteners Fuel Tank Fasteners...
Page 27 GENERAL / SPECIFICATIONS STEP 3: Loosen Master Cylinder 44 in-lbs (5 N·m) adjuster nut 90 degrees Mounting Nut (front) (1/4 turn). Master Cylinder Bleeder 10 ft-lbs (14 N·m) Swingarm Lock Ring 44 ft-lbs (60 N·m) Screw (front) Swingarm Pivot Adjuster 11 (15 N·m) Master Cylinder Mounting Fasteners...
Page 28 GENERAL / SPECIFICATIONS Horn to Frame Bracket 96 in-lbs (11 N·m) Fastener Ignition Fastener 88 in-lbs (10 N·m) Ignition Coil Fastener 88 in-lbs (10 N·m) Instrument Cluster 84 in-lbs (9 N·m) Housing Fastener License Plate Mount 96 in-lbs (11 N·m) Fasteners Oil Cooler Mount 72 in-lbs (8 N·m)
Page 29 GENERAL / SPECIFICATIONS S S A A E E T T A A P P D D R R I I L L L L S S I I Z Z E E S S M M E E T T R R I I C C T T A A P P D D R R I I L L L L S S I I Z Z E E S S NEAREST THREAD SIZE / DRILL THREAD SIZE / DRILL...
Page 30 GENERAL / SPECIFICATIONS D D E E C C I I M M A A L L E E Q Q U U I I V V A A L L E E N N T T S S 1/64 in = .0156 in 39/64 in = .6094 in 1/32 in = .0312 in [1 mm = .0394 in] 5/8 in = .625 in [16mm=.
Page 31 GENERAL / SPECIFICATIONS F F A A H H R R E E N N H H E E I I T T T T O O C C E E L L S S I I U U S S M M E E A A S S U U R R E E M M E E N N T T C C O O N N V V E E R R S S I I O O N N C C H H A A R R T T UNIT OF MULTIPLIED...
Page 33 ........2.4 INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS .
Page 34 MAINTENANCE ................2.47 SPARK PLUG INSPECTION / GAP .
Page 35 Brake Hydraulic Fluid — DOT 4 Engine / Transmission Oil 15W60 Full Synthetic 5 qts. (4.73 L) Dry Engine Indian Motorcycle Fork Oil 10.65 oz (315 cc) per leg Fork Oil Fuchs SAF 5113 or approved equivalent 91 Octane (Recommended) 3.5 gal (13.2 L) / Reserve 0.5 gal (1.9 L)
Page 36 MAINTENANCE I I N N D D I I A A N N M M O O T T O O R R C C Y Y C C L L E E S S E E R R V V I I C C E E P P R R O O D D U U C C T T S S A A N N D D L L U U B B R R I I C C A A N N T T S S MAINTENANCE PRODUCT PART NUMBERS PART...
Page 37 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 38 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 39 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 40 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 41 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 42 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual 2.10...
Page 43 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual 2.11...
Page 44 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual 2.12...
Page 45 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual 2.13...
Page 46 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual 2.14...
Page 47 Tires / Wheels 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) 9929391 R01 - 2019 FTR 1200 Service Manual 2.15...
Page 48 Tires / Wheels 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) When the vehicle goes beyond 50,000 miles, return to the 500 mile chart and start the interval process over.
Page 49 MAINTENANCE G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S - - O O I I L L I I N N G G S S Y Y S S T T E E M M S S P P E E C C I I A A L L T T O O O O L L S S - - M M A A I I N N T T E E N N A A N N C C E E The FTR 1200 uses a semi-dry sump lubrication TOOL DESCRIPTION...
Page 50 MAINTENANCE B B R R E E A A K K - - I I N N P P R R O O C C E E D D U U R R E E Engine break-in for Indian Motorcycles occurs in the first 500 miles (800 km) of operation.
Page 51 MAINTENANCE M M A A I I N N T T E E N N A A N N C C E E P P R R O O C C E E D D U U R R E E S S W W A A S S H H I I N N G G P P R R E E C C A A U U T T I I O O N N S S 3.
Page 52 MAINTENANCE 6. Remove three fasteners to remove alignment 11. Install air filter access cover and secure with seven bracket. fasteners. TORQUE Air Filter Access Cover Fastener: 14 in-lbs (2 N·m) 12. Install the alignment bracket and secure with fasteners. TORQUE Bodywork Alignment Bracket Fastener: 36 in-lbs (4 N·m) 13.
Page 53 5. Oil level should be in the middle the sight glass. If oil level is low, remove engine oil fill plug add Indian Motorcycle 15W–60 Full Synthetic engine oil. Repeat steps 1- 4 until the reading is within the safe operation range.
Page 54 9. Use new sealing washers and reinstall the drain plugs. Torque to specification. IMPORTANT TORQUE Use Indian Motorcycle 50/50 Extended Life Coolant only. Do not mix coolant types. Engine Oil Drain Plug: 15 ft-lbs (20 N·m) The engine coolant level is controlled or maintained by the recovery system.
Page 55 • Straight water or antifreeze may cause the system to using a cooling system pressure tester. freeze, corrode, or overheat. (Commercially available). FLUID CAPACITY Recommended Coolant: Indian Motorcycle 50/50 Pre-Mixed Extended Life Antifreeze System Capacity: 2.32 qt (2.2 L) Pressurized Circuit Capacity: 2.16 qt (2.05 L) Recovery Bottle Capacity: .16 qt (.15 L)
Page 56 MAINTENANCE 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 6.
Page 57 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 P P R R E E S S S S U U R R E E T T E E S S T T WARNING Never remove pressure cap when engine is warm or hot.
Page 58 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 H H O O S S E E S S NUMBER DESCRIPTION Recovery Bottle Drain Hose Head Outlet Hose Radiator Outlet Hose Bypass Hose...
Page 59 MAINTENANCE R R A A D D I I A A T T O O R R 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 CAUTION Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness.
Page 60 MAINTENANCE C C O O O O L L A A N N T T D D R R A A I I N N / / F F I I L L L L Cooling System Fill / Bleeding NOTICE WARNING Pressure test before and after servicing the cooling...
Page 61 6. Remove the vacuum bleeder and install the pressure cap and safety set screw. 7. Remove the pinch pliers from the coolant line between the reservoir and thermostat housing. 8. Add Indian Motorcycle Extended Life 50/50 Engine Coolant to the reservoir fill opening until the coolant reservoir it is between markings.
Page 62 MAINTENANCE I I D D L L E E S S P P E E E E D D / / F F A A S S T T I I D D L L E E S S P P E E E E D D NOTICE Idle speed cannot be adjusted manually, it is continuously monitored and adjusted by the ECM.
Page 63 MAINTENANCE T T I I R R E E P P R R E E S S S S U U R R E E / / 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 WARNING Indian motorcycles are produced using the designated tires listed below as original equipment.
Page 64 MAINTENANCE C C L L U U T T C C H H C C A A B B L L E E I I N N S S P P E E C C T T I I O O N N / / 3.
Page 65 MAINTENANCE 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 C C L L U U T T C C H H L L E E V V E E R R F F R R E E E E P P L L A A Y Y 1.
Page 66 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 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 B B R R A A K K E E 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 1.
Page 67 MAINTENANCE B B R R A A K K E E P P E E D D A A L L I I N N S S P P E E C C T T I I O O N N 2.
Page 68 MAINTENANCE 4. Remove the spring 8. Install the spring 5. Loosen the nut on the stop adjustment screw. 9. Install the master cylinder control assembly with mounting fasteners and footpeg mounting fasteners . Torque to specification. 6. Adjust stop screw until desired brake pedal position is achieved.
Page 69 MAINTENANCE 10. Connect the master cylinder pin to the brake 12. Tighten nut on master cylinder pushrod. pedal. TORQUE Master Cylinder Pushrod Nut: 54 in-lbs (6 N·m) 13. Adjust pushrod length until the correct brake lever free travel is achieved. 11.
Page 70 MAINTENANCE B B R R A A K K E E P P E E D D A A L L L L U U B B R R I I C C A A T T I I O O N N NUMBER TORQUE (IF APPLICABLE) DESCRIPTION...
Page 71 MAINTENANCE Lubricate brake pedal at intervals listed on periodic 4. Remove the brake pedal pivot c-clip and flat maintenance table. See Maintenance Intervals page washer 2.5. 1. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 2.
Page 72 MAINTENANCE S S H H I I F F T T P P E E D D A A L L A A D D J J U U S S T T M M E E N N T T 9.
Page 73 MAINTENANCE 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 I I N N S S P P E E C C T T I I O O N N IMPORTANT IMPORTANT Make sure Dots...
Page 74 MAINTENANCE 7. Reinstall reservoir cover and torque screws to 13. Carefully add enough DOT 4 brake fluid to bring specification. level to between the MIN and MAX markings. 14. Install diaphragm and cover. TORQUE Front Master Cylinder Cap Screws: F F R R O O N N T T B B R R A A K K E E P P A A D D I I N N S S P P E E C C T T I I O O N N 10 in-lbs (1 N·m) NOTICE Rear Brake Fluid Inspection...
Page 75 MAINTENANCE R R E E A A R R B B R R A A K K E E P P A A D D I I N N S S P P E E C C T T I I O O N N C C R R A A N N K K C C A A S S E E V V E E N N T T I I L L A A T T I I O O N N S S Y Y S S T T E E M M NOTICE 1.
Page 76 MAINTENANCE F F U U E E L L T T A A N N K K V V E E N N T T I I N N S S P P E E C C T T I I O O N N 1.
Page 77 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 IMPORTANT The fuel tank vent line is routed to a vapor canister where the fuel vapor is stored until specific operating parameters are met and the ECM opens the purge valve.
Page 78 Indian Motorcycle replacement parts. WARNING The fuel lines exiting fuel pump are subjected to high pressure. Replace with genuine Indian Motorcycle replacement parts to reduce the possibility of fuel line failure. Be sure fuel lines are routed properly and do not come in contact with sharp or hot objects, or anything that may cause wear or damage.
Page 79 MAINTENANCE S S P P A A R R K K P P L L U U G G I I N N S S P P E E C C T T I I O O N N / / G G A A P P S S P P A A R R K K P P L L U U G G I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 80 MAINTENANCE E E N N G G I I N N E E C C O O M M P P R R E E S S S S I I O O N N T T E E S S T T High engine compression may indicate: 1.
Page 81 MAINTENANCE B B A A T T T T E E R R Y Y E E N N G G I I N N E E C C O O M M P P R R E E S S S S I I O O N N T T E E S S T T ( ( W W E E T T ) ) This motorcycle is equipped with a maintenance free If a cylinder leakage tester is not available, perform a battery.
Page 82 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 E E R R 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. Test battery using the battery tester PU-50296. Indian Motorcycle recommends using the BatteryMINDer® 2012 AGM - 2 AMP battery charger 2.
Page 83 – – D D E E E E P P L L Y Y D D I I S S C C H H A A R R G G E E D D ( ( B B E E L L O O W W 3 3 V V O O L L T T S S ) ) The nominal voltage for an Indian Motorcycle battery AGM batteries discharged to a voltage of 3 volts or is 12.8 Volts when fully charged.
Page 84 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 5.
Page 85 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. Disconnect negative battery terminal. 1. Remove the battery cover by removing three 3.
Page 86 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 cover and three fasteners. 1.
Page 87 NOTICE remove any dirt or grit. The chain must be lubricated Inspect drive chain in accordance with Periodic using Indian Motorcycle chain lube (2884172). See Maintenance Interval Chart and replace at specified Maintenance Intervals page 2.5 intervals regardless of chain condition. See Maintenance Intervals page 2.5.
Page 88 MAINTENANCE D D R R I I V V E E C C H H A A I I N N S S T T R R E E T T C C H H I I N N S S P P E E C C T T I I O O N N D D R R I I V V E E C C H H A A I I N N T T E E N N S S I I O O N N Special Tool Required: Chain Tension Gauge PV- 1.
Page 89 D D R R I I V V E E C C H H A A I I N N A A D D J J U U S S T T M M E E N N T T 4. Compare the measured value with the specification. Lubricate the drive chain with Indian Motorcycle chain spray lube or an approved chain lube at the interval Drive Chain Deflection Specification: specified in the Periodic Maintenance Chart.
Page 90 MAINTENANCE 3. Adjust the tension bolts evenly until correct 5. Without moving the tension bolts, Tighten jam nuts. tension is achieved. Reference Drive Chain Ensure the axle is pushed forward against the Tension page 2.56. adjuster bolts. IMPORTANT TORQUE To minimize change in chain tension, use RIGHT SIDE Swingarm Jam Nut: adjuster only to make final adjustments to chain 12 ft-lbs (16 N·m)
Page 91 Clean the chain using a chain brush or clean rag to remove any dirt or grit. The chain must be lubricated using Indian Motorcycle chain lube (2884172). See Maintenance Intervals page 2.5 CAUTION Always have the motorcycle off and the transmission in neutral when performing this procedure.
Page 92 MAINTENANCE 3. If any fuse is blown, turn off main switch. Install 4. Upon reassembly, torque cover fasteners to new fuse of specified amperage. Turn on switches specification. and see if system operates correctly. Repeat fuse TORQUE failure indicates an electrical problem. V-Cover Fastener: CAUTION 36 in-lbs (4 N·m)
Page 93 MAINTENANCE H H E E A A D D L L I I G G H H T T A A I I M M I I N N S S P P E E C C T T I I O O N N - - F F T T R R 1 1 2 2 0 0 0 0 / / F F T T R R 1 1 2 2 0 0 0 0 S S On LOW beam, the top of the horizontal cut-off of the light beam should be 7 in.
Page 94 MAINTENANCE 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 S S I I D D E E - - S S T T A A N N D D I I N N S S P P E E C C T T I I O O N N 1.
Page 95 MAINTENANCE S S I I D D E E - - S S T T A A N N D D R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 3.
Page 96 MAINTENANCE S S T T E E E E R R I I N N G G H H E E A A D D / / F F R R O O N N T T W W H H E E E E L L Installation: I I N N S S P P E E C C T T I I O O N N 6.
Page 97 MAINTENANCE S S W W I I N N G G A A R R M M I I N N S S P P E E C C T T I I O O N N 5. Rotate rear wheel and inspect for smooth rotation of rear wheel bearings.
Page 98 MAINTENANCE R R E E A A R R S S H H O O C C K K P P R R E E L L O O A A D D I I N N S S P P E E C C T T I I O O N N COMBINED WEIGHT DIMENSION (MM) OF RIDER,...
Page 99 MAINTENANCE S S H H O O C C K K A A N N A A L L Y Y S S I I S S Shock “misting” or “weepage” is common and should be present during normal vehicle operation. All Shock Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock.
Page 100 MAINTENANCE S S U U S S P P E E N N S S I I O O N N A A D D J J U U S S T T M M E E N N T T G G U U I I D D E E IMPORTANT Make sure rear shock preload is set correctly before changing compression and rebound settings below.
Page 101 MAINTENANCE RIDING TYPE: SHOCK COMPRESSION SHOCK REBOUND (S MODEL ONLY) Aggressive Riding (Track) 0.75 turns (out from full in) 5 clicks (out from full in) 9929391 R01 - 2019 FTR 1200 Service Manual 2.69 © Copyright Polaris Industries Inc.
Page 102 MAINTENANCE Front Fork Factory Setting FTR1200S FTR1200 Fork Rebound, right side screw slot 7 clicks (out from full in) (20 click range) Fork Compression, left side screw 10 clicks (out from full in) slot (20 click range) Fork Preload, 19 mm hex (10 turn 5 turns (in from full out) range) FTR1200S Recommended Damping Settings...
Page 103 MAINTENANCE FTR1200S Recommended Pre-Load Settings Adjustments can be make to the fork to increase or decrease pre-load for a personal rider preference. IMPORTANT Make sure both forks are adjusted evenly. 9929391 R01 - 2019 FTR 1200 Service Manual 2.71 © Copyright Polaris Industries Inc.
Page 104 MAINTENANCE V V A A L L V V E E C C L L E E A A R R A A N N C C E E I I N N S S P P E E C C T T I I O O N N 11.
Page 105 MAINTENANCE V V A A L L V V E E C C L L E E A A R R A A N N C C E E A A D D J J U U S S T T M M E E N N T T 4.
Page 107 ENGINE / COOLING / EXHAUST CHAPTER 3 ENGINE / COOLING / EXHAUST GENERAL INFORMATION ................3.4 .
Page 108 ENGINE / COOLING / EXHAUST ................3.35 COOLANT DRAIN / FILL .
Page 109 ENGINE / COOLING / EXHAUST ..............3.81 VALVE LASH - TAPPET SELECTION .
Page 110 ENGINE / COOLING / EXHAUST G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S - - E E N N G G I I N N E E A floor jack or commercially available motorcycle engine lift or hoist is required for engine removal.
Page 111 ENGINE / COOLING / EXHAUST S S P P E E C C I I A A L L T T O O O O L L S S - - E E N N G G I I N N E E PART NUMBER TOOL DESCRIPTION Engine Stand Adapter...
Page 112 ENGINE / COOLING / EXHAUST A A I I R R C C L L E E A A N N E E R R S S E E R R V V I I C C E E A A I I R R B B O O X X A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
Page 113 ENGINE / COOLING / EXHAUST A A I I R R F F I I L L T T E E R R R R E E P P L L A A C C E E M M E E N N T T 5.
Page 114 ENGINE / COOLING / EXHAUST 8. Remove the air filter from the airbox. CAUTION A loose fitting cover or improperly installed filter element may allow debris to enter the engine which may cause premature engine wear. 9. Inspect filter element and replace if dirty, wet, or oil fouled.
Page 115 ENGINE / COOLING / EXHAUST A A I I R R B B O O X X R R E E M M O O V V A A L L 6. Remove fastener securing the air box cover 1. Remove the seat. See Seat Removal / Installation page 7.8.
Page 116 ENGINE / COOLING / EXHAUST 9. Remove two fasteners securing ECM mount. 15. Remove air filter access panel and air filter. 16. Remove three fasteners securing air box to the air box adapter. 10. Remove three fasteners securing oil separator to air box 17.
Page 117 ENGINE / COOLING / EXHAUST A A I I R R B B O O X X I I N N S S T T A A L L L L A A T T I I O O N N 2.
Page 118 ENGINE / COOLING / EXHAUST 3. Install three fasteners securing air box to the air 6. Install oil separator and secure with three fasteners box adapter. TORQUE TORQUE Air Box Adapter Fasteners: Oil Separator Fasteners: 36 in-lbs (4 N·m) 14 in-lbs (2 N·m) 4.
Page 119 ENGINE / COOLING / EXHAUST 11. Install alignment bracket and secure with three 14. Install four fasteners securing air box bezel. fasteners TORQUE TORQUE Air Box Bezel Fastener Bodywork Alignment Bracket Fasteners: 36 in-lbs (4 N·m) 36 in-lbs (4 N·m) 15.
Page 120 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A S S S S E E M M B B L L Y Y V V I I E E W W S S E E N N G G I I N N E E B B R R A A C C K K E E T T / / F F A A S S T T E E N N E E R R C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE)
Page 121 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E R R E E M M O O V V A A L L 13. Disconnect jumper harness connector P P R R E E P P A A R R A A T T I I O O N N F F O O R R E E N N G G I I N N E E R R E E M M O O V V A A L L NOTICE Different methods can be used to remove the engine depending on the equipment available to...
Page 122 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E T T O O F F R R A A M M E E , , R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 123 ENGINE / COOLING / EXHAUST INSTALLATION 6. Connect gear position sensor 1. Installation is performed by reversing the removal procedure. TORQUE Headmount Bracket To Cylinder Head Fastener: 26 ft-lbs (35 N·m) TORQUE Mid Frame Through Bolt: 51 ft-lbs (69 N·m) TORQUE Headmount To Main Frame Fastener: 7.
Page 124 ENGINE / COOLING / EXHAUST L L U U B B R R I I C C A A T T I I O O N N / / C C O O O O L L I I N N G G T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G - - L L U U B B R R I I C C A A T T I I O O N N S S Y Y S S T T E E M M G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N LOW OIL PRESSURE...
Page 125 ENGINE / COOLING / EXHAUST S S E E R R V V I I C C E E 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 - - L L U U B B R R I I C C A A T T I I O O N N OIL PUMP CLEARANCES (SCAVENGE) S S Y Y S S T T E E M M Pump Gerotor...
Page 126 ENGINE / COOLING / EXHAUST COOLING SYSTEM SPECIFICATIONS Cooling Fan Off 210Ω 226.4 Degrees F (108 Degrees Room 68 Degrees F 2500Ω Temperature (20 Degrees C) 9929391 R01 - 2019 FTR 1200 Service Manual 3.20 © Copyright Polaris Industries Inc.
Page 127 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S 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 A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
Page 128 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Radiator Isolator Fasteners 96 in-lbs (11 N·m) Coolant Recovery Bottle Fasteners 36 in-lbs (4 N·m) T T H H E E R R M M O O S S T T A A T T A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
Page 129 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T F F L L O O W W D D I I A A G G R R A A M M Cooling System Flow Thermostat Closed (Bypass) Cooling System Flow...
Page 130 ENGINE / COOLING / EXHAUST W W A A T T E E R R P P U U M M P P A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
Page 131 ENGINE / COOLING / EXHAUST L L U U B B R R I I C C A A T T I I O O N N S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W Pressure Lubrication System Assembly View NUMBER DESCRIPTION...
Page 132 ENGINE / COOLING / EXHAUST Scavenge Lubrication System Assembly View TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Engine Oil Scavenge Pump Oil Scavenge Pump Fasteners (QTY: 5) 88 in-lbs (10 N·m) Scavenge Inlet Tube Fastener 88 in-lbs (10 N·m) Oil Drain Plug 15 ft-lbs (20 N·m) Oil Drain Plug Sealing Washer Scavenge Pickup...
Page 133 ENGINE / COOLING / EXHAUST O O I I L L F F L L O O W W D D I I A A G G R R A A M M 9929391 R01 - 2019 FTR 1200 Service Manual 3.27 ©...
Page 134 ENGINE / COOLING / EXHAUST O O I I L L C C O O O O L L E E R R 4. Remove three fasteners securing oil cooler O O I I L L C C O O O O L L E E R R R R E E P P L L A A C C E E M M E E N N T T WARNING Engine components get hot and remain hot for a period of time after the engine is stopped.
Page 135 ENGINE / COOLING / EXHAUST O O I I L L C C O O O O L L E E R R A A D D A A P P T T E E R R R R E E P P L L A A C C E E M M E E N N T T 5.
Page 136 ENGINE / COOLING / EXHAUST O O I I L L P P R R E E S S S S U U R R E E T T E E S S T T O O I I L L P P U U M M P P S S E E R R V V I I C C E E S S C C A A V V E E N N G G E E O O I I L L P P U U M M P P R R E E M M O O V V A A L L CAUTION Use caution when working around hot engine oil.
Page 137 ENGINE / COOLING / EXHAUST S S C C A A V V E E N N G G E E O O I I L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 138 ENGINE / COOLING / EXHAUST P P R R E E S S S S U U R R E E O O I I L L P P U U M M P P R R E E M M O O V V A A L L 5.
Page 139 ENGINE / COOLING / EXHAUST P P R R E E S S S S U U R R E E O O I I L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 140 If pressure loss is evident FLUID CAPACITY within five minutes, check the radiator, all cooling Recommended Coolant: system hoses, hose clamps and water pump for Indian Motorcycle 50/50 Pre-Mixed Extended Life leakage. Antifreeze NOTICE System Capacity: 2.32 qt (2.2 L)
Page 141 ENGINE / COOLING / EXHAUST 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 P P R R E E S S S S U U R R E E C C A A P P T T E E S S T T C C O O O O L L A A N N T T D D R R A A I I N N / / F F I I L L L L WARNING WARNING...
Page 142 6. Remove the vacuum bleeder and install the pressure cap and safety set screw. 7. Remove the pinch pliers from the coolant line between the reservoir and thermostat housing. 8. Add Indian Motorcycle Extended Life 50/50 Engine Coolant to the reservoir fill opening until the coolant reservoir it is between markings.
Page 143 ENGINE / COOLING / EXHAUST R R A A D D I I A A T T O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 11.
Page 144 ENGINE / COOLING / EXHAUST 8. Remove the radiator fasteners 11. Installation is performed by reversing the removal procedure. TORQUE Radiator Isolator Fasteners: 96 in-lbs (11 N·m) TORQUE Radiator Wing Fasteners: 36 in-lbs (4 N·m) 12. Fill and bleed cooling system. See Coolant Drain / Fill page 3.35.
Page 145 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T R R E E C C O O V V E E R R Y Y B B O O T T T T L L E E R R E E M M O O V V A A L L / / 5.
Page 146 ENGINE / COOLING / EXHAUST W W A A T T E E R R P P U U M M P P R R E E P P L L A A C C E E M M E E N N T T 1.
Page 147 ENGINE / COOLING / EXHAUST 6. Remove water pump impeller 9. Install new water pump seal in engine case by hand. Thread water pump seal installation tool PF- 51608 on the water pump shaft. 7. Remove the water pump seal assembly with a hooked tool or equivalent taking care to not damage the water pump shaft or engine case.
Page 148 ENGINE / COOLING / EXHAUST Water Pump Shaft Oil Seal Replacement 1. Remove water pump seal. Refer to Water Pump Seal Removal and Installation. 2. Remove water pump shaft oil seal with a hooked tool or equivalent taking care to not damage water pump shaft or engine case.
Page 149 ENGINE / COOLING / EXHAUST 5. Use a suitable driver to install the seal so the outer face is flush with the step on the engine case. 6. Install new water pump seal. Refer to Water Pump Seal Removal and Installation. 7.
Page 150 ENGINE / COOLING / EXHAUST T T H H E E R R M M O O S S T T A A T T R R E E P P L L A A C C E E M M E E N N T T 6.
Page 151 ENGINE / COOLING / EXHAUST 10. Remove two fasteners securing fuel rail. 14. Remove the retainer securing the thermostat assembly to the thermostat port. Disconnect fuel rail from routing clip remove from unit. Cover the fuel injector holes to prevent debris from entering the engine. 15.
Page 152 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R 7.
Page 153 ENGINE / COOLING / EXHAUST T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G Overheating • Low coolant level •...
Page 154 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D / / V V A A L L V V E E S S S S E E R R V V I I C C E E N N O O T T E E S S - - C C A A M M C C H H A A I I N N G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N Read the following tips to ease the removal,...
Page 155 ENGINE / COOLING / EXHAUST S S P P E E C C I I A A L L T T O O O O L L S S - - C C Y Y L L I I N N D D E E R R H H E E A A D D PART NUMBER TOOL DESCRIPTION Valve Spring Compressor...
Page 156 ENGINE / COOLING / EXHAUST CYLINDER HEAD & VALVE TRAIN DATA ITEM STANDARD SERVICE LIMIT Cam Chain Tensioner Hydraulic / Self-Adjusting MIN: .9844" (25.003 mm) .9745” (24.753 mm) INTAKE MAX: .9920" (25.197 mm) Lobe Height MIN: .9844" (25.003 mm) .9745” (24.753 mm) EXHAUST MAX: .9920"...
Page 157 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S C C A A M M C C H H A A I I N N C C O O M M P P O O N N E E N N T T S S A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
Page 158 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Water Pump Driven Gear Shaft Assembly Cam Driven Sprocket Fastener 11 ft-lbs (15 N·m) Cam Chain Guide Bolt (QTY.2) 88 in-lbs (10 N·m) Cam Chain Fixed Cover Guide (Rear) Cam Driven Sprocket Cam Chain Fixed Cover Guide (Front) 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 159 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D / / C C A A M M S S H H A A F F T T A A S S S S E E M M B B L L Y Y V V I I E E W W NUM- QUANTITY TORQUE...
Page 160 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
Page 161 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T T T I I M M I I N N G G M M A A R R K K S S Camshaft Timing Front Cylinder 9929391 R01 - 2019 FTR 1200 Service Manual 3.55...
Page 163 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N S S E E R R V V I I C C E E C C A A M M C C H H A A I I N N T T E E N N S S I I O O N N E E R R R R E E M M O O V V A A L L C C A A M M C C H H A A I I N N G G U U I I D D E E ( ( U U P P P P E E R R ) ) , , R R E E M M O O V V A A L L CAUTION Do not rotate engine with tensioner(s) removed.
Page 164 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N T T E E N N S S I I O O N N E E R R I I N N S S P P E E C C T T I I O O N N C C A A M M S S H H A A F F T T S S P P R R O O C C K K E E T T R R E E M M O O V V A A L L 1.
Page 165 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S P P R R O O C C K K E E T T R R E E M M O O V V A A L L 11.
Page 166 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S H H A A F F T T R R E E M M O O V V A A L L 5.
Page 167 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N G G U U I I D D E E ( ( L L O O W W E E R R ) ) , , R R E E M M O O V V A A L L C C A A M M C C H H A A I I N N I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 168 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S H H A A F F 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 3.
Page 169 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N G G U U I I D D E E ( ( L L O O W W E E R R ) ) , , I I N N S S T T A A L L L L A A T T I I O O N N C C A A M M D D R R I I V V E E S S P P R R O O C C K K E E 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 1.
Page 170 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T S S P P R R O O C C K K E E 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 / / T T I I M M I I N N G G 5.
Page 171 ENGINE / COOLING / EXHAUST 5. Verify that the timing marks line up with the top 11. The single dot timing mark on the primary drive of the head with the chain installed and drive gear gear will be at approximately 10 o’clock. to intake cam sprocket slack removed.
Page 172 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N T T E E N N S S I I O O N N E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 173 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D S S E E R R V V I I C C E E V V A A L L V V E E C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N V V A A L L V V 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 1.
Page 174 ENGINE / COOLING / EXHAUST V V A A L L V V E E C C L L E E A A R R A A N N C C E E A A S S S S E E M M B B L L Y Y 6.
Page 175 ENGINE / COOLING / EXHAUST 10. If any of the valve clearance measurements are out 17. Reinstall the camshafts and camshaft carriers and of specification, remove the camshaft carriers and tighten the bolts evenly to specification. camshafts and proceed with this procedure. TORQUE NOTICE Camshaft Carrier Fasteners (short &...
Page 176 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T I I N N S S P P E E C C T T I I O O N N For the following camshaft inspection procedure, refer to the camshaft service specifications section.
Page 177 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D R R E E M M O O V V A A L L 8.
Page 178 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D D D I I S S A A S S S S E E M M B B L L Y Y 11.
Page 179 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D I I N N S S P P E E C C T T I I O O N N 4.
Page 180 ENGINE / COOLING / EXHAUST V V A A L L V V E E S S P P R R I I N N G G F F R R E E E E L L E E N N G G T T H H I I N N S S P P E E C C T T I I O O N N •...
Page 181 ENGINE / COOLING / EXHAUST V V A A L L V V E E I I N N S S P P E E C C T T I I O O N N NOTICE Valve service specifications can be found at the beginning of this chapter.
Page 182 ENGINE / COOLING / EXHAUST V V A A L L V V E E I I N N S S P P E E C C T T I I O O N N - - Q Q U U I I C C K K R R E E F F E E R R E E N N C C E E CONDITION ILLUSTRATION POSSIBLE CAUSE...
Page 183 3. Apply a light coating of machinist’s layout fluid or 3. Apply Indian Motorcycle engine oil to valve guide paste to valve face. seal and install seal on valve, rotating the seal as you install it.
Page 184 C C Y Y L L I I N N D D E E R R H H E E A A D D I I N N S S T T A A L L L L A A T T I I O O N N 5. Apply a thin coat of Indian Motorcycle engine oil to...
Page 185 88 in-lbs (10 N·m) 11. Temporarily install the upper cam chain guide and torque the carrier fasteners per the specified 8. Apply a thin coat of Indian Motorcycle engine oil to sequence. each of the tappets and install them in the same position from which they were removed.
Page 186 ENGINE / COOLING / EXHAUST 17. Install intake manifold. See Throttle Body Assembly Removal / Installation page 4.17. 18. Install engine in frame. See Engine to Frame, Removal / Installation page 3.16. 9929391 R01 - 2019 FTR 1200 Service Manual 3.80 ©...
Page 187 ENGINE / COOLING / EXHAUST V V A A L L V V E E L L A A S S H H - - T T A A P P P P E E T T S S E E L L E E C C T T I I O O N N A 440 tappet means the thickness of the tappet is 4.40 mm.
Page 188 ENGINE / COOLING / EXHAUST T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G C C Y Y L L I I N N D D E E R R H H E E A A D D A A N N D D V V A A L L V V E E T T R R A A I I N N NOTICE Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test.
Page 189 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Piston Rings or Piston Ring Replace Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Chain Tensioner and / or Guide Replace Worn Bottom End Area Main Bearings...
Page 190 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S NOTE Clean the machine thoroughly before removing...
Page 191 ENGINE / COOLING / EXHAUST S S E E R R V V I I C C E E 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 - - C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N ITEM STANDARD...
Page 192 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
Page 193 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N S S E E R R V V I I C C E E P P I I S S T T O O N N R R I I N N G G P P R R O O F F I I L L E E A A N N D D O O R R I I E E N N T T A A T T I I O O N N Lower Oil Ring Rail End Gap Arrows on piston crown indicate installation...
Page 194 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R R R E E M M O O V V A A L L C C Y Y L L I I N N D D E E R R B B O O R R E E M M E E A A S S U U R R E E M M E E N N T T 1.
Page 195 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N T T O O C C Y Y L L I I N N D D E E R R C C L L E E A A R R A A N N C C E E W W O O R R K K S S H H E E E E T T FRONT CYLINDER RECORDED MEASUREMENT SPECIFICATION...
Page 196 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R W W A A R R P P A A G G E E M M E E A A S S U U R R E E M M E E N N T T P P I I S S T T O O N N &...
Page 197 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N & & P P I I S S T T O O N N R R I I N N G G I I N N S S P P E E C C T T I I O O N N 7.
Page 198 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N P P I I N N / / P P I I N N B B O O R R E E I I N N S S P P E E C C T T I I O O N N 4.
Page 199 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N R R I I N N G G I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 200 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N I I N N S S T T A A L L L L A A T T I I O O N N C C Y Y L L I I N N D D E E R R I I N N S S T T A A L L L L A A T T I I O O N N The pistons are marked with an arrow on the crown IMPORTANT...
Page 201 ENGINE / COOLING / EXHAUST 7. Install piston ring compressor over rings and compress rings into ring grooves. CAUTION Be sure compressor band end gap does not align with any ring end gap when compressing the rings. IMPORTANT Install cylinders in their original locations. Cylinder with cam chain tensioner is the front cylinder.
Page 202 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
Page 203 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Wrist Pin, Wrist Pin Replace Bore and / or Connecting Worn Piston Rings or Replace Piston Ring Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Chain Tensioner and / or...
Page 204 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T E E X X H H A A U U S S T T S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
Page 205 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Front Head Pipe Assembly 88 in-lbs (10 N·m) Central Heat Shield Base Fastener Central Heat Shield Base Central Heat Shield 88 in-lbs (10 N·m) Central Heat Shield Fastener 2& Exhaust Gasket Exhaust Clamp (Front Head Pipe to Resonator) 144 in-lbs (16 N·m)
Page 206 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T S S E E R R V V I I C C E E 5. Installation is performed by reversing the removal procedure.
Page 207 ENGINE / COOLING / EXHAUST R R E E S S O O N N A A T T O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 208 ENGINE / COOLING / EXHAUST F F R R O O N N T T H H E E A A D D P P I I P P E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 209 ENGINE / COOLING / EXHAUST R R E E A A R R H H E E A A D D P P I I P P E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 9.
Page 210 ENGINE / COOLING / EXHAUST 7. Remove head pipe fasteners 8. Remove rear head pipe. 9. Installation is performed by reversing the removal procedure. TORQUE Exhaust Studs: 88 in-lbs (10 N·m) TORQUE Head Pipe Fasteners: 16 ft-lbs (22 N·m) TORQUE Rear Heat Shield Fasteners: 88 in-lbs (10 N·m) TORQUE...
Page 211 FUEL DELIVERY / EFI CHAPTER 4 FUEL DELIVERY / EFI GENERAL INFORMATION ................4.3 .
Page 212 FUEL DELIVERY / EFI ...............4.47 FUEL INJECTOR RESISTANCE TEST .
Page 213 FUEL DELIVERY / EFI G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S WARNING Many hazards are present when working on or around...
Page 214 FUEL DELIVERY / EFI S S P P E E C C I I A A L L T T O O O O L L S S - - F F U U E E L L S S Y Y S S T T E E M M / / E E F F I I TOOL DESCRIPTION PART NUMBER Fuel Pressure Adapter...
Page 215 FUEL DELIVERY / EFI E E F F I I S S Y Y S S T T E E M M P P R R E E C C A A U U T T I I O O N N S S Static electricity can damage the electronic controllers beyond repair.
Page 216 FUEL DELIVERY / EFI A A S S S S E E M M B B L L Y Y V V I I E E W W S S F F U U E E L L S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION Fuel Tank Mounting Fastener...
Page 217 FUEL DELIVERY / EFI TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Fuel Pump Fasteners 88 in-lbs (10 N·m) PFA Lock Ring Fuel Pump Assembly PFA Seal Fuel Feed Lines 48 in-lbs (5 N·m) Fuel Feed Line Retainer Fastener Fuel Feed Line Retainer F F U U E E L L L L I I N N E E R R O O U U T T I I N N G G / / R R E E T T E E N N T T I I O O N N Fuel Vent Line Routing / Retention 9929391 R01 - 2019 FTR 1200 Service Manual...
Page 219 FUEL DELIVERY / EFI Purge Hose Routing / Retention NUMBER DESCRIPTION Throttle Body Assembly Purge Valve Carbon Canister 9929391 R01 - 2019 FTR 1200 Service Manual © Copyright Polaris Industries Inc.
Page 220 FUEL DELIVERY / EFI Vapor Canister Vent Line Routing / Retention NUMBER DESCRIPTION Carbon Canister Routing Clip 9929391 R01 - 2019 FTR 1200 Service Manual 4.10 © Copyright Polaris Industries Inc.
Page 221 FUEL DELIVERY / EFI S S E E N N S S O O R R S S - - P P O O W W E E R R T T R R A A I I N N M M A A N N A A G G E E M M E E N N T T C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
Page 222 FUEL DELIVERY / EFI TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Fuse Box Ignition Coil 88 in-lbs (10 N·m) Fuel Injector 88 in-lbs (10 N·m) Coolant Temperature Sensor 17 ft-lbs (23 N·m) Oxygen Sensor 14 ft-lbs (19 N·m) Angle Sensor Speed Sensor 88 in-lbs (10 N·m) 9929391 R01 - 2019 FTR 1200 Service Manual 4.12...
Page 223 Fuel Vent Valve: The fuel vent valves direct fuel vapors down into the canister. Fuel Cap: It is important to note that Indian Motorcycle does not use an enhanced EVAP control system. This means the system does not detect a gross leak, or restrictions in the EVAP system such as a missing or loose fuel cap.
Page 224 FUEL DELIVERY / EFI E E V V A A P P C C O O N N D D I I T T I I O O N N S S A A N N D D S S Y Y M M P P T T O O M M S S The following conditions and symptoms should be taken into consideration when working on a vehicle with an EVAP System: •...
Page 225 FUEL DELIVERY / EFI C C A A R R B B O O N N C C A A N N I I S S T T E E R R R R E E P P L L A A C C E E M M E E N N T T C C A A R R B B O O N N C C A A N N I I S S T T E E R R B B R R A A C C K K E E T T R R E E P P L L A A C C E E M M E E N N T T 1.
Page 226 FUEL DELIVERY / EFI P P U U R R G G E E V V A A L L V V E E R R E E P P L L A A C C E E M M E E N N T T P P U U R R G G E E V V A A L L V V E E O O H H M M T T E E S S T T Use a multimeter to test the resistance of purge valve 1.
Page 227 FUEL DELIVERY / EFI F F U U E E L L D D E E L L I I V V E E R R Y Y S S E E R R V V I I C C E E T T H H R R O O T T T T L L E E B B O O D D Y Y A A S S S S E E M M B B L L Y Y R R E E M M O O V V A A L L / / 5.
Page 228 FUEL DELIVERY / EFI Installation 3. Torque upper clamps securing the throttle body assembly to the throttle adapters. 1. If removed, install throttle adapters orientated correctly. TORQUE TORQUE Throttle Body Clamp: 17 in-lbs (2 N·m) Throttle Body Clamp: 17 in-lbs (2 N·m) 4.
Page 229 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P P P R R E E S S S S U U R R E E I I N N S S P P E E C C T T I I O O N N 4.
Page 230 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M D D E E P P R R E E S S S S U U R R I I Z Z A A T T I I O O N N 4.
Page 231 FUEL DELIVERY / EFI 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 7. Remove fastener securing the air box cover remove air box cover.
Page 232 FUEL DELIVERY / EFI 11. Remove passenger foot peg mount by removing its 14. Remove tail light by removing two fasteners disconnecting electrical connection. fasteners . Repeat step for remaining side. 15. Remove front seat support bracket by removing its 12.
Page 233 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P R R E E M M O O V V A A L L 20. Repeat step 19 for opposite side. NOTICE WARNING To aid in removal, lift fuel tank up when removing...
Page 234 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 6.
Page 235 FUEL DELIVERY / EFI 2. Install PFA lock ring and secure with fasteners 3. Connect fuel pump feed line 4. Connect fuel pump electrical connector IMPORTANT 5. Install front seat support bracket and fasteners Ensure fuel pump is indexed with the lock ring as shown.
Page 236 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K 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.
Page 237 FUEL DELIVERY / EFI 10. Install the front and rear seat support brackets and 13. Torque fasteners to specification. hand tighten their fasteners TORQUE Sub-frame Fasteners M10: 47 ft-lbs (64 N·m) TORQUE Sub-frame Fasteners M6: 96 in-lbs (11 N·m) TORQUE Fuel Tank Support Fasteners (Bottom): 96 in-lbs (11 N·m) TORQUE...
Page 238 FUEL DELIVERY / EFI 14. Install passenger foot peg bracket and fasteners 19. Install four fasteners securing air box bezel. TORQUE TORQUE Air Box Bezel Fastener: Footpeg Bracket Fasteners (Passenger): 36 in-lbs (4 N·m) 17 ft-lbs (23 N·m) 20. Reconnect battery connections and install battery cover.
Page 239 FUEL DELIVERY / EFI F F U U E E L L L L E E V V E E L L S S E E N N S S O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T F F U U E E L L P P U U M M P P S S U U P P P P L L Y Y V V O O L L T T A A G G E E T T E E S S T T Before performing this test, verify that battery is fully 1.
Page 240 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P C C U U R R R R E E N N T T D D R R A A W W T T E E S S T T 8.
Page 241 FUEL DELIVERY / EFI P P R R I I M M I I N N G G T T H H E E F F U U E E L L S S Y Y S S T T E E M M 3.
Page 242 FUEL DELIVERY / EFI E E F F I I S S E E R R V V I I C C E E F F U U E E L L I I N N J J E E C C T T I I O O N N S S Y Y S S T T E E M M - - O O V V E E R R V V I I E E W W O O F F The locations of sensors and other EFI system related O O P P E E R R A A T T I I O O N N components are outlined in this chapter.
Page 243 FUEL DELIVERY / EFI E E C C M M C C O O N N N N E E C C T T O O R R M M A A P P NOTICE Unused pins are not included in the list below IMPORTANT Last 2 digits of 100 series number correspond to connector cavity number.
Page 244 FUEL DELIVERY / EFI CRANKSHAFT POSITION ECM SWITCHED POWER SENSOR POSITIVE SIGNAL ENGINE COOLANT WH/GN PEDAL POSITION SENSOR 1 SIGNAL OG/DB TEMPERATURE SENSOR SIGNAL AMBIENT AIR TEMP SENSOR OG/BD SIGNAL RUN/STOP SWITCH OUTPUT REAR BRAKE PRESSURE RD/BK BK/YE GROUND SWITCH OUTPUT GROUND PEDAL POSITION SENSOR 2 +5V TIP-OVER SENSOR (TOS) YE/RD...
Page 245 FUEL DELIVERY / EFI D D I I A A G G N N O O S S T T I I C C T T R R O O U U B B L L E E C C O O D D E E S S COMPONENT CONDITION CODE...
Page 246 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Open / Short C1030 Wheel Speed Sensor (Front) Input Abnormal / Signal Failure C1031 Plausibility Fault C103D Short to B+ C113D Open/Short to GND C123D Wheel Speed Sensor (Rear) Open/Short C1036 Abnormal Frequency C133D Incorrect Sensor / Improper Mounting C143D...
Page 247 FUEL DELIVERY / EFI COMPONENT CONDITION CODE ABS Pulsar (rear) COG Chip 520251 C1023 ABS Solenoid (RRI) Open / Short 520252 C1024 ABS Solenoid (RRO) Open / Short 520253 C1025 ABS Solenoid (FFI) Open/Short 520254 C1026 ABS Solenoid (FFO) Open/Short 520255 C1027 ABS Solenoid (RFI)
Page 248 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Voltage Too High P132A Knock Sensor Negative Line 520332 Voltage Too Low P132B Voltage High P1137 Oxygen Sensor (Pre) (BANK 2) 520333 Voltage Low P1138 Data Valid But Above Normal Operating Range - Least Severe Level (System Too P0170 Rich) Adaptive Fuel Correction Bank 1...
Page 249 FUEL DELIVERY / EFI ABS Trouble Codes TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Bad Intelligent Device Replace Module 520140 ABS ECU C2437 ABS Valve Relay Replace Module 520131 Condition Exists C2420 ABS Solenoid (Front In) Replace Module...
Page 250 FUEL DELIVERY / EFI TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Check Supply/ Voltage Below Normal Signal Line C123D Voltage Check Tone Wheel Speed Sensor Wheel Speed Sensor Wheel Alignment 520135 C2430 Signal Error...
Page 251 FUEL DELIVERY / EFI TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Check wiring and PGN 61441 Missing connection to 516136 Condition Exists U1112 EBC1–Lamp Info Gauge and ABS Check wiring and connections for PGN 65265 Missing Abnormal Update Rate...
Page 252 FUEL DELIVERY / EFI S S E E N N S S O O R R D D I I A A G G N N O O S S T T I I C C S S E E C C M M P P I I N N O O U U T T T T E E S S T T I I N N G G If a sensor fails or reads outside a “normal”...
Page 253 FUEL DELIVERY / EFI E E C C M M C C O O N N N N E E C C T T O O R R D D I I S S C C O O N N N N E E C C T T / / E E C C M M R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 254 FUEL DELIVERY / EFI T T E E M M P P E E R R A A T T U U R R E E M M A A N N I I F F O O L L D D A A B B S S O O L L U U T T E E 2.
Page 255 FUEL DELIVERY / EFI C C O O O O L L A A N N T T T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R , , T T E E S S T T Testing CHT TEST OVERVIEW INDICATES...
Page 256 FUEL DELIVERY / EFI F F U U E E L L I I N N J J E E C C T T O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 10.
Page 257 FUEL DELIVERY / EFI F F U U E E L L I I N N J J E E C C T T O O R R O O - - R R I I N N G G S S F F U U E E L L I I N N J J E E C C T T O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T 1.
Page 258 FUEL DELIVERY / EFI C C R R A A N N K K S S H H A A F F T T P P O O S S I I T T I I O O N N S S E E N N S S O O R R , , T T E E S S T T / / Crankshaft Position Sensor (CPS) Replacement R R E E P P L L A A C C E E 1.
Page 259 FUEL DELIVERY / EFI L L E E A A N N A A N N G G L L E E S S E E N N S S O O R R The Lean Angle Sensor is located on the back side of the battery tray.
Page 260 FUEL DELIVERY / EFI C C Y Y L L I I N N D D E E R R 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 The ECU monitors crankshaft speed via the crankshaft position sensor.
Page 261 FUEL DELIVERY / EFI D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I A A G G N N O O S S T T I I C C S S O O F F T T W W A A R R E E G G U U I I D D E E D D D D I I A A G G N N O O S S T T I I C C A A V V A A I I L L A A B B L L E E O O V V E E R R V V I I E E W W Guided diagnostics are available within Digital...
Page 262 FUEL DELIVERY / EFI D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I A A G G N N O O S S T T I I C C C C O O N N N N E E C C T T O O R R D D I I G G I I T T A A L L W W R R E E N N C C H H S S E E R R I I A A L L N N U U M M B B E E R R L L O O C C A A T T I I O O N N The diagnostic connector...
Page 263 NOTICE IMPORTANT Versions and updates are subject to change. Only authorized Indian Motorcycle dealers and distributors can access the dealer website. 1. Open the Digital Wrench software. Locate the version ID shown on the lower right side of the 1.
Page 264 FUEL DELIVERY / EFI 6. If the update file date listed is newer than your 8. When the update is complete, the version shown on current version and update, download the file. the right side of the Digital Wrench start-up screen should match the update you just downloaded.
Page 265 FUEL DELIVERY / EFI D D I I G G I I T T A A L L W W R R E E N N C C H H F F E E A A T T U U R R E E M M A A P P 9929391 R01 - 2019 FTR 1200 Service Manual 4.55 ©...
Page 266 FUEL DELIVERY / EFI E E N N G G I I N N E E C C O O N N T T R R O O L L L L E E R R R R E E P P R R O O G G R R A A M M M M I I N N G G •...
Page 267 FUEL DELIVERY / EFI 8. Copy (CTRL+C) the Request Code that will be required on the dealer website in the next step. DO NOT CLOSE Digital Wrench or the Request Code will be invalid. NOTICE All characters are letters; there are no numbers in a request code.
Page 268 FUEL DELIVERY / EFI V V E E H H I I C C L L E E M M O O D D E E L L C C O O N N V V E E R R S S I I O O N N P P R R O O C C E E S S S S 1.
Page 269 FUEL DELIVERY / EFI 9. Copy (CTRL+C) the Request Code that will be 19. Login to www.polarisdealers.com and click on required on the dealer website in the next step. DO “Certificate of Conformity” from the “Dealer NOT CLOSE Digital Wrench or the Request Code Management”...
Page 270 FUEL DELIVERY / EFI T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 1 1 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
Page 271 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 2 2 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
Page 272 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 3 3 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
Page 273 Won’t Accept Non-Current Go to Dealer website and New Calibration Calibration File Set download the most current Low Battery Voltage Indian Motorcycle Calibration Attempting Re-Flash File Set Without Proper VIN, Calibration I.D. Attach Battery Charger number, or calibration During Re-Flash, and Re-...
Page 275 CLUTCH / PRIMARY / SHIFT CHAPTER 5 CLUTCH / PRIMARY / SHIFT GENERAL INFORMATION ................5.2 .
Page 276 Engine Stand Adapter PF-51609 • Oil additives of any kind are not recommended by Indian Motorcycle. Using oil additives or oil of the Flywheel Puller PA-49316–A wrong viscosity can have a detrimental affect on clutch performance, operation, and service life.
Page 277 CLUTCH / PRIMARY / SHIFT A A S S S S E E M M B B L L Y Y V V I I E E W W S S P P R R I I M M A A R R Y Y C C O O V V E E R R A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
Page 279 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T A A S S S S E E M M B B L L Y Y V V I I E E W W Internal View NUMBER DESCRIPTION...
Page 280 CLUTCH / PRIMARY / SHIFT External View NUMBER DESCRIPTION Shaft Bearing (Clutch Pinion Shaft) Shaft Seal Clutch Pinion Shaft Primary Cover 9929391 R01 - 2019 FTR 1200 Service Manual © Copyright Polaris Industries Inc.
Page 281 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION NUMBER...
Page 282 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P L L A A T T E E A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION Friction Plate B...
Page 284 CLUTCH / PRIMARY / SHIFT 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 P P R R I I M M A A R R Y Y C C O O V V E E R R R R E E M M O O V V A A L L P P R R I I M M A A R R Y Y D D R R I I V V E E / / C C L L U U T T C C H H C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
Page 285 CLUTCH / PRIMARY / SHIFT P P R R I I M M A A R R Y Y C C O O V V E E R R L L I I P P S S E E A A L L R R E E P P L L A A C C E E M M E E N N T T 3.
Page 286 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T R R E E M M O O V V A A L L 6.
Page 287 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T S S E E A A L L C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F 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 R R E E P P L L A A C C E E M M E E N N T T 1.
Page 288 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T R R A A T T C C H H E E T T R R E E M M O O V V A A L L / / I I N N S S P P E E C C T T I I O O N N 10.
Page 289 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T R R A A T T C C H H E E 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 15.
Page 290 CLUTCH / PRIMARY / SHIFT 2. Install thrust washer external ring retaining 7. Remove locking pin to release the detent roller arm. and press new oil seal into position until flush with crankcase. Reference Shift Shaft Seal Replacement page 5.17 8.
Page 291 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T L L E E V V E E R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N S S H H I I F F T T S S H H A A F F T T S S E E A A L L R R E E P P L L A A C C E E M M E E N N T T Removal 1.
Page 292 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H S S E E R R V V I I C C E E C C L L U U T T C C H H R R A A C C K K R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N C C L L U U T T C C H H R R E E M M O O V V A A L L 1.
Page 293 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H D D I I S S A A S S S S E E M M B B L L Y Y 10. Lift the clutch assembly out of the basket and set aside.
Page 294 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H I I N N S S P P E E C C T T I I O O N N 7. Inspect surface of steel plate guides on outer edge of hub for wear, grooves, or damage.
Page 295 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y 14. Inspect lifter bearing visually for any signs or wear or discoloration.
Page 296 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 297 CLUTCH / PRIMARY / SHIFT 8. Torque the stake nut to specification. TORQUE Stake Nut, Clutch: 125 ft-lbs (170 N·m) 9. Using a punch and a hammer, stake the nut. 10. Install clutch pressure plate assembly and torque fasteners to specification. TORQUE Pressure Plate Fasteners: 88 in-lbs (10 N·m)
Page 298 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L S S E E R R V V I I C C E E S S T T A A T T O O R R C C O O V V E E R R R R E E M M O O V V A A L L S S T T A A T T O O R R C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N NOTICE 1.
Page 299 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L R R E E M M O O V V A A L L 4. Install flywheel remove tool PA-49316-A on the flywheel and tighten puller to remove flywheel...
Page 300 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L I I N N S S T T A A L L L L A A T T I I O O N N 5.
Page 301 CLUTCH / PRIMARY / SHIFT T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G C C L L U U T T C C H H / / P P R R I I M M A A R R Y Y / / S S H H I I F F T T PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
Page 302 CLUTCH / PRIMARY / SHIFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Will Not Shift Broken shift drum Shift drum Replace shift drum Bent shift forks Shift fork Replace shift forks Worn shift drum Shift drum Replace shift drum Broken gears Transmission gears Replace broken gear(s)

Indian Motorcycle FTR 1200 2019 Service Manual

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