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Indian Motorcycle Indian Chief 2022-2024 Manual
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Indian Motorcycle Indian Chief 2022-2024 Manual

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2022-2024 Indian Chief / Chief Bobber /
Super Chief / Sport Chief
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'.
Publication Printed October 2023 (PN 9941445 R03)
© Copyright 2023 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due 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 Indian Chief 2022-2024

  • 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 Torx®, is a registered Trademark of Textron. Garmin®, is a registered trademark of Garmin, Ltd. Some Indian Motorcycle factory publications can be downloaded from www. polarisindustries. com, purchased from www.purepolaris.com or by contacting the nearest Indian Motorcycle dealer. REVISION INDEX...
  • Page 4 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris 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...
  • Page 5 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief 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 :...
  • Page 7 GENERAL / SPECIFICATIONS CHAPTER 1 GENERAL / SPECIFICATIONS VEHICLE INFORMATION................1.2 .
  • Page 8 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 1st Digit 2nd Digit 3rd Digit...
  • Page 9 GENERAL / SPECIFICATIONS E E N N G G I I N N E E 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 engine number is stamped into the bottom of the RH engine case.
  • Page 10 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 / / P P R R O O D D U U C C T T 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 / / P P 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 Sequential Production Vehicle Descriptor...
  • Page 11 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 2 2 2 2 M M O O D D E E 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 NOTICE Chief Bobber Shown.
  • Page 12 GENERAL / SPECIFICATIONS CAPACITIES Engine Oil 6.0 qts. (5.7 l) with filter at oil change Fuel 4.0 gal (15.1 L) Fuel Reserve 0.6 gal (2.3 L) (fuel light on) WHEELS / TIRES Front Wheel 19 in. x 3.5 in. Cast 16 in x 3.0 in Wire Wheel Size/Type Rear Wheel...
  • Page 13 GENERAL / SPECIFICATIONS MODEL YEAR CHIEF BASE / CHIEF BOBBER BASE / CHIEF PREMIUM / CHIEF BOBBER 2022 SUPER CHIEF BASE PREMIUM / SUPER CHIEF PREMIUM ENGINE Crank Gear 55 Teeth Clutch Gear 86 Teeth Clutch Type Wet, Multi-Plate Primary Reduction 1.564:1 Ratio...
  • Page 14 GENERAL / SPECIFICATIONS 2 2 0 0 2 2 3 3 M M O O D D E E 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 NOTICE Chief Bobber Shown.
  • Page 15 GENERAL / SPECIFICATIONS Gross Axle Weight Front 425 lb (193 kg) Rating Rear 735 lb (333 kg) (GAWR) Maximum Load Capacity 475 lb (215 489 lb (222 kg) 465 lb (211 kg) 421 lb (191 kg) (riders, cargo, accessories) CAPACITIES Engine Oil 6.0 qt (5.71 L) with filter at oil change Fuel...
  • Page 16 GENERAL / SPECIFICATIONS Front Brakes Dual / 320 mm Rotor / Single / 300 mm Rotor / 4-Piston Caliper 4-Piston Calipers Rear Brakes Single / 300 mm Rotor / 2-Piston Caliper MODEL YEAR CHIEF BASE / CHIEF BOBBER BASE / CHIEF PREMIUM / CHIEF BOBBER 2023 SUPER CHIEF BASE...
  • Page 17 GENERAL / SPECIFICATIONS MODEL YEAR CHIEF BASE / CHIEF BOBBER BASE / CHIEF PREMIUM / CHIEF BOBBER 2023 SUPER CHIEF BASE PREMIUM / SUPER CHIEF PREMIUM / SPORT CHIEF ENGINE 1st Gear 9.403:1 2nd Gear 6.411:1 3rd Gear 4.763:1 4th Gear 3.796:1 5th Gear 3.243:1...
  • Page 18 GENERAL / SPECIFICATIONS 2 2 0 0 2 2 4 4 M M O O D D E E 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 NOTICE Chief Base Shown MODEL...
  • Page 19 GENERAL / SPECIFICATIONS Gross Axle Weight Front 425 lb (193 kg) Rating Rear 735 lb (333 kg) (GAWR) Maximum Load Capacity 475 lb (215 489 lb (222 kg) 465 lb (211 kg) 421 lb (191 kg) (riders, cargo, accessories) CAPACITIES Engine Oil 6.0 qt (5.71 L) with filter at oil change Fuel...
  • Page 20 GENERAL / SPECIFICATIONS Front Brakes Dual / 320 mm Rotor / Single / 300 mm Rotor / 4-Piston Caliper 4-Piston Calipers Rear Brakes Single / 300 mm Rotor / 2-Piston Caliper MODEL YEAR CHIEF BASE / CHIEF BOBBER BASE / CHIEF PREMIUM / CHIEF BOBBER 2024 SUPER CHIEF BASE...
  • Page 21 GENERAL / SPECIFICATIONS MODEL YEAR CHIEF BASE / CHIEF BOBBER BASE / CHIEF PREMIUM / CHIEF BOBBER 2024 SUPER CHIEF BASE PREMIUM / SUPER CHIEF PREMIUM / SPORT CHIEF ENGINE 1st Gear 9.403:1 2nd Gear 6.411:1 3rd Gear 4.763:1 4th Gear 3.796:1 5th Gear 3.243:1...
  • Page 22 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 23 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 24 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 models are equipped with an Evaporative...
  • Page 25 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 26 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 27 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 Battery Tester ABS Tool Bearing Removal Kit PV-50104 PU-50296...
  • Page 28 GENERAL / SPECIFICATIONS Seal and Bearing Driver Set Engine Case Assembly Cup Mainshaft / Crankcase Installer PV-43558 PF-51663 PV-45030 Cup Adapter Swingarm Bushing Tool MultiLink XP PF-51665 PF-51237 PU-52792 Water Pump Seal Installation Tool Spanner Socket (Stem) Piston Ring Compressor PF-51608 PV-43508 PV-43570-A...
  • Page 29 GENERAL / SPECIFICATIONS Crankshaft Rotation Tool Valve Spring Compressor Electrical Tester Kit PF-51239 PV-1253 PV-43526 Engine Stand Adapter Cylinder Bore Gauge Fork Oil Level Tool PF-51240 PV-3017 PV-59000A Wheel Bearing Adapter Fuel Pressure Adapter Fork Seal Tool PV-49494 PF-53041 PV-48656 Fuel Pressure Gauge Oil Filter Wrench Oil Pressure Gauge...
  • Page 30 GENERAL / SPECIFICATIONS Output Shaft Seal Tool Relay Bypass Tool TPMS Activation Tool PF-51243 PU-49466 PF-51288 Shock Spanner Wrench Shock Spanner Wrench Ball Joint Service Kit PV-2884811 2890086 Commercially Available (Similar to OTC 7249) Seal Guide (43mm) PV-47037 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 1.24 ©...
  • Page 31 GENERAL / SPECIFICATIONS 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 I I I I U U S S E E R R M M A A N N U U A A L L 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 Review the Digital Wrench II user manual for The connector...
  • Page 32 GENERAL / SPECIFICATIONS 6. Once connected, proceed with using Digital Wrench. NOTICE Required Digital Wrench Special Tools are listed in the User Manual. See Digital Wrench II User Manual page 1.25 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 1.26 ©...
  • Page 33 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 CHAPTER 2: MAINTENANCE 88 in-lbs (10 N·m) Air Box Cover Fastener...
  • Page 34 GENERAL / SPECIFICATIONS 15 ft-lbs (20 N·m) Detonation Sensor Fastener Engine Mount Fastener (Allen M8) 18 ft-lbs (25 N·m) Engine Mount Fastener (Hex M10) 44 ft-lbs (60 N·m) Engine Mount Fastener (Rear) (Hex M12) 74 ft-lbs (100 N·m) Engine Mount Fastener (Lower) (Allen M10) 44 ft-lbs (60 N·m) Exhaust Clamp Fastener 41 ft-lbs (55 N·m)
  • Page 35 GENERAL / SPECIFICATIONS CHAPTER 4: FUEL DELIVERY / EFI 57 in-lbs (6.5 N·m) Air Box Base Fastener 88 in-lbs (10 N·m) Air Box Cover Fastener Air Box Support Fastener 88 in-lbs (10 N·m) Crankshaft Position Sensor (CPS) Fastener 88 in-lbs (10 N·m) Fuel Pump Fastener / Nut 44 in-lbs (5 N·m) 88 in-lbs (10 N·m)
  • Page 36 GENERAL / SPECIFICATIONS CHAPTER 5: CLUTCH / PRIMARY / SHIFT 88 in-lbs (10 N·m) Clutch Cable Mount Bracket Fastener 125 ft-lbs (170 N·m) Clutch Stake Nut 62 in-lbs (7 N·m) Clutch Pinion Shaft Fastener 88 in-lbs (10 N·m) Detent Roller Fastener Primary Cover Fastener 177 in-lbs (20 N·m) Primary Drive Gear Fastener...
  • Page 37 GENERAL / SPECIFICATIONS Engine Mount Fastener (Rear) (Hex M12) 74 ft-lbs (100 N·m) Fender Fastener (Front) 17 ft-lbs (24 N·m) Fender Fastener (Rear) 18 ft-lbs (25 N·m) Fender Tray Fastener 88 in-lbs (10 N·m) 18 ft-lbs (25 N·m) Floorboard Fastener Foot Control Fastener (Floor Board Controls) 35 ft-lbs (47 N·m) Foot Peg Fastener (Passenger)
  • Page 38 GENERAL / SPECIFICATIONS Shift Lever Fastener (Forward Controls) 88 in-lbs (10 N·m) Shift Lever Fastener (Mid Controls) 88 in-lbs (10 N·m) Shift Pedal Pivot Shaft (Mid Controls) 50 ft-lbs (68 N·m) Shift Pedal Pivot Shaft (Forward Controls) 50 ft-lbs (68 N·m) Shift Pedal Pivot Shaft (Floor Board Controls) 50 ft-lbs (68 N·m) Shift Rod Fastener (Floor Board Controls)
  • Page 39 GENERAL / SPECIFICATIONS Grip Fastener 53 in-lbs (6 N·m) 80 in-lbs (9 N·m) Lower Belt Guard Fastener Step 1: Tighten bearing lock by following its tightening procedure. Step 2: Tighten bottom bolts on lower triple clamp. Step 3: Tighten top bolts on lower triple clamp. Step 4: repeat step 2.
  • Page 40 GENERAL / SPECIFICATIONS CHAPTER 9: BRAKES ABS Mounting Fastener 88 in-lbs (10 N·m) 88 in-lbs (10 N·m) ABS Bracket Fastener Banjo Bolt 18 ft-lbs (25 N·m) Brake Caliper Pin (Front) (Single Caliper) 12 ft-lbs (17 N·m) Brake Caliper Pin (Front) (Dual Caliper) 53 in-lbs (6 N·m) 22 ft-lbs (30 N·m) Brake Disc Fastener...
  • Page 41 GENERAL / SPECIFICATIONS Battery Box Rear Fastener 115 in-lbs (13 N·m) Battery Strap Fastener 35 in-lbs (4 N·m) Battery Terminal Fasteners 48 in-lbs (5.4 N·m) 17 in-lbs (2 N·m) Cell Modem Fastener 4.4 in-lbs (0.5 N·m) Clutch Switch Cover Fastener 4.4 in-lbs (0.5 N·m) Clutch Switch Fastener 88 in-lbs (10 N·m)
  • Page 42 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 THREAD SIZE / DRILL THREAD SIZE / DRILL DECIMAL...
  • Page 43 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 44 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 45 GENERAL / SPECIFICATIONS UNIT OF MULTIPLIED COVERTS TO MEASURE Kilograms force = Kilo pascals x 98.1 per cm (kPa) = Cylinder p (3.14159) x R x H (height) Volume 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 1.39 ©...
  • Page 46 GENERAL / SPECIFICATIONS NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 1.40 © Copyright Polaris Inc.
  • Page 47 ........2.3 INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS .
  • Page 48 DOT 4 6.0 Qts (5.7 L) with filter at oil Engine / 20W40 Semi-Synthetic change Transmission Oil Indian Motorcycle Fork 466 g (550 cc) per leg Oil 2208093 Fork Oil 466 g (550 cc) per leg Fuchs Titan SAF 5113 91 Octane 4.0 gal (15.1 L) / Reserve 0.6...
  • Page 49 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 50 MAINTENANCE P P E E R R I I O O D D I I C C M M A A I I N N T T E E N N A A N N C C E E I I N N T T E E R R V V A A L L T T A A B B L L E E MILES (KILOMETERS) ENGINE Air Filter...
  • Page 51 MAINTENANCE MILES (KILOMETERS) CHASSIS Battery Brake Fluid** Brake Pads Clutch Lever Control Cable Ends Fasteners Front Brake Lever Front Fork Oil** Front Forks and Front Axle Gear Shift Pedal Head Light Rear Brake Pedal Rear Shock Absorber Rear Wheel Alignment Road Test Sidestand / Sidestand Safety Switch...
  • Page 52 When inspection reveals the need for follow all break-in procedures to ensure the long-term replacement parts, use genuine Indian Motorcycle performance and durability of the engine. parts available from your Indian Motorcycle dealer. IMPORTANT CAUTION Service and adjustments are critical. If you’re not...
  • Page 53 MAINTENANCE R R O O U U T T I I N N E E 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 E E N N G G I I N N E E O O I I L L &...
  • Page 54 MAINTENANCE 4. Remove the drain plugs. Allow the oil to drain 16. Dispose of used filter and oil properly. completely. 17. Check for leaks around drain plug and oil filter. 5. Install new sealing washers on the drain plugs. The NOTICE sealing surfaces on drain plugs and engine should be clean and free of burrs, nicks or scratches.
  • Page 55 MAINTENANCE 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 C C H H E E C C K K 6. Add the recommended oil as needed to bring the level between the ADD and FULL marks.
  • Page 56 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 57 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 6.
  • Page 58 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 5.
  • Page 59 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 F F U U S S E E R R E E P P L L A A C C E E M M E E N N T T The battery will self-discharge when disconnected Fuses and relays are located in the fuse box under the from a vehicle, and will discharge at a faster rate when...
  • Page 60 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 Adjust headlight aim when there is a change in load (rider, cargo, accessories, etc.) or after suspension adjustment.
  • Page 61 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 1.
  • Page 62 MAINTENANCE M M A A J J O O R R 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 IMPORTANT Reference the PERIODIC MAINTENANCE INTERVAL TABLE page 2.4 for details on how often to perform each procedure.
  • Page 63 MAINTENANCE MAINTENANCE PROCEDURE LOCATION Front Brake Lever Inspection Front Brake Lever Inspection page Front Brake Lever Lubrication page 9.5 Front Brake Lever Lubrication Brake Pedal Inspection Brake Pedal Inspection page 9.5 Brake Pedal Lubrication page 9.5 Brake Pedal Lubrication Front Brake Pad Inspection Front Brake Pad Inspection page 9.6 Front Brake Pad Inspection (Sport Chief) Front Brake Pad Inspection (Sport Chief) page 9.7...
  • Page 64 MAINTENANCE NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 2.18 © Copyright Polaris Inc.
  • Page 65 ENGINE / COOLING / EXHAUST CHAPTER 3 ENGINE / COOLING / EXHAUST ENGINE MAINTENANCE ................3.4 .
  • Page 66 ENGINE / COOLING / EXHAUST ................3.28 SERVICE SPECIFICATIONS .
  • Page 67 ENGINE / COOLING / EXHAUST ...........3.89 SERVICE SPECIFICATIONS - CYLINDER / PISTON .
  • Page 68 6.0 quarts S S E E L L F F H H E E L L P P For additional details on the oil check, change, and fill processes, visit the Indian Motorcycle Help Center: www.indianmotorcycle.com/help and search “Oil Change”.
  • Page 69 ENGINE / COOLING / EXHAUST 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 S S P P A A R R K K P P L L U U G G R R E E M M O O V V A A L L NOTICE CAUTION...
  • Page 70 Due to this system, system. cranking speed can greatly affect compression readings. Indian Motorcycle strongly recommends using the cylinder leakdown method to determine how well the combustion chamber is sealing. 2. Shift transmission into neutral and stop engine.
  • Page 71 Due to this system, cranking 11. Repeat procedure for other cylinder. speed can greatly affect compression readings. Indian Motorcycle strongly recommends using the Specification - Thunderstroke 111 / 116: All Models cylinder leakdown method to determine how well the STD: 111: 90-110 psi (620-758 kPa) combustion chamber is sealing.
  • Page 72 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 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 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 / / 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 73 ENGINE / COOLING / EXHAUST 5. Inspect the air box seal and the filter retainer plate seal . Replace if needed. Installation is performed by reversing the removal procedure. 6. Torque fastener to specification. TORQUE Air Box Base Fastener: 57 in-lbs (6.5 N·m) TORQUE Air Box Cover Fastener: 88 in-lbs (10 N·m)
  • Page 74 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 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 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 E E R R V V I I C C E E N N O O T T E E S S...
  • Page 75 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 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 S S / / F F A A S S T T E E N N E E R R S S TORQUE ITEM DESCRIPTION...
  • Page 76 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 T T I I O O N N 12.
  • Page 77 ENGINE / COOLING / EXHAUST R R E E M M O O V V I I N N G G E E N N G G I I N N E E F F R R O O M M F F R R A A M M E E 21.
  • Page 78 ENGINE / COOLING / EXHAUST 6. Remove left hand engine mount and cradle fasteners 7. Push engine slightly to the LH side to free up from alignment dowels. With an assistant, lower the engine from the frame and remove from vehicle. 8.
  • Page 79 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E 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 80 ENGINE / COOLING / EXHAUST 6. Torque engine mount fasteners to specification. 8. Connect starter cable nut TORQUE TORQUE Starter Cable Nut: Engine Mount Fastener (Hex M10): 88 in-lbs (10 N·m) 44 ft-lbs (60 N·m) TORQUE Engine Mount Fastener (Allen M8): 18 ft-lbs (25 N·m) TORQUE Lower Engine Mount Fastener (Allen M10):...
  • Page 81 ENGINE / COOLING / EXHAUST 16. Connect the fuel injector electrical connectors Slide red CPA lock into latched position. 17. Install harness retainer and retain with push pins 18. Install intake manifold. See Intake Manifold Removal / Installation page 4.13. 19.
  • Page 82 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 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 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 S S E E R R V V I I C C E E N N O O T T E E S S –...
  • Page 83 Engine Oil Capacity (At Change without Filter) Follow the oil change procedure outlined in the 5.9 U.S. qts (5.6 Liters ) Not Applicable Maintenance chapter. Recommended Engine Oil if Indian Motorcycle Indian Motorcycle Semi-Synthetic 20W/40 is not available, use motorcycle oil with Not Applicable 20W/40 same specifications.
  • Page 84 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 F F I I L L T T E E R R A A D D A A P P T T E E R R TORQUE ITEM DESCRIPTION...
  • Page 85 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 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 3.21 ©...
  • Page 86 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 TORQUE ITEM DESCRIPTION Fastener, Oil Feed Pipe - M6 x 1.0 x 15 (QTY.3)
  • Page 87 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 I I N N S S P P E E C C T T I I O O N N O O I I L L P P R R E E S S S S U U R R E E CAUTION Use caution when working around hot engine oil.
  • Page 88 ENGINE / COOLING / EXHAUST 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 5. Remove the three fasteners from the oil pump assembly.
  • Page 89 ENGINE / COOLING / EXHAUST 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 4.
  • Page 90 ENGINE / COOLING / EXHAUST 8. Assemble engine crankcase. See Crankcase Assembly page 6.41. 9. Install engine in frame. See Engine Installation page 3.15. 10. Verify engine oil pressure after assembly. See Oil Pressure page 3.23. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 3.26 ©...
  • Page 91 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 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 P P E E C C I I A A L L T T O O O O L L S S The Thunderstroke 111 / 116 engines use a single cam...
  • Page 92 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 CAMSHAFT DATA DESCRIPTION SPECIFICATION...
  • Page 93 ENGINE / COOLING / EXHAUST CYLINDER HEAD & VALVE TRAIN DATA ITEM STANDARD SERVICE LIMIT Cam Chain Ratchet / Spring Tensioner Lobe Height 1.6299" (41.401 mm) 1.6260” (41.301 mm) INTAKE 1.5827" (40.202 mm) 1.5788” (40.102 mm) EXHAUST .9835 - .9840" (24.979 Cam Shaft Journal O.D.
  • Page 94 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 TORQUE ITEM DESCRIPTION...
  • Page 95 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T S S TORQUE ITEM DESCRIPTION Fastener, Bearing Retainer Plate - M5 x 0.8 x 12 62 in-lbs (7 N·m) (QTY.6) Retaining Plate, Cam Bearings Fastener, Timing Gear - M10 x 1.5 x 40 (QTY.2)
  • Page 96 ENGINE / COOLING / EXHAUST TORQUE ITEM DESCRIPTION Camshaft, Intake (Center) Camshaft, Exhaust (Rear) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 3.32 © Copyright Polaris Inc.
  • Page 97 ENGINE / COOLING / EXHAUST L L I I F F T T E E R R S S / / P P U U S S H H R R O O D D S S TORQUE ITEM DESCRIPTION O-ring, Pushrod Tube —...
  • Page 98 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 TORQUE ITEM DESCRIPTION Valve, Exhaust — Valve, Intake — Gasket, Cylinder Base —...
  • Page 99 ENGINE / COOLING / EXHAUST TORQUE ITEM DESCRIPTION Fastener, Outer Valve Cover - M6 x 12 x 15 88 in-lbs (10 N·m) (QTY.3) Cylinder Head Temperature Sensor (CHT) 71 in-lbs (8 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 3.35 ©...
  • Page 100 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 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 3.36 ©...
  • Page 101 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 2. Remove the ten fasteners securing the cam chain cover to the inner timing cover.
  • Page 102 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 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 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 1.
  • Page 103 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 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 R R E E M M O O V V A A L L 1.
  • Page 104 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N R R E E M M O O V V A A L L 1. Place motorcycle in an upright position with the front wheel clamped in a wheel vise.
  • Page 105 ENGINE / COOLING / EXHAUST 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 •...
  • Page 106 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T / / L L I I F F T T E E R R S S E E R R V V I I C C E E - - E E N N G G I I N N E E 4.
  • Page 107 ENGINE / COOLING / EXHAUST L L I I F F T T 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 8.
  • Page 108 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T C C A A R R R R I I E E R R R R E E M M O O V V A A L L NOTICE Base and head gasket seal is released when removing camshaft carrier.
  • Page 109 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T C C A A R R R R I I E E R R D D I I S S A A S S S S E E M M B B L L Y Y 6.
  • Page 110 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 111 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T C C A A R R R R I I E E R R A A S S S S E E M M B B L L Y Y 3.
  • Page 112 ENGINE / COOLING / EXHAUST 7. Install woodruff keys and split gear assemblies onto the exhaust camshafts and set aside. IMPORTANT Care must be taken when installing the exhaust camshafts into the carrier bearings to ensure they are in the correct location. The lobe of the RH exhaust camshaft should be closer to the bearing carrier than the LH exhaust camshaft lobe.
  • Page 113 ENGINE / COOLING / EXHAUST 11. Install exhaust camshaft fasteners and washers into carrier assembly so they are finger tight. 12. Place the camshaft carrier in a soft-jawed vise and use nylon strapping or rope to create an interference between the camshaft gear teeth, thus locking the camshafts.
  • Page 114 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T C C A A R R R R I I 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 3.
  • Page 115 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T S S E E R R V V I I C C E E - - I I N N B B I I K K E E PREPARATION C C A A M M S S H H A A F F T T R R E E M M O O V V A A L L IMPORTANT...
  • Page 116 ENGINE / COOLING / EXHAUST RIGHT FLOORBOARD REMOVAL 2. Remove and keep two screws from brake master cylinder , disengage pushrod from brake pedal assembly, and remove brake master cylinder from RH floorboard assembly and move out of the 2022 way.
  • Page 117 ENGINE / COOLING / EXHAUST RIGHT FOOT PEG REMOVAL SEAT REMOVAL 1. Remove cotter pin and washer BOBBER SEAT 1. Remove seat fasteners 2. Remove brake line retention fastener 3. Remove master cylinder fasteners 2. Lift seat upward to remove. 4.
  • Page 118 ENGINE / COOLING / EXHAUST SOLO SEAT 2. Pull pillion seat upward off of seat stud to remove. 1. Remove seat faster 3. Remove pillion seat stud 2. Lift the rear of the seat upward and slide back to remove. 4.
  • Page 119 ENGINE / COOLING / EXHAUST SPORT SEAT INTAKE REMOVAL 1. Lift the rear of the seat upward to disconnect the 1. Remove air box cover fasteners and air box seat from the pillion fastener. cover . 2. Move the seat rearward to disconnect the front 2.
  • Page 120 ENGINE / COOLING / EXHAUST 4. Remove air box by removing its fasteners DEPRESSURIZE THE FUEL SYSTEM WARNING Allow engine and exhaust to cool completely before disconnecting fuel line or removing tank. Wear eye protection. 1. Locate the fuel pump relay. 5.
  • Page 121 ENGINE / COOLING / EXHAUST 5. Squeeze both release buttons (one on each side of FUEL TANK REMOVAL fitting) and hold. Gently slide fitting straight off fuel Be prepared to place the fuel tank in a secure location rail. with a drain pan positioned to catch any fuel that may leak or drip from disconnected hoses or fittings.
  • Page 122 ENGINE / COOLING / EXHAUST 4. Slowly pull the fuel tank up and disconnect the fuel SPARK PLUG REMOVAL pump electrical connector and fuel vent line CAUTION HOT COMPONENTS Wear insulated gloves and/or allow engine and exhaust to cool before handling these parts. NOTICE The front spark plug can be removed without having to remove the fuel tank by using a 3”...
  • Page 123 ENGINE / COOLING / EXHAUST THROTTLE BODY REMOVAL REMOVE FUEL INJECTORS 1. Disconnect throttle body electrical connector and 1. Disconnect fuel injector electrical connectors. remove the throttle body wiring from the holder. IMPORTANT Disengage Red CPA connection lock before disconnecting injector. 2.
  • Page 124 ENGINE / COOLING / EXHAUST REMOVE CAMSHAFTS 4. Remove and retain chain tensioner fastener chain tensioner 1. Remove and retain ten fasteners , make note of different sizes and locations. Remove cam chain cover and gasket. 5. Remove and retain external snap ring and chain tensioner arm and spring assembly 2.
  • Page 125 ENGINE / COOLING / EXHAUST 7. Remove screws and washers from crankshaft 9. Install Special Tool PF-52544 as shown. and camshaft. Pull camshaft sprocket , crankshaft sprocket and cam chain off as an assembly and set aside. Collect woodruff key from crankshaft and set aside.
  • Page 126 ENGINE / COOLING / EXHAUST 12. On Special Tool PF-51455, loosely assemble the 15. Install camshaft gear washers and fasteners until lower camshaft retainer plate to the main plate they are hand-tight. using two fasteners 16. With the flat side of the retaining pin aligned 13.
  • Page 127 ENGINE / COOLING / EXHAUST 18. Use the second etched line (marked “B”) to 21. Rotate the camshaft using a suitable wrench while determine when the shaft is fully seated in the hole pressing on the retaining pin until it seats at the marked “B”.
  • Page 128 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 T T A A L L L L A A T T I I O O N N 24.
  • Page 129 ENGINE / COOLING / EXHAUST 3. Using a suitable wrench, rotate each camshaft 7. Install the three fasteners and torque to while pulling the respective retaining pin out of the specification. plate bore to release the lifters. TORQUE Camshaft Carrier Fasteners: 15 ft-lbs (20 N·m) 4.
  • Page 130 ENGINE / COOLING / EXHAUST CAM GEAR AND CHAIN INSTALLATION 6. Install cam chain guide and fasteners . Torque to specification. 1. Place the woodruff key in the end of the crankshaft. 2. Working on a flat surface, assemble the timing chain onto the crankshaft and camshaft sprockets as shown.
  • Page 131 ENGINE / COOLING / EXHAUST 12. Install the ten fasteners securing the cam chain cover to the inner timing cover. 13. Torque cam chain cover fasteners following the specified torque sequence. TORQUE Cam Chain Cover Fasteners: 10 ft-lbs (13 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 3.67 ©...
  • Page 132 ENGINE / COOLING / EXHAUST THROTTLE BODY INSTALLATION 3. Install the NEW throttle body and throttle body screws . Torque fasteners to specification. 1. Install four screws and four washers to the airbox support bracket . Torque fasteners to specification. TORQUE Throttle Body Fasteners: TORQUE...
  • Page 133 ENGINE / COOLING / EXHAUST FUEL INJECTOR INSTALLATION FUEL TANK INSTALLATION 1. Always lubricate injector O-rings with clean, 1. Apply alcohol, soapy water solution, or rubber silicone-free motor oil. lubricant to the isolators and carefully lower the fuel tank onto the frame. CAUTION 2.
  • Page 134 ENGINE / COOLING / EXHAUST CONNECT THE BATTERY 6. Install fuel tank console and secure it with fasteners . Torque fasteners to specification. Connect the negative (-) battery cable to the battery terminal. Torque fastener to specification. TORQUE TORQUE Fuel Tank Console Fastener: 88 in-lbs (10 N·m) Battery Terminal Fastener: 48 in-lbs (5.4 N·m)
  • Page 135 ENGINE / COOLING / EXHAUST INSTALL INTAKE 3. Install airbox and airbox screws . Torque fasteners to specification. 1. Inspect the air box seal and the filter retainer plate seal . Replace if needed. TORQUE Air Box Base Fasteners: 2. Connect the breather hose to the breather fitting on the engine.
  • Page 136 ENGINE / COOLING / EXHAUST 6. Install airbox cover and secure with airbox cover 2. Lower brake master cylinder in place, engaging screws . Torque fasteners to specification pushrod onto brake pedal assembly and attach with two retained screws . Torque screws to specification.
  • Page 137 ENGINE / COOLING / EXHAUST 4. Test foot brake and verify pedal feels firm and no RIGHT FOOT PEG INSTALLATION air has entered hydraulic circuit. Bleed brakes if 1. Install foot peg bracket fasteners necessary. 2. Install and torque master cylinder fasteners TORQUE Master Cylinder Mounting Fasteners (rear): 18 ft-lbs (25 N·m)
  • Page 138 ENGINE / COOLING / EXHAUST SEAT INSTALLATION 7. Thread the rear bracket bolt and washer through the bracket and nylon grommet. Torque the bolt 1. Position the seat by inserting the seat mounting to specification. tabs from rear to front into the frame. 2.
  • Page 139 ENGINE / COOLING / EXHAUST OIL FILL AND LEVEL CHECK 8. Stop the engine and check the oil level before adding any additional oil. 1. Install new sealing washers on the drain plugs. The sealing surfaces on drain plugs and engine should IMPORTANT be clean and free of burrs, nicks or scratches.
  • Page 140 ENGINE / COOLING / EXHAUST e. Remove the dipstick and view the oil level. NOTICE Do not overfill. Overfilling can result in loss of engine performance and an oil-saturated air filter. Use a suction device to remove excess oil if overfilled. f.
  • Page 141 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 IMPORTANT...
  • Page 142 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 R R O O C C K K E E R R A A R R M M R R E E M M O O V V A A L L 1.
  • Page 143 ENGINE / COOLING / EXHAUST R R O O C C K K E E R R 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 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 NOTICE CAUTION...
  • Page 144 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 145 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 6. Measure valve stem deflection for each valve to determine if valve or valve guide requires NOTICE replacement.
  • Page 146 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 CONDITION ILLUSTRATION POSSIBLE CAUSE CORRECTIVE ACTION Uneven seat width Bent valve stem, worn Replace valve and reface...
  • Page 147 ENGINE / COOLING / EXHAUST V V A A L L V V E E G G U U I I D D 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 V V A A L L V V E E S S E E A A T T I I N N S S P P E E C C T T I I O O N N NOTICE CAUTION...
  • Page 148 1. If previously removed, lubricate push rod tube o- 3. Apply Indian Motorcycle engine oil to valve guide rings with a small amount of engine oil and press seal and install seal on valve, rotating the seal as them into the lifter blocks until fully seated.
  • Page 149 ENGINE / COOLING / EXHAUST 8. Install washers and nuts on cylinder studs. Tighten finger tight. 9. Fully torque cylinder head following the procedure below to ensure accurate final torque: TORQUE Cylinder Head Nuts: Step 1: 26 ft-lbs (35 N·m)Step 2: Turn additional 50°Step 3: Turn additional 90°...
  • Page 150 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 151 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Camshaft or Rocker Replace Rocker Arm Bearing Replace Damage Replace Cam Bearings Worn or Damaged Worn Pistons and / or Replace Cylinders Worn Wrist Pin, Wrist Pin Replace Piston / Cylinder Area Bore and / or Connecting...
  • Page 152 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 P P E E C C I I A A L L T T O O O O L L 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 TOOL DESCRIPTION...
  • Page 153 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 154 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 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 TORQUE ITEM DESCRIPTION...
  • Page 155 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 NOTICE Compression rings 1 &...
  • Page 156 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 157 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 158 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 7.
  • Page 159 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 5.
  • Page 160 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 4.
  • Page 161 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R S S T T U U D D R R E E P P L L A A C C E E M M E E N N T T 5.
  • Page 162 ENGINE / COOLING / EXHAUST 10. Carefully install cylinder(s) over piston/ring assembly. Do not force cylinder over piston. Monitor rings carefully. If a piston ring becomes dislodged from the ring compressor; remove cylinder, inspect ring carefully for damage. 11. Remove piston ring compressor when rings are fully captive in cylinder.
  • Page 163 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 / / P P I I S S T T O O N N PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
  • Page 164 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Pistons and / or Replace Cylinders Worn Wrist Pin, Wrist Pin Replace Piston / Cylinder Area Bore and / or Connecting Worn Piston Rings or Replace Piston Ring Lands General Exhaust Leak Reseal Exhaust...
  • Page 165 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R L L E E A A K K A A G G E E T T E E S S T T •...
  • Page 166 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 M M A A I I N N T T E E N N A A N N C C E E E E X X H H A A U U S S T T H H E E A A T T S S H H I I E E L L D D After 500 Miles (805 km) of riding, check orientation and re-torque all clamps...
  • Page 167 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 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 TORQUE TORQUE ITEM...
  • Page 168 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 3. Pull mufflers rearward to remove. M M U U F F F F L L 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 WARNING Engine and exhaust components get hot and remain hot for a period of time after the engine is stopped.
  • Page 169 ENGINE / COOLING / EXHAUST 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 2.
  • Page 170 ENGINE / COOLING / EXHAUST 6. Disconnect oxygen sensor electrical connector 1. Installation is performed by reversing the removal procedure. 2. Inspect exhaust gasket prior to head pipe assembly. TORQUE Head Pipe Nut: Step 1: Start all four nuts.Step 2: Torque front upper nut to 88 in-lbs (10 N·m) and back off nut 2 revolutionsStep 3: Torque front lower nut to 88 in- lbs (10 N·m).Step 4: Torque rear upper nut to 88...
  • Page 171 FUEL DELIVERY / EFI CHAPTER 4 FUEL DELIVERY / EFI GENERAL INFORMATION ................4.3 .
  • Page 172 FUEL DELIVERY / EFI ..........4.49 CYLINDER HEAD TEMPERATURE SENSOR, TEST / REPLACE .
  • Page 173 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 - - F F U U E E L L D D E E L L I I V V E E R R Y Y / / E E F F I I WARNING Many hazards are present when working on or around...
  • Page 174 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 / / E E F F I I M M A A I I N N T T E E N N A A N N C C E E 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 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 TOOL DESCRIPTION...
  • Page 175 DESCRIPTION The fuel lines exiting fuel pump are subjected to high Fuel Line pressure. Replace with genuine Indian Motorcycle replacement parts to reduce the possibility of fuel Fuel Tank to Carbon Canister Line line failure. Be sure fuel lines are routed properly and...
  • Page 176 FUEL DELIVERY / EFI S S E E R R V V I I C C E E P P R R E E C C A A U U T T I I O O N N S S 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 177 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 L L I I N N E E R R O O U U T T I I N N G G 5 5 0 0 S S T T A A T T E E ITEM DESCRIPTION...
  • Page 178 FUEL DELIVERY / EFI 4 4 9 9 S S T T A A T T E E ITEM DESCRIPTION Fuel Line Fuel Vent Line 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual ©...
  • Page 179 FUEL DELIVERY / EFI 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 NOTICE Left side of fuel tank is hidden for viewing purposes.
  • Page 180 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
  • Page 181 FUEL DELIVERY / EFI A A I I R R B B O O X X C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION 88 in-lbs (10 N·m) Air Filter Cover Fastener —...
  • Page 182 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 ITEM DESCRIPTION ITEM...
  • Page 183 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 I I N N T T A A K K E E M M A A N N I I F F O O L L D D R R E E M M O O V V A A L L / / 7.
  • Page 184 FUEL DELIVERY / EFI 13. Remove supply line by squeezing both release 18. Installation is performed by reversing the buttons (one on each side of quick connection) and removal procedure. hold. Gently slide fitting straight off fuel rail. IMPORTANT Verify fuel line is properly seated and locked in CAUTION place by listening for an audible “click”...
  • Page 185 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 186 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 5.
  • Page 187 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 5. Rotate the fuel tank brackets downward to disconnect the mount from the isolator.
  • Page 188 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 4. Remove fuel pump fasteners CAUTION Be careful when performing this procedure to avoid damaging the fuel pump, electrical wiring, or hoses.
  • Page 189 FUEL DELIVERY / EFI F F U U E E L L 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 6.
  • Page 190 FUEL DELIVERY / EFI 4. Remove cable tie holding suction line and return 8. Insert a large flat blade screwdriver and pry near line together. the filter tee fitting to separate the filter element assembly from the pump motor. Use caution not to 5.
  • Page 191 FUEL DELIVERY / EFI INSTALLATION 1. Reinstall the level sender assembly by gently sliding forward on the filter assembly until securely locked in place. 2. Install pump onto filter assembly by gently pressing filter tee fitting onto pump inlet until fully seated.
  • Page 192 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 c.
  • Page 193 FUEL DELIVERY / EFI 3. Install fuel pump fasteners and tighten to 4. Attach the push pin retaining strap to the fuel specification following the torque sequence shown. line. 5. Install the fuel line push pin retaining strap onto NOTICE the pump bracket as shown.
  • Page 194 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 6.
  • Page 195 FUEL DELIVERY / EFI 7. Connect the fuel line to the fuel rail. 1. Remove the fuel pump. See Fuel Pump Removal page 4.18. IMPORTANT 2. Set multimeter to measure resistance. Attach Verify fuel line is properly seated and locked in suitable test probe adaptors to meter leads (from place by listening for an audible “click”...
  • Page 196 FUEL DELIVERY / EFI 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 8.
  • Page 197 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 5.
  • Page 198 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 Prime procedure should be performed: •...
  • Page 199 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 M M O O V V A A L L / / 5.
  • Page 200 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 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 1.
  • Page 201 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 202 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 203 FUEL DELIVERY / EFI Engine Intake Voltage Below Manifold #1 Normal, Or Shorted P0107 Pressure To Low Source Voltage Above Engine Intake Normal, Or Shorted Manifold #1 P0108 To High Source Pressure Engine Intake Data Erratic, Manifold 1 Intermittent Or P0111 Temperature Incorrect...
  • Page 204 FUEL DELIVERY / EFI Cruise Control Abnormal Update U0104 States Rate Cruise Control Checksum Error U0405 States Cruise Control Counter Error U1405 States Data Erratic, Clutch Switch Intermittent Or P0704 Incorrect Clutch Switch Counter Error U0256 Clutch Switch Checksum Error U0557 Abnormal Update Clutch Switch...
  • Page 205 FUEL DELIVERY / EFI Ignition Coil Voltage Below Primary Driver 1 Normal, Or Shorted P2300 (Front) (MAG) To Low Source 1268 Ignition Coil Voltage Above Primary Driver 1 Normal, Or Shorted P2301 (Front) (MAG) To High Source Ignition Coil Voltage Below Primary Driver 2 Normal, Or Shorted P2303...
  • Page 206 FUEL DELIVERY / EFI Current Below Oxygen Sensor Bank Normal Or Open P0150 2 Sensor 1 Circuit Voltage Below Oxygen Sensor Bank Normal, Or Shorted P0151 2 Sensor 1 To Low Source Voltage Above Oxygen Sensor Bank Normal, Or Shorted P0152 2 Sensor 1 To High Source...
  • Page 207 FUEL DELIVERY / EFI Mechanical System Cylinder 1 Misfire Not Responding Or 65591 P0301 Out Of Adjustment Mechanical System Cylinder 2 Misfire Not Responding Or 65592 P0302 Out Of Adjustment ETC Accelerator Data Erratic, Position Sensor Intermittent Or P1135 Outputs 1 & 2 Incorrect Correlation 65613...
  • Page 208 FUEL DELIVERY / EFI Current Below Canister Purge Normal Or Open P0444 Valve Circuit Voltage Below Canister Purge Normal, Or Shorted P0445 Valve To Low Source Data Valid But Below Fuel Correction Normal Operating P0171 Front Range - Least Severe Level 520204 Data Valid But...
  • Page 209 FUEL DELIVERY / EFI Throttle Body Voltage Above Control - Power Normal, Or Shorted P150D Stage To High Source Throttle Body Voltage Below Control - Power Normal, Or Shorted P150E Stage To Low Source 520277 Throttle Body Data Erratic, Control - Power Intermittent Or P151A Stage...
  • Page 210 FUEL DELIVERY / EFI Voltage Above Brake Light Normal, Or Shorted P1594 To High Source Voltage Below Brake Light Normal, Or Shorted P1595 To Low Source Current Below Tail Light 520321 Normal Or Open P1596 Circuit Voltage Above Tail Light Normal, Or Shorted 520321 P1597...
  • Page 211 FUEL DELIVERY / EFI Data Valid But Idle Fuel Correction Above Normal P2190 Bank 2 Operating Range - Least Severe Level Data Valid But Below Adaptive Fuel Normal Operating P2177 Correction Bank 1 Range - Least Severe Level 520344 Data Valid But Adaptive Fuel Above Normal P2178...
  • Page 212 FUEL DELIVERY / EFI Current Below Front Right Turn Normal Or Open P17A5 Driver Circuit Circuit Voltage Above Rear Left Turn Normal, Or Shorted P17A6 Driver Circuit To High Source Voltage Below Rear Left Turn 520547 Normal, Or Shorted P17A7 Driver Circuit To Low Source Current Below...
  • Page 213 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 214 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 215 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 216 FUEL DELIVERY / EFI 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 E E C C M M C C O O N N N N E E C C T T O O R R R R E E M M O O V V A A L L NOTICE 1.
  • Page 217 FUEL DELIVERY / EFI 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 1.
  • Page 218 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 4.
  • Page 219 FUEL DELIVERY / EFI C C Y Y L L I I N N D D E E R R H H E E A A D D 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 / / R R E E P P L L A A C C E E CHT TEST OVERVIEW INDICATES...
  • Page 220 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 1.
  • Page 221 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 222 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 / / CPS Replacement R R E E P P L L A A C C E E 1.
  • Page 223 FUEL DELIVERY / EFI T T H H R R O O T T T T L L E E B B O O D D Y Y ( ( E E T T C C ) ) R R E E M M O O V V A A L L / / NOTICE I I N N S S T T A A L L L L A A T T I I O O N N Accelerator Position Sensor (APS) has two different...
  • Page 224 FUEL DELIVERY / EFI T T I I P P O O V V E E R R S S E E N N S S O O R R The Tip Over Sensor adds load to standard high- current hand control switches for terminal cleaning and to provide ECM interface signal integrity.
  • Page 225 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 226 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 227 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 228 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 229 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/ PIN, Calibration I.D. Attach Battery Charger number, or calibration During Re-Flash, and Re-...
  • Page 230 FUEL DELIVERY / EFI NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 4.60 © Copyright Polaris Inc.
  • Page 231 CLUTCH / PRIMARY / SHIFT CHAPTER 5 CLUTCH / PRIMARY / SHIFT GENERAL INFORMATION ................5.3 .
  • Page 232 CLUTCH / PRIMARY / SHIFT ................. . .5.35 CLUTCH DISASSEMBLY .
  • Page 233 Cable Mechanism • Oil additives of any kind are not recommended by Operated Indian Motorcycle. Using oil additives or oil of the Primary Reduction Ratio wrong viscosity can have a detrimental affect on 1.56 : 1 clutch performance, operation, and service life.
  • Page 234 CLUTCH / PRIMARY / SHIFT 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 3.
  • Page 235 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H C C A A B B L L 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 236 CLUTCH / PRIMARY / SHIFT 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 237 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T 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 / / L L U U B B R R I I C C A A T T I I O O N N 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 1.
  • Page 238 CLUTCH / PRIMARY / SHIFT • Tighten jam nuts to specification. TORQUE Shift Rod Jam Nuts: 88 in-lbs (10 N·m) CAUTION Do not remove and reposition the shift arm on the shift shaft to adjust gear shift pedal height. Dots on shift shaft and shift arm must be aligned for gears to shift correctly.
  • Page 239 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 ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE ITEM DESCRIPTION...
  • Page 240 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 ( ( 2 2 0 0 2 2 3 3 ) ) TORQUE ITEM DESCRIPTION...
  • Page 241 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 ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE ITEM DESCRIPTION...
  • Page 242 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 ( ( 2 2 0 0 2 2 3 3 ) ) TORQUE ITEM DESCRIPTION...
  • Page 243 CLUTCH / PRIMARY / SHIFT P P R R I I M M A A R R Y Y D D R R I I V V E E G G E E A A R R TORQUE ITEM DESCRIPTION Primary Drive Gear Fastener (2022) 50 ft-lbs (68 N·m) + 38°...
  • Page 244 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE ITEM DESCRIPTION — Clutch Rack Retaining Ring — — Clutch Lifter 125 ft-lbs (170 N·m) Clutch Stake Nut Spring Disc...
  • Page 245 CLUTCH / PRIMARY / SHIFT TORQUE ITEM DESCRIPTION Stopper Plate Fastener 62 in-lbs (7 N·m) Stopper Plate — Clutch Spring — Clutch Seat Spring — — Inner Clutch Hub — Clutch Friction Disc — Clutch Steel Disc Judder Spring — Judder Spring Seat —...
  • Page 246 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H ( ( 2 2 0 0 2 2 3 3 ) ) TORQUE TORQUE ITEM DESCRIPTION ITEM DESCRIPTION — — Pressure Plate Lift Rack Internal Judder Spring —...
  • Page 247 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 ( ( 2 2 0 0 2 2 2 2 ) ) 7.
  • Page 248 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 R R E E M M O O V V A A L L ( ( 2 2 0 0 2 2 3 3 ) ) 7.
  • Page 249 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 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 R R E E M M O O V V A A L L &...
  • Page 250 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 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 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 &...
  • Page 251 CLUTCH / PRIMARY / SHIFT 7. Pull the shift lever and spring assembly out of 11. Inspect fit of rivet on shift ratchet assembly. It the bore. should allow for free movement, but not be excessively loose. 8. Inspect shift shaft return spring for cracks or loss of tension.
  • Page 252 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 3.
  • Page 253 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T S S H H A A F F T T B B E E A A R R I I N N G G & & 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 1.
  • Page 254 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 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 2 0 0 2 2 2 2 ) ) 1.
  • Page 255 CLUTCH / PRIMARY / SHIFT 6. Torque the primary cover fasteners to specification following the torque sequence. TORQUE Primary Cover Fasteners: 177 in-lbs (20 N·m) Primary Cover Torque Sequence 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 5.25 ©...
  • Page 256 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 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 2 0 0 2 2 3 3 ) ) 1.
  • Page 257 CLUTCH / PRIMARY / SHIFT 6. Torque the primary cover fasteners to specification following the torque sequence. TORQUE Primary Cover Fasteners: 177 in-lbs (20 N·m) Primary Cover Torque Sequence 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 5.27 ©...
  • Page 258 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 ( ( 2 2 0 0 2 2 2 2 ) ) 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 2.
  • Page 259 CLUTCH / PRIMARY / SHIFT 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 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 1.
  • Page 260 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. Lift clutch assembly out of basket and set aside 1.
  • Page 261 CLUTCH / PRIMARY / SHIFT 8. Inspect surface of steel plate guides on outer 14. Inspect pressure plate for cracks, scoring, or wear edge of hub for wear, grooves, or damage. on friction surface. Clutch Springs 15. Inspect clutch springs for cracks or distortion. Clutch Release Rack and Bearing NOTICE Clutch rack is serviceable as an assembly only.
  • Page 262 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 4. Install clutch hub 1. Install the thrust washer and the pressure plate into the clutch basket.
  • Page 263 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 IMPORTANT When installing clutch assembly on the input shaft, make sure that the thrust washer between the clutch...
  • Page 264 CLUTCH / PRIMARY / SHIFT 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 S S E E R R V V I I C C E E ( ( 2 2 0 0 2 2 3 3 ) ) 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 1.
  • Page 265 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 7. Remove inner hub and clutch assembly CAUTION Clutch is under spring pressure.
  • Page 266 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 posts for cracks or damage.
  • Page 267 CLUTCH / PRIMARY / SHIFT 13. Inspect pressure plate for cracks, scoring, or wear on friction surface. Clutch Springs 14. Inspect clutch springs for cracks or distortion. Clutch Release Rack and Bearing NOTICE Clutch rack is serviceable as an assembly only. 15.
  • Page 268 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 4. Install the hub bearing and sleeve into the clutch assembly.
  • Page 269 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 IMPORTANT When installing clutch assembly on the input shaft, make sure that the thrust washer between the clutch...
  • Page 270 CLUTCH / PRIMARY / SHIFT P P R R I I M M A A R R Y Y D D R R I I V V E E G G E E A A R R S S E E R R V V I I C C E E P P R R I I M M A A R R Y Y D D R R I I V V E E G G E E A A 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 G G E E A A 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 271 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 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 WARNING CAUTION The flywheel contains powerful magnets.
  • Page 272 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...
  • Page 273 CLUTCH / PRIMARY / SHIFT REPAIR PROBLEM POSSIBLE CAUSE PART(S) AFFECTED RECOMMENDED Transmission Will Not Broken shift drum Shift drum Replace shift drum Shift Bent shift forks Shift fork Replace shift forks Worn shift drum Shift drum Replace shift drum Broken gears Transmission gears Replace broken gear(s)
  • Page 274 CLUTCH / PRIMARY / SHIFT NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 5.44 © Copyright Polaris Inc.
  • Page 275 TRANSMISSION / CRANKSHAFT CHAPTER 6 TRANSMISSION / CRANKSHAFT GENERAL INFORMATION ................6.3 .
  • Page 276 TRANSMISSION / CRANKSHAFT ................6.40 TRANSMISSION INSTALLATION .
  • Page 277 TRANSMISSION / CRANKSHAFT 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 •...
  • Page 278 TRANSMISSION / CRANKSHAFT 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 - - T T R R A A N N S S M M I I S S S S I I O O N N / / C C R R A A N N K K S S H H A A F F T T CONNECTING ROD / CRANKSHAFT SPECIFICATIONS PART...
  • Page 279 TRANSMISSION / CRANKSHAFT TRANSMISSION SPECIFICATIONS ITEM PART SPECIFIC STANDARD SERVICE LIMIT Shift Fork 12.00 - 12.026 mm 12.05 mm (.4744") Shift Fork I.D. (Rail) (.4725 - .4732") 6.036 - 6.136 mm 6.02 mm (.2370") Shift Fork Pin O.D. (.2376 - .2416") Shift Fork Rail 11.948 - 11.972 mm 11.92 mm (.4693")
  • Page 280 TRANSMISSION / CRANKSHAFT 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 R R A A N N K K C C A A S S E E TORQUE ITEM DESCRIPTION...
  • Page 281 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T TORQUE ITEM DESCRIPTION Bearing, Crankshaft Main (RH) — Non- — Serviceable Fastener, Connecting Rod Bearing Cap 22 ft-lbs (30 N·m) + 90° (QTY.4) Bearing Caps, Connecting Rod —...
  • Page 282 TRANSMISSION / CRANKSHAFT C C R R A A N N K K C C A A S S E E F F A A S S T T E E N N E E R R L L E E N N G G T T H H A A N N D D T T O O R R Q Q U U E E P P A A T T T T E E R R N N NOTICE Items 1, 3, 4, 11, 13 &...
  • Page 283 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N I I N N P P U U T T S S H H A A F F T T ITEM DESCRIPTION Input Shaft, Transmission...
  • Page 284 TRANSMISSION / CRANKSHAFT O O U U T T P P U U T T S S H H A A F F T T ITEM DESCRIPTION Snap Ring Spacer Gear, 1st — Driven Bearing, 1st Gear Slider, Gear Dog Gear Dog Gear, 3rd —...
  • Page 285 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N ( ( 2 2 0 0 2 2 3 3 + + ) ) Input Shaft ITEM DESCRIPTION...
  • Page 286 TRANSMISSION / CRANKSHAFT Output Shaft ITEM DESCRIPTION Snap Ring Spacer Gear, 1st — Driven Bearing, 1st Gear Slider, Gear Dog Gear Dog Gear, 3rd — Driven Bearing Gear, 5th — Driven Gear, 6th — Driven Gear, 4th — Driven Gear, 2nd — Driven Bearing, 2nd Gear Output Shaft, Transmission 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual...
  • Page 287 TRANSMISSION / CRANKSHAFT S S H H I I F F T T D D R R U U M M / / S S H H I I F F T T F F O O R R K K ITEM DESCRIPTION Bearing, Shift Drum —...
  • Page 288 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T TORQUE ITEM DESCRIPTION Fastener, Balance Shaft Gear — M10 x 1.5 x 40 59 ft-lbs (80 N·m) (QTY.1) —...
  • Page 289 TRANSMISSION / CRANKSHAFT G G E E A A R R T T R R A A I I N N 1st Gear 2nd Gear 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 6.15 ©...
  • Page 290 TRANSMISSION / CRANKSHAFT 3rd Gear 4th Gear 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 6.16 © Copyright Polaris Inc.
  • Page 291 TRANSMISSION / CRANKSHAFT 5th Gear 6th Gear 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 6.17 © Copyright Polaris Inc.
  • Page 292 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T S S E E R R V V I I C C E E I I N N N N E E R R C C A A M M C C H H A A I I N N C C O O V V E E R R R R E E M M O O V V A A L L B B A A L L A A N N C C 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 1.
  • Page 293 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C 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 8.
  • Page 294 TRANSMISSION / CRANKSHAFT 12. Install the spacer onto the crankshaft. 13. Install the inner cam cover. See Inner Cam Chain Cover Installation page 6.21. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 6.20 ©...
  • Page 295 TRANSMISSION / CRANKSHAFT I I N N N N E E R R C C A A M M C C H H A A I I N N 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 296 TRANSMISSION / CRANKSHAFT S S T T A A R R T T E E R R D D R R I I V V E E S S E E R R V V I I C C E E S S T T A A R R T T E E R R D D R R I I V V E E R R E E M M O O V V A A L L S S T T A A R R T T E E R R D D R R I I V V E E I I N N S S P P E E C C T T I I O O N N 1.
  • Page 297 TRANSMISSION / CRANKSHAFT S S T T A A R R T T E E R R D D R R I I V V E E 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 298 TRANSMISSION / CRANKSHAFT 5. Install spacer onto the crankshaft. 6. Install inner cam chain cover. See Inner Cam Chain Cover Installation page 6.21. 7. Check engine oil and fill to proper level. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 6.24 ©...
  • Page 299 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T S S E E R R V V I I C C E E C C R R A A N N K K C C A A S S E E S S E E P P A A R R A A T T I I O O N N 18.
  • Page 300 TRANSMISSION / CRANKSHAFT 21. Position the main plate assembly onto the IMPORTANT engine case as shown. The threaded spacers should line up with the corresponding engine case • Plate surface should be parallel to the surface of fastener holes. the engine crankcase. •...
  • Page 301 TRANSMISSION / CRANKSHAFT 25. Holding nut stationary with an open ended wrench, turn the case splitting adapter clockwise until the engine cases begin to part. STOP. 26. Using a soft-faced mallet, work around the seam of the engine cases tapping lightly to release the sealed bond.
  • Page 302 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N R R E E M M O O V V A A L L 5.
  • Page 303 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S 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 ( ( A A L L L L M M O O D D E E L L Y Y E E A A R R S S ) ) Input Shaft ITEM MEASUREMENT LOCATION...
  • Page 304 TRANSMISSION / CRANKSHAFT Output Shaft ITEM MEASUREMENT LOCATION DIAMETER SPECIFICATION Gear, 2nd — I.D. 39.010 — 39.026 mm Bushing, 2nd Gear — O.D. 38.955 — 38.980 mm Bushing, 2nd Gear — I.D. 32.010 — 32.035 mm Gear, 4th — I.D. 39.010 —...
  • Page 305 TRANSMISSION / CRANKSHAFT Shafts 1. Measure outside diameter of shafts and bearing areas for wear and concentricity. Look closely at splines for wear. Inspect ends of shafts for signs of wear: • Dull finish • Discoloration • Rough or uneven surface •...
  • Page 306 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T R R E E M M O O V V A A L L C C O O N N N N E E C C T T I I N N G G R R O O D D S S I I D D 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 1.
  • Page 307 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D R R E E M M O O V V A A L L / / C C O O N N N N E E C C T T I I N N G G R R O O D D I I N N S S P P E E C C T T I I O O N N ( ( B B I I G G E E N N D D ) ) 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 IMPORTANT...
  • Page 308 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G C C L L E E A A R R A A N N C C E E 4.
  • Page 309 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G S S E E L L E E C C T T I I O O N N 3.
  • Page 310 TRANSMISSION / CRANKSHAFT C C R R A A N N K K 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 5.
  • Page 311 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T C C L L E E A A N N I I N N G G M M A A I I N N B B E E A A R R I I N N G G O O I I L L 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 1.
  • Page 312 TRANSMISSION / CRANKSHAFT L L E E F F T T C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y R R I I G G H H T T C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y Prepare LEFT crankcase for assembly: Prepare RIGHT crankcase for assembly:...
  • Page 313 TRANSMISSION / CRANKSHAFT C C R R A A N N K K 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 NOTICE Install left engine case onto an engine stand.
  • Page 314 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S 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 6.
  • Page 315 TRANSMISSION / CRANKSHAFT C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 5. Place the Engine Case Splitting / Assembly tool PF-51234 on a flat surface and assemble the M6 1.
  • Page 316 TRANSMISSION / CRANKSHAFT 11. Pull crankcase together by tightening nut and IMPORTANT tapping on crankcase with a soft mallet. • Plate surface should be parallel to the surface of NOTICE the engine crankcase. The cases will mate before the output shaft is drawn •...
  • Page 317 TRANSMISSION / CRANKSHAFT S S T T A A K K E E N N U U 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 •...
  • Page 318 TRANSMISSION / CRANKSHAFT 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 REPAIR RECOMMENDED Transmission Will Not Broken Shift Cam Shift Cam...
  • Page 319 TRANSMISSION / CRANKSHAFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Incorrect Oil Viscosity Engine oil and filter Refer to Engine / Cooling / Exhaust chapter Incorrect Clutch Clutch Adjustment Refer to Clutch / Primary Adjustment / Shift chapter Bent, Rubbing, Sticky, Shifter Ratchet Assembly Refer to Clutch / Primary Broken Shift Shaft...
  • Page 320 TRANSMISSION / CRANKSHAFT NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 6.46 © Copyright Polaris Inc.
  • Page 321 FRAME / BODY CHAPTER 7 FRAME / BODY GENERAL INFORMATION ................7.2 .
  • Page 322 FRAME / BODY 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 F F R R A A M M E E / / B B O O D D Y Y M M A A I I N N T T E E N N A A N N C C E E S S E E R R V V I I C C E E N N O O T T E E S S This section covers the removal and installation of 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...
  • Page 323 FRAME / BODY 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 5.
  • Page 324 FRAME / BODY S S I I D D E E - - S S T T A A N N 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.
  • Page 325 FRAME / BODY 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 B B O O D D Y Y W W O O R R K K C C O O M M P P O O N N E E N N T T S S NOTICE All front bodywork fasteners are to be torqued to 88 in-lbs (10 N·m).
  • Page 326 FRAME / BODY DESCRIP- TORQUE TORQUE ITEM ITEM DESCRIPTION TION Harness Tray Upper Battery Tray — — Side Cover Bracket — — Push Rivet Voltage 88 in-lbs (10 Regulator Side Cover Bracket 35 in-lbs (4 N·m) N·m) Bracket Fastener Fastener Voltage Fender Tray Fastener 88 in-lbs (10 N·m)
  • Page 327 FRAME / BODY W W I I N N D D S S H H I I E E L L D D DESCRIP- TORQUE TORQUE ITEM ITEM DESCRIPTION TION Windshield 88 in-lbs (10 — Spool Rubber Washer N·m) Fastener Windshield Windshield —...
  • Page 328 FRAME / BODY F F A A I I R R I I N N G G TORQUE ITEM DESCRIPTION Cowl Mount (Upper) — Cowl Mount Fastener (Upper) 88 in-lbs (10 N·m) 9 in-lbs (1 N·m) Windshield Fastener Cowl Mount (Lower) —...
  • Page 329 FRAME / BODY F F E E N N D D 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 ITEM DESCRIPTION 18 ft-lbs (25 N·m) Rear Fender Fastener —...
  • Page 330 FRAME / BODY F F E E N N D D E E R R C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE ITEM DESCRIPTION...
  • Page 331 FRAME / BODY S S E E A A T T B B A A G G G G E E R R S S E E A A T T TORQUE ITEM DESCRIPTION 13 ft-lbs (18 N·m) Pillion Seat Fastener —...
  • Page 332 FRAME / BODY F F L L O O A A T T I I N N G G S S E E A A T T TORQUE ITEM DESCRIPTION Floating Seat — 18 ft-lbs (25 N·m) Seat Mount Fastener —...
  • Page 333 FRAME / BODY S S O O L L O O S S E E A A T T TORQUE ITEM DESCRIPTION — Solo Seat 13 ft-lbs (18 N·m) Solo Seat Fastener Solo Seat Bracket 53 in-lbs (6 N·m) Solo Seat Bracket Fastener 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 7.13 ©...
  • Page 334 FRAME / BODY S S E E A A T T ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE ITEM DESCRIPTION Sport Seat —...
  • Page 335 FRAME / BODY S S A A D D D D L L E E B B A A G G C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
  • Page 336 FRAME / BODY F F R R A A M M E E C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION 44 ft-lbs (60 N·m) Frame Cradle Fastener —...
  • Page 337 FRAME / BODY TORQUE ITEM DESCRIPTION Cylinder Head Mount Bracket — Cylinder Head Mount Bracket Faster (to frame) 33 ft-lbs (45 N·m) Cylinder Head Mount Bracket Faster (to engine) Engine Bracket — Engine Mount Fastener (Hex M10) 44 ft-lbs (60 N·m) Engine Mount Fastener (Allen M8) 18 ft-lbs (25 N·m) Lower Engine Mount Fastener (Allen M10)
  • Page 338 FRAME / BODY F F O O O O T T P P E E G G C C O O M M P P O O N N E E N N T T S S F F O O R R W W A A R R D D C C O O N N T T R R O O L L S S ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE TORQUE ITEM...
  • Page 339 FRAME / BODY F F O O R R W W A A R R D D C C O O N N T T R R O O L L S S ( ( 2 2 0 0 2 2 3 3 + + ) ) TORQUE TORQUE ITEM...
  • Page 340 FRAME / BODY M M I I D D C C O O N N T T R R O O L L S S ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE TORQUE ITEM DESCRIPTION ITEM DESCRIPTION...
  • Page 341 FRAME / BODY M M I I D D C C O O N N T T R R O O L L S S ( ( 2 2 0 0 2 2 3 3 + + ) ) TORQUE TORQUE ITEM DESCRIPTION...
  • Page 342 FRAME / BODY F F L L O O O O R R B B O O A A R R D D C C O O N N T T R R O O L L S S ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE TORQUE ITEM...
  • Page 343 FRAME / BODY F F L L O O O O R R B B O O A A R R D D C C O O N N T T R R O O L L S S ( ( 2 2 0 0 2 2 3 3 + + ) ) TORQUE TORQUE ITEM...
  • Page 344 FRAME / BODY P P A A S S S S E E N N G G E E R R F F O O O O T T P P E E G G S S TORQUE ITEM DESCRIPTION Passenger Foot Peg LH —...
  • Page 345 FRAME / BODY B B O O D D Y Y / / F F R R A A M M E E S S E E R R V V I I C C E E S S A A D D D D L L E E B B A A G G 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 D D R R I I V V E E R R F F O O O O T T P P E E G G 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 R R E E M M O O V V A A L L...
  • Page 346 FRAME / BODY 4. Torque driver foot peg bracket bolts to 6. Torque driver foot peg bolts to specification. specification. TORQUE TORQUE Foot Control Fastener: Foot Control Fastener: 35 ft-lbs (47 N·m) 35 ft-lbs (47 N·m) TORQUE TORQUE Master Cylinder Mounting Fasteners (rear): Shift Rod Fastener: 18 ft-lbs (25 N·m) 88 in-lbs (10 N·m)
  • Page 347 FRAME / BODY F F O O O O T T P P E E G G S S P P A A S S S S E E N N G G E E R R R R E E M M O O V V A A L L / / S S E E A A T T 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 F F L L O O A A T T I I N N G G S S E E A A T T...
  • Page 348 FRAME / BODY B B A A G G G G E E R R S S E E A A T T 6. INSTALLATION IS PERFORMED BY REVERSING THE REMOVAL PROCEDURE. 1. Remove pillion seat fastener TORQUE Seat Fastener (Floating): 18 ft-lbs (25 N·m) TORQUE Seat Mount Fastener (Floating):...
  • Page 349 FRAME / BODY 4. Lift the rear of the seat upward and slide back to 2. Move the seat rearward to disconnect the front remove. retention feature and remove seat. 5. INSTALLATION IS PERFORMED BY 3. Installation is performed by reversing the REVERSING THE REMOVAL PROCEDURE.
  • Page 350 FRAME / BODY F F R R O O N N T T B B O O D D Y Y C C O O M M P P O O N N E E N N T T S S R R E E M M O O V V A A L L / / 5.
  • Page 351 FRAME / BODY F F R R O O N N T T B B O O D D Y Y C C O O M M P P O O N N E E N N T T S S I I N N S S T T A A L L L L A A T T I I O O N N 8.
  • Page 352 FRAME / BODY 3. Install the turn signals to the front cover and the 5. Align the covers to 6.6 mm +/- 1 mm (0.26 in. +/- 0.04 in.). Torque fasteners to specification. fasteners . Torque fasteners to specification. TORQUE TORQUE Front Bodywork Fastener: Turn Signal Fastener:...
  • Page 353 FRAME / BODY F F O O R R K K C C O O 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 7.
  • Page 354 FRAME / BODY F F O O R R K K C C O O V V E E R R A A L L I I G G N N M M E E N N T T 2. Loosen the fork cover fasteners, and align the covers to 6.6 mm +/- 1 mm (0.26 in.
  • Page 355 FRAME / BODY F F A A I I R R I I N N G G 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 W W I I N N D D S S C C R R E E E E N N 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 1.
  • Page 356 FRAME / BODY F F A A I I R R I I N N G G R R I I N N G G G G R R O O M M M M E E T T 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 P P O O R R T T C C H H I I E E F F ) ) R R E E M M O O V V A A L L 1.
  • Page 357 FRAME / BODY F F R R O O N N T T F F E E N N D D 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 F F R R O O N N T T F F E E 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 Motorcycle should be parked on a level surface CAUTION...
  • Page 358 FRAME / BODY R R E E A A R R F F E E N N D D 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 5.
  • Page 359 FRAME / BODY 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 R R E E M M O O V V A A L L / / 4.
  • Page 360 FRAME / BODY U U S S B B C C H H A A R R G G E E P P O O R R T T R R E E P P L L A A C C E E M M E E N N T T I I G G N N I I T T I I O O N N C C O O 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 1.
  • Page 361 STEERING / SUSPENSION CHAPTER 8 STEERING / SUSPENSION FRONT WHEEL & SUSPENSION ............... . . 8.4 .
  • Page 362 STEERING / SUSPENSION .....8.57 TRIPLE CLAMP INSTALLATION / STEERING HEAD BEARING ADJUSTMENT ............8.59 TROUBLESHOOTING FRONT WHEEL / SUSPENSION REAR WHEEL &...
  • Page 363 STEERING / SUSPENSION ................8.87 SWINGARM REMOVAL .
  • Page 364 (Inverted Forks) the tire information label. Fork Seal Driver PV-49494 Tubeless tires are used on certain Indian Motorcycle (Inverted Forks) models. Operating the motorcycle with damaged Fork Seal Installation rims creates a safety hazard including air pressure...
  • Page 365 Fork Tube Diameter (Inverted Forks) 43 mm ( 1.69 in.) Not Applicable .20 mm (.008 in.) Fork Tube Runout Indian Motorcycle Fork Oil (2208093) Fork Oil Type Fuchs Titan SAF 5113 Fork Spring Rate 10 N/mm (57 lb/in) Not Applicable Fork Spring Free Length 400 mm (15.75 in.)
  • Page 366 STEERING / SUSPENSION 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 N N T T R R O O L L S S LEFT (2022) TORQUE ITEM...
  • Page 367 STEERING / SUSPENSION LEFT (2023+) TORQUE ITEM DESCRIPTION — Front Switch Cover — Switch Cube Front Grip Fastener 53 in-lbs (6 N·m) — Switch Cube Rear 9 in-lbs (1 N·m) Switch Cube Fastener — Rear Switch Cover 9 in-lbs (1 N·m) Switch Cube Cover Fastener 88 in-lbs (10 N·m) Torque upper fastener Clutch Perch Fastener...
  • Page 368 STEERING / SUSPENSION RIGHT TORQUE ITEM DESCRIPTION — Front Switch Cover — Switch Cube Front Throttle Grip — — Switch Cube Rear 9 in-lbs (1 N·m) Switch Cube Fastener — Rear Switch Cover 9 in-lbs (1 N·m) Switch Cube Cover Fastener 88 in-lbs (10 N·m) Torque upper fastener, Master Cylinder Fastener then lower...
  • Page 369 STEERING / SUSPENSION H H A A N N D D L L E E B B A A R R C C O O M M P P O O N N E E N N T T S S 2022 TORQUE TORQUE...
  • Page 370 STEERING / SUSPENSION 2023+ TORQUE TORQUE ITEM DESCRIPTION ITEM DESCRIPTION 18 ft-lbs (25 N·m) Torque Riser Cap Fastener — front Riser Bottom fasteners, then rear Riser Cap — Triple Clamp Cap — Triple Clamp Top — 72 ft-lbs (98 N·m) Handlebar —...
  • Page 371 STEERING / SUSPENSION H H A A N N D D L L E E B B A A R R C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE TORQUE ITEM...
  • Page 372 STEERING / SUSPENSION T T R R I I P P L L E E C C L L A A M M P P C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
  • Page 373 STEERING / SUSPENSION TORQUE ITEM DESCRIPTION Step 1: Tighten bearing lock by following its tightening procedure. Step 2: Tighten bottom bolts on lower triple clamp. Step 3: Tighten top bolts on lower triple clamp. Lower Triple Clamp Pinch Fastener Step 4: repeat step 2. Step 5: Repeat step 3.
  • Page 374 STEERING / SUSPENSION T T R R I I P P L L E E C C L L A A M M P P C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE ITEM DESCRIPTION...
  • Page 375 STEERING / SUSPENSION TORQUE ITEM DESCRIPTION — Washer Top Triple Clamp Nut 72 ft-lbs (98 N·m) Triple Clamp Nut Cap — 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.15 © Copyright Polaris Inc.
  • Page 376 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K C C O O M M P P O O N N E E N N T T S S 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.16 ©...
  • Page 377 STEERING / SUSPENSION DESCRIP- TORQUE TORQUE ITEM ITEM DESCRIPTION TION 15 ft-lbs (20 Fork Cap — Seal Cover N·m) Spring Seal Wiper — — Spacer Spring Seat Snap Ring — — Main Spring — — Main Seal Spring Mount — —...
  • Page 378 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.18 ©...
  • Page 379 STEERING / SUSPENSION DESCRIP- TORQUE TORQUE ITEM ITEM DESCRIPTION TION 17 ft-lbs (23 Fork Cap Cylinder Comp. — N·m) O-Ring — Kit, Seals — 12 ft-lbs (16 Tube Comp. Fork Cap Nut — N·m) Inner Spring Sealing Washer — — Guide, Upper Spring, 17 ft-lbs (23...
  • Page 380 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L C C O O M M P P O O N N E E N N T T S S SPOKE WHEEL TORQUE ITEM...
  • Page 381 STEERING / SUSPENSION CAST WHEEL TORQUE ITEM DESCRIPTION Wheel Speed Sensor — 22 ft-lbs (30 N·m) Brake Disc Fastener — Brake Disc Wheel Bearing LH — Wheel Bearing Spacer — — Cast Wheel Wheel Bearing RH — Wheel Bearing Seal —...
  • Page 382 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE ITEM DESCRIPTION...
  • Page 383 STEERING / SUSPENSION 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 4. Disconnect switch cube electrical connectors. H H A A N N D D L L E E B B A A 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 384 STEERING / SUSPENSION 8. Remove switch cube cover fasteners 13. Follow the handlebar harness and disconnect electrical connectors. NOTICE Tape a cord or braided wire sleeve with cord to harness before removing from the handlebars. 9. Disconnect switch cube electrical connections. 10.
  • Page 385 STEERING / SUSPENSION H H A A N N D D L L E E B B A A 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 P P O O R R T T 16.
  • Page 386 STEERING / SUSPENSION 4. Disconnect switch cube electrical connectors. 9. Disconnect switch cube electrical connections. 5. Remove switch cube fasteners and remove. 10. Remove switch cube fasteners 6. To remove left hand grip, remove its fastener. 11. Remove right hand grip and in-bar ETC. 7.
  • Page 387 STEERING / SUSPENSION M M I I R R R R 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 14.
  • Page 388 STEERING / SUSPENSION C C L L U U T T C C H H C C A A B B L L 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 389 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L 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 390 STEERING / SUSPENSION FRONT WHEEL INSTALLATION • Install axle pinch bolts on lower right fork leg. • Secure the motorcycle in an upright position with tie-down straps and a platform jack positioned beneath the engine cases. IMPORTANT Do not operate the front brake lever with the calipers or wheel removed.
  • Page 391 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L 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 2.
  • Page 392 STEERING / SUSPENSION F F R R O O N N T T 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 5.
  • Page 393 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T 4.
  • Page 394 STEERING / SUSPENSION 6. Install new seal on the non-brake side. 7. Install the brake disc. See Brake Disc Removal / Installation page 9.44. 8. Install the front wheel. See Front Wheel Removal / Installation page 8.29. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.34 ©...
  • Page 395 STEERING / SUSPENSION F F O O R R K K S S E E R R V V I I C C E E 6. Slide fork leg down and remove. FRONT FORK REMOVAL WARNING This procedure requires raising and supporting the motorcycle so that the front wheel is off the ground.
  • Page 396 STEERING / SUSPENSION FRONT FORK DISASSEMBLY 4. Compress the fork to expose the spring spacer. IMPORTANT The following procedure requires the use of dampener Tool (PF-53122). NOTICE Refer to Front Fork Assembly View. See Front Fork Components page 8.16. Clean fork tubes before disassembly.
  • Page 397 STEERING / SUSPENSION 9. Gently pry dust seal upward. 12. Looking down from the top of the fork, insert special tool PF-53122 to hold the damper tube. 10. Gently pry out clip. 13. Finish removing bottom cartridge bolt and washer 11.
  • Page 398 STEERING / SUSPENSION 15. Using a slide hammer action, separate the inner 2. Inspect inner and outer tube for scoring, heavy fork tube from the outer leg. scratches, dents due to rocks or other road debris, or excessive wear. Replace tube(s) if deep scratches, pitting, or dents are found.
  • Page 399 STEERING / SUSPENSION FRONT FORK ASSEMBLY 4. Install the inner fork tube assembly into the lower tube. NOTICE Clean all parts prior to assembly. 1. Install washer , upper bushing , and lower bushing onto inner fork tube. 5. Looking down from the top of the fork, insert special tool PF-53122 to hold the damper tube.
  • Page 400 STEERING / SUSPENSION 6. Install cartridge bolt and torque to specification. 8. Using the smaller diameter of fork seal installer (PV-49494), drive in the new main seal. TORQUE IMPORTANT Fork Cartridge Fastener Note orientation of seal during installation. 22 ft-lbs (30 N·m) Correct 7.
  • Page 401 STEERING / SUSPENSION 9. Install spring clip 14. Install spring mount , main spring , spring seat , and spring seat 10. Using the larger diameter end of (PV-49494), install the new seal wiper. 15. Install fork cap TORQUE Fork Cap: 15 ft-lbs (20 N·m) 11.
  • Page 402 STEERING / SUSPENSION FRONT FORK INSTALLATION 3. Install and hand tighten the triple clamp pinch fasteners. IMPORTANT Clean the fork tubes and the clamping surfaces of the triple clamps to remove any oil or grease prior to installation. 1. Install one fork tube assembly into lower triple clamp.
  • Page 403 STEERING / SUSPENSION TRIPLE CLAMP REMOVAL 8. Remove brake line and wire harness guides from upper and lower triple clamp. WARNING 9. Remove center nut and washer on upper triple This procedure requires raising and supporting clamp. the motorcycle so that the front wheel is off the ground.
  • Page 404 STEERING / SUSPENSION 12. If equipped, remove bearing cover. NOTICE Note Orientation for installation. 13. Remove lower triple clamp, with steering stem, and lower bearing (outer race will remain in head tube). 14. Inspect bearings and bearing races. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.44 ©...
  • Page 405 STEERING / SUSPENSION TRIPLE CLAMP INSTALLATION / STEERING HEAD BEAR- 4. If previously removed, reinstall bearing cover. ING ADJUSTMENT 1. Inspect both top and bottom bearing races for pitting, dents, or worn surface. Replace bearings and races as a set if they are worn or damaged. 2.
  • Page 406 STEERING / SUSPENSION 10. Loosen adjuster nut 90 degrees (1/4 turn) so the reference mark on frame is aligned with the next one of the four slots on the stem nut. 11. Set upper triple clamp in place on stem. Install washer and nut and tighten top nut until it is...
  • Page 407 STEERING / SUSPENSION F F O O R R K K S S E E R R V V I I C C E E ( ( S S P P O O R R T T C C H H I I E E F F ) ) 6.
  • Page 408 STEERING / SUSPENSION FRONT FORK DISASSEMBLY 3. Compress outer tube and drain fork oil. NOTICE The following procedure requires the use of Fork Spring Compressor (PV-49463). NOTICE Refer to appropriate Front Fork Exploded View. IMPORTANT Clean fork tubes before disassembly. 1.
  • Page 409 STEERING / SUSPENSION 7. Compress spring until jam nut is shown. 13. Remove cartridge bolt 8. Break loose jam nut and remove top cap. 14. Remove cartridge 15. Cycle damper rod on the cartridge to remove oil. 9. Remove tension off the spring compressor. 10.
  • Page 410 STEERING / SUSPENSION 18. Use a slide hammer action to separate the inner and outer tube. 19. Remove upper tube bushing by slightly spreading it apart. 20. Remove slider tube bushing , washer , and oil seal 21. Remove snap ring and dust cap. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.50 ©...
  • Page 411 STEERING / SUSPENSION FRONT FORK INSPECTION 3. Install dust cap 1. Inspect inner fork tube for scoring, heavy scratches, dents due to rocks or other road debris, or excessive wear. Replace tube if worn or damaged. 2. Place fork tube in V-blocks or truing stand and measure runout.
  • Page 412 STEERING / SUSPENSION 10. Slide outer fork tube over inner fork tube. 13. Install oil seal into outer tube and use seal driver to seat. 11. Lightly install lower tube busing and washer into outer fork tube. 14. Install snap ring 12.
  • Page 413 STEERING / SUSPENSION 17. Install cartridge holder tool PV-49452. 23. With the fork extended, cup your hand over the top of the outer tube and push down. This will eliminate air bubbles. 18. Install cartridge bolt and new sealing washer. 24.
  • Page 414 STEERING / SUSPENSION 27. Install the assembly into spring compressor. 32. Remove pressure off compressor and remove fork assembly. 28. Thread special tool PV-49453 onto damper rod. 33. Slide tube up to top cap tighten. 29. Pull up on damper and compress the assembly. TORQUE Top Cap: 17 ft-lbs (23 N·m)
  • Page 415 STEERING / SUSPENSION FRONT FORK INSTALLATION (SPORT CHIEF) 5. Torque fasteners to specification. IMPORTANT TORQUE Clean the fork tubes and the clamping surfaces of the Fork Triple Clamp Fasteners (Lower): triple clamps to remove any oil or grease prior to Step 1: Tighten bearing lock by following its installation.
  • Page 416 STEERING / SUSPENSION TRIPLE CLAMP REMOVAL 9. Remove cap , center nut , and washer on upper triple clamp. WARNING This procedure requires raising and supporting the motorcycle so that the front wheel is off the ground. Precautions should be taken to ensure the motorcycle is properly stabilized at all times.
  • Page 417 STEERING / SUSPENSION TRIPLE CLAMP INSTALLATION / STEERING HEAD BEAR- 12. If equipped, remove bearing cover. ING ADJUSTMENT 1. Inspect both top and bottom bearing races for pitting, dents, or worn surface. Replace bearings and races as a set if they are worn or damaged. 2.
  • Page 418 STEERING / SUSPENSION 4. If previously removed, reinstall bearing cover. 10. Loosen adjuster nut 90 degrees (1/4 turn) so the reference mark on frame is aligned with the next one of the four slots on the stem nut. 11. Set upper triple clamp in place on stem. Install washer and nut and tighten top nut until it is...
  • Page 419 STEERING / SUSPENSION 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 R R O O N N T T W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
  • Page 420 STEERING / SUSPENSION PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Fork Tube Height Unequal Install Correctly Fork Oil Level Unequal Set Correctly Replace Fork Spring Free Length Different Between Right & Left Wheel Assembly Out-of-Balance Balance Low Tire Pressure Inflate to specification Front Suspension Too Soft Weak Fork Springs Replace...
  • Page 421 Use only the recommended tires inflated to the recommended tire pressures. Tubeless tires are used on certain Indian Motorcycle models. Operating the motorcycle with damaged rims creates a safety hazard including air pressure loss, steering imbalance and/or reduced steering control.
  • Page 422 STEERING / SUSPENSION 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 - - R R E E A A R R W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N SERVICE ITEM...
  • Page 423 STEERING / SUSPENSION 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 424 STEERING / SUSPENSION S S T T E E E E R R I I N N G G / / S S U U S S P P E E N N S S I I O O N N M M A A I I N N T T E E N N A A N N C C E E D D R R I I V V E E B B E E L L T T 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 D D R R I I V V E E B B E E L L T T I I N N S S P P E E C C T T I I O O N N DRIVE BELT DEFLECTION DATA...
  • Page 425 STEERING / SUSPENSION D D R R I I V V E E B B E E L L T T T T E E N N S S I I O O N N • Continue to rotate the wheel in normal drive direction (COUNTER-CLOCKWISE) 1-2 Special Tool: Belt Tension Gauge PV-43532 revolutions until your reference mark (the...
  • Page 426 STEERING / SUSPENSION D D R R I I V V E E B B E E L L T T A A D D J J U U S S T T M M E E N N T T 8.
  • Page 427 STEERING / SUSPENSION 6. When belt tension is correct, check and adjust 8. Rotate the wheel in FORWARD direction and verify final belt alignment as follows. that sprocket teeth are visible on both sides of the drive belt. Belt Alignment WARNING Drive belt misalignment can cause drive line noise and damage the drive belt, causing possible belt...
  • Page 428 STEERING / SUSPENSION S S P P R R O O C C K K E E T T I I N N S S P P E E C C T T I I O O N N 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 I I N N S S P P E E C C T T I I O O N N NOTICE WARNING Drive belt and sprocket service life are maximized...
  • Page 429 STEERING / SUSPENSION 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 6. Inspect rear shock for leakage and all rear suspension components for damage or loose WARNING fasteners.
  • Page 430 STEERING / SUSPENSION R R E E A A R R S S H H O O C C K K REAR SHOCK PRELOAD ADJUSTMENT REAR SHOCK PRELOAD INSPECTION 1. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise.. Periodically inspect rear shock preload.
  • Page 431 STEERING / SUSPENSION R R E E A A R R S S H H O O C C K K ( ( S S P P O O R R T T C C H H I I E E F F ) ) REAR SHOCK PRELOAD ADJUSTMENT (SPORT CHIEF) REAR SHOCK PRELOAD INSPECTION (SPORT CHIEF) 1.
  • Page 432 STEERING / SUSPENSION 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 R R E E A A R R S S U U S S P P E E N N S S I I O O N N C C O O M M P P O O N N E E N N T T S S IMPORTANT Both the swingarm pivot nut and swingarm pivot jam nut...
  • Page 433 STEERING / SUSPENSION R R E E A A R R S S U U S S P P E E N N S S I I O O N N C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) IMPORTANT Both the swingarm pivot nut and swingarm pivot jam nut...
  • Page 434 STEERING / SUSPENSION R R E E A A R R W W H H E E E E L L C C O O M M P P O O N N E E N N T T S S CAST WHEEL TORQUE ITEM...
  • Page 435 STEERING / SUSPENSION SPOKED WHEEL TORQUE ITEM DESCRIPTION 22 ft-lbs (30 N·m) Brake Disc Fastener — Brake Disc Wheel Bearing NOTICE — The tone ring is built into the bearing Bearing Spacer — Ball Bearing — Damper — Sprocket — Spacer —...
  • Page 436 Replace Belt Missing Teeth 1. Inspect sprockets and verify sprocket fasteners are tight. Bevel Wear OK to run, but 2. Install drive belt with Indian Motorcycle script (Outer Edge monitor situated so that it reads correctly when viewed from Only) condition the Right hand side of the unit.
  • Page 437 STEERING / SUSPENSION 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 S S E E R R V V I I C C E E 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 C C O O 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 1.
  • Page 438 STEERING / SUSPENSION 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 / / 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 439 STEERING / SUSPENSION 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 P P E E C C T T I I O O N N 5.
  • Page 440 STEERING / SUSPENSION D D R R I I V V E E N N S S P P R R O O C C K K E E T T S S E E R R V V I I C C E E D D R R I I V V E E N N S S P P R R O O C C K K E E T T 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 N N 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 441 STEERING / SUSPENSION D D R R I I V V E E N N 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 4.
  • Page 442 STEERING / SUSPENSION R R E E A A R R W W H H E E E E L L S S E E R R V V I I C C E E 6. Loosen right and left axle adjusters two full turns.
  • Page 443 STEERING / SUSPENSION 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 W W H H E E E E L L B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 444 STEERING / SUSPENSION B B R R A A K K E E D D I I S S C C 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 2.
  • Page 445 STEERING / SUSPENSION S S H H O O C C K K A A B B S S O O R R B B 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 O O C C K K A A B B S S O O R R B B E E R R I I N N S S P P E E C C T T I I O O N N 1.
  • Page 446 STEERING / SUSPENSION S S H H O O C C K K A A B B S S O O R R B B E E R R S S T T U U 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 1.
  • Page 447 STEERING / SUSPENSION S S W W I I N N G G A A R R M M S S E E R R V V I I C C E E 4. Disconnect the Rear Brake Line Retention Clip from the swingarm so the brake line and wheel S S W W I I N N G G A A R R M M R R E E M M O O V V A A L L speed sensor wires can be removed.
  • Page 448 STEERING / SUSPENSION 7. Remove swingarm pivot jam nut 11. Remove lower belt guard by removing its fasteners 8. Remove swingarm pivot 9. Remove the swingarm assembly. 10. Remove upper belt guard by removing its fasteners 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.88 ©...
  • Page 449 STEERING / SUSPENSION S S W W I I N N G G A A R R M M B B U U S S H H I I N N G G / / B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T INSTALLATION REMOVAL 1.
  • Page 450 STEERING / SUSPENSION S S W W I I N N G G A A R R M M 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 451 STEERING / SUSPENSION 10. Install outer pivot spacer and new swingarm 16. Test ride motorcycle to be sure rear suspension op- erates smoothly without binding or abnormal pivot nut noises. TORQUE Swingarm pivot Nut: 65 ft-lbs (88 N·m) 11. Install the rear wheel. See Rear Wheel Removal / Installation page 8.82.
  • Page 452 STEERING / SUSPENSION 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 R R E E A A R R W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
  • Page 453 STEERING / SUSPENSION 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 I I N N A A L L D D R R I I V V E E PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED...
  • Page 454 STEERING / SUSPENSION T T I I R R E E S S 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 - - T T I I R R E E S S WARNING The use of tires other than original equipment may...
  • Page 455 STEERING / SUSPENSION 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 - - T T I I R R E E S S Refer to Steering / Suspension Chapter (Front Wheel and Suspension) for front wheel specifications.
  • Page 456 STEERING / SUSPENSION T T I I R R 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 T T I I R R E E C C U U P P P P I I N N G G Front of tread block worn more than rear of tread T T I I R R E E W W E E A A R R P P A A T T T T E E R R N N S S block:...
  • Page 457 • Manual manipulation of tire irons Indian Motorcycle permits and recommends all three of the general methods, but realizes that careless or improper work habits can damage both the tire and rim no matter which method is used. With any of the...
  • Page 458 CAUTION Indian Motorcycle does not recommend the use of liquid balancer/sealers. These are a form of temporary repair which may adversely affect ply material and mask secondary damage caused by the penetrating object.
  • Page 459 STEERING / SUSPENSION 12. Bounce tire on the floor several times while rotating tire. This will expand tire bead outward slightly NOTICE which will make tire inflation easier. Refer to manufacturer’s instructions for proper 13. Inflate tire observing the precautions listed below. tire changer operation.
  • Page 460 STEERING / SUSPENSION T T I I R R E E B B A A L L A A N N C C I I N N G G WARNING It is essential that the wheel assembly be balanced before use and rebalanced each time the tire is removed.
  • Page 461 STEERING / SUSPENSION W W H H E E E E L L I I N N S S P P E E C C T T I I O O N N T T I I R R E E R R E E P P A A I I R R P P R R E E C C A A U U T T I I O O N N S S V V I I S S U U A A L L I I N N S S P P E E C C T T I I O O N N / / R R U U N N O O U U T T WARNING 1.
  • Page 462 STEERING / SUSPENSION V V A A L L V V E E S S T T E E M M V V A A L L V V E E S S T T E E M M I I N N S S P P E E C C T T I I O O N N 1.
  • Page 463 STEERING / SUSPENSION 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 T T I I R R E E S S PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
  • Page 464 STEERING / SUSPENSION NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 8.104 © Copyright Polaris Inc.
  • Page 465 BRAKES CHAPTER 9 BRAKES GENERAL INFORMATION ................9.3 .
  • Page 466 BRAKES ........... .9.42 BRAKE LEVER RESERVE INSPECTION (SPORT CHIEF) BRAKE SYSTEM SERVICE .
  • Page 467 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 Use only genuine Indian Motorcycle replacement Brake fluid and some types of brake cleaners will parts when servicing the brake system.
  • Page 468 BRAKES S S P P E E C C I I A A L L T T O O O O L L S S - - B B R R A A K K E E S S 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 - - B B R R A A K K E E S S TOOL DESCRIPTION PART NUMBER STAN-...
  • Page 469 BRAKES B B R R A A K K E E S S M M A A I I N N T T E E N N A A N N C C E E 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 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 Lubricate brake pedal at intervals listed on periodic maintenance table.
  • Page 470 BRAKES 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 3.
  • Page 471 BRAKES 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 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 ( ( S S P P O O R R T T C C H H I I E E F F ) ) IMPORTANT...
  • Page 472 BRAKES 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 R R O O N N T T B B R R A A K K E E 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 TORQUE ITEM DESCRIPTION...
  • Page 473 BRAKES TORQUE ITEM DESCRIPTION 88 in-lbs (10 N·m) Torque upper fastener Front Master Cylinder Fastener then lower Master Cylinder Cover Fastener 13 in-lbs (1.5 N·m) Banjo Bolt 18 ft-lbs (25 N·m) 48 in-lbs (6 N·m) Brake Lever Pivot Nut 9 in-lbs (1 N·m) Brake Lever Pivot Fastener 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual ©...
  • Page 474 BRAKES F F R R O O N N T T B B R R A A K K E E 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 ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE ITEM DESCRIPTION...
  • Page 475 BRAKES R R E E A A R R B B R R A A K K E E 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 TORQUE ITEM DESCRIPTION...
  • Page 476 BRAKES TORQUE ITEM DESCRIPTION Master Cylinder Cover Fastener 13 in-lbs (1.5 N·m) Banjo Bolt 18 ft-lbs (25 N·m) Rear Master Cylinder Fastener 18 ft-lbs (25 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.12 ©...
  • Page 477 BRAKES B B R R A A K K E E L L I I N N E E R R O O U U T T I I N N G G A A B B S S TORQUE TORQUE ITEM DESCRIPTION...
  • Page 478 BRAKES TORQUE ITEM DESCRIPTION — Brake Line Retainer 80 in-lbs (9 N·m) Brake Line Retainer Fastener — Brake Line Boss Retainer P-Clip Fastener 80 in-lbs (9 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.14 ©...
  • Page 479 BRAKES TORQUE ITEM DESCRIPTION Retention Clip — Rear Retainer Clip — Panduit Strap — Rear Retainer Clip Fastener 80 in-lbs (9 N·m) Rear Master Cylinder to ABS Module Line — — Brake Manifold to ABS Module Line Front Brake Caliper to ABS Module Line —...
  • Page 480 BRAKES TORQUE ITEM DESCRIPTION Rear Brake Line Retention Clip — ABS Module to Rear Brake Caliper Line — 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.16 © Copyright Polaris Inc.
  • Page 481 BRAKES N N O O N N - - A A B B S S ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Master Cylinder to Brake Manifold — Brake Manifold — Line 80 in-lbs (9 N·m) Wire Form Guide — Brake Manifold Fastener Brake Manifold to Front Brake Wire Form Guide 80 in-lbs (9 N·m)
  • Page 482 BRAKES TORQUE ITEM DESCRIPTION P-Clamp Fastener 80 in-lbs (9 N·m) P-Clamp — Rear Master Cylinder to Rear Brake Manifold — Rear Retainer Clip — Panduit Strap — Rear Retainer Clip Fastener 80 in-lbs (9 N·m) — Brake Line Retainer — Rear Brake Manifold 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.18...
  • Page 483 BRAKES TORQUE ITEM DESCRIPTION Rear Brake Line Retention Clip — Brake Manifold to Rear Brake Caliper Line — 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.19 © Copyright Polaris Inc.
  • Page 484 BRAKES B B R R A A K K E E L L I I N N E E R R O O U U T T I I N N G G ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE TORQUE ITEM...
  • Page 485 BRAKES TORQUE ITEM DESCRIPTION — Brake Line Retainer 80 in-lbs (9 N·m) Brake Line Retainer Fastener — Brake Line Boss Retainer P-Clip Fastener 80 in-lbs (9 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.21 ©...
  • Page 486 BRAKES TORQUE ITEM DESCRIPTION Retention Clip — Rear Retainer Clip — Panduit Strap — Rear Retainer Clip Fastener 80 in-lbs (9 N·m) Rear Master Cylinder to ABS Module Line — — Brake Manifold to ABS Module Line Front Brake Caliper to ABS Module Line —...
  • Page 487 BRAKES TORQUE ITEM DESCRIPTION Rear Brake Line Retention Clip — ABS Module to Rear Brake Caliper Line — 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.23 © Copyright Polaris Inc.
  • Page 488 BRAKES F F R R O O N N T T M M A A S S T T E E R R C C Y Y L L I I N N D D 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 TORQUE ITEM...
  • Page 489 BRAKES R R E E A A R R M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R C C O O M M P P O O N N E E N N T T S S DESCRIP- TORQUE TORQUE...
  • Page 490 BRAKES F F R R O O N N T T B B R R A A K K E E C C A A L L I I P P 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 ITEM DESCRIPTION...
  • Page 491 BRAKES F F R R O O N N T T B B R R A A K K E E C C A A L L I I P P E E R R C C O O M M P P O O N N E E N N T T S S ( ( S S P P O O R R T T C C H H I I E E F F ) ) TORQUE ITEM DESCRIPTION...
  • Page 492 BRAKES R R E E A A R R B B R R A A K K E E C C A A L L I I P P 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 ITEM DESCRIPTION...
  • Page 493 BRAKES A A B B S S M M O O D D U U L L E E DESCRIPTION DESCRIPTION Ground for ECU Ground for Mount CAN High CAN Low Front Wheel Speed Sensor Front Wheel Speed Sensor Voltage Signal Ignition Rear Wheel Speed Sensor Voltage...
  • Page 494 Digital Wrench and perform an ABS System • Always maintain the recommended tire pressure. inspection to determine the cause. • Indian Motorcycle DOT 4 Brake Fluid is • When the ABS lamp is illuminated, the anti-lock recommended. Change every 10,000 miles (16,000 brakes will not activate, but the conventional brake km) or 2 years, whichever comes first.
  • Page 495 BRAKES A A B B S S 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 A A B B S S O O V V E E R R V V I I E E W W O O F F O O P P E E R R A A T T I I O O N N The following parts function in the same manner as the The ABS system is active and available when vehicle same component in a non-ABS system, although parts...
  • Page 496 BRAKES A A B B S S S S Y Y S S T T E E M M S S E E R R V V I I C C E E W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R R R E E P P L L A A C C E E M M E E N N T T 4.
  • Page 497 BRAKES R R E E A A R R W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R 6.
  • Page 498 BRAKES A A B B S S M M O O D D U U L L E E R R E E P P L L A A C C E E M M E E N N T T 7.
  • Page 499 BRAKES 9. Installation is performed by reversing the 4. Remove ABS bracket fasteners removal procedure. TORQUE ABS Mounting Fastener: 88 in-lbs (10 N·m) TORQUE Banjo Bolt: 18 ft-lbs (25 N·m) TORQUE ABS Tray Fastener: 35 in-lbs (4 N·m) 5. Disconnect gear position sensor electrical connector from the bracket.
  • Page 500 BRAKES W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R 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 What is the ohm reading between pin 13 (BN/RD –...
  • Page 501 • Always torque banjo bolts and other brake system fluid such as silicone-based or petroleum-based. fasteners and components to specified torque. • Always install NEW genuine Indian Motorcycle replacement parts and rubber parts upon assembly. WARNING Apply special lubricant where indicated (included in service kits).
  • Page 502 BRAKES A A B B S S F F L L U U I I D D C C H H A A N N G G E E 3. Fill rear brake fluid reservoir and leave cover off so fluid can be added as it is drawn through the Review Brake Fluid Replacement and Bleeding system.
  • Page 503 BRAKES A A B B S S F F R R O O N N T T B B R R A A K K E E B B L L E E E E D D I I N N G G 10.
  • Page 504 BRAKES 9. Torque bleed screw to specification and install the rubber cap. TORQUE Caliper Bleeder Screws: 53 in-lbs (6 N·m) 10. Clean the reservoir cover, diaphragm, diaphragm plate, and reservoir sealing surface. If diaphragm is extended, return it to normal (flat) position. Install diaphragm, diaphragm plate, and cover.
  • Page 505 BRAKES A A B B S S F F R R O O N N T T B B R R A A K K E E B B L L E E E E D D I I N N G G ( ( S S P P O O R R T T 11.
  • Page 506 BRAKES B B R R A A K K E E L L E E V V E E R R R R E E S S E E R R V V E E I I N N S S P P E E C C T T I I O O N N 4.
  • Page 507 BRAKES B B R R A A K K E E S S Y Y S S T T E E M M S S E E R R V V I I C C E E C C H H I I E E F F F F R R O O N N T T B B R R A A K K E E S S E E R R V V I I C C E E 3.
  • Page 508 BRAKES B B R R A A K K E E D D I I S S C C 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 F F R R O O N N T T C C A A L L I I P P E E R R S S E E R R V V I I C C E E 1.
  • Page 509 BRAKES 3. Cover the brake hose connection on the caliper 8. Remove each piston with a caliper piston pliers. If a and clean the outer surfaces of caliper assembly caliper piston pliers is not available, wrap the with brake cleaner (commercially available) or caliper in a shop towel and apply short bursts of isopropyl alcohol.
  • Page 510 BRAKES F F R R O O N N T T C C A A L L I I P P 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 511 BRAKES S S P P O O R R T T C C H H I I E E F F F F R R O O N N T T B B R R A A K K E E S S E E R R V V I I C C E E 2.
  • Page 512 BRAKES B B R R A A K K E E D D I I S S C C 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 P P O O R R T T INSTALLATION C C H H I I E E F F ) ) 1.
  • Page 513 BRAKES F F R R O O N N T T C C A A L L I I P P E E R R S S E E R R V V I I C C E E ( ( S S P P O O R R T T C C H H I I E E F F ) ) 4.
  • Page 514 BRAKES F F R R O O N N T T C C A A L L I I P P 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 ( ( S S P P O O R R T T C C H H I I E E F F ) ) 8.
  • Page 515 BRAKES R R E E A A R R B B R R A A K K E E P P A A D D R R E E P P L L A A C C E E M M E E N N T T 7.
  • Page 516 BRAKES 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 1. Visually inspect disc for cracks or damage. 2.
  • Page 517 BRAKES F F R R O O N N T T M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R S S E E R R V V I I C C E E 5.
  • Page 518 BRAKES 21. Install master cylinder on handlebar. Torque clamp 8. Remove primary cup and spring fasteners to specification. IMPORTANT TORQUE Note spring orientation for assembly of new spring (new parts) Brake Lever Perch Fasteners: 88 in-lbs (10 N·m) Torque upper fastener, then lower 9.
  • Page 519 BRAKES R R E E A A R R M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R S S E E R R V V I I C C E E 3.
  • Page 520 BRAKES 6. Remove piston , primary cup , spring cup and spring 7. Inspect cylinder bore and chamfer on the front of the bore for corrosion, scratches, scoring, or pitting. Replace master cylinder if any of these conditions are evident. 8.
  • Page 521 BRAKES R R E E A A R R C C A A L L I I P P E E R R S S E E R R V V I I C C E E 8. Inspect bore and surface of piston for corrosion, scratches, scoring, or pitting.
  • Page 522 BRAKES B B R R A A K K E E M M A A N N I I F F O O L L D D R R E E M M O O V V A A L L / / R R E E A A 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...
  • Page 523 BRAKES 5. Installation is performed by reversing the removal procedure. TORQUE Brake Manifold Fastener: 80 in-lbs (9 N·m) TORQUE Banjo Bolt: 18 ft-lbs (25 N·m) TORQUE ABS Tray Fastener: 35 in-lbs (4 N·m) TORQUE J-Case Fastener: 88 in-lbs (10 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.59 ©...
  • Page 524 BRAKES 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 POSSIBLE REPAIR NEEDED Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component Erratic Braking...
  • Page 525 / dirt on pads and / brake disc. or brake disc. Repair as Necessary. Inspect Pad Pad Not Secure in Caliper Installation Aftermarket (not genuine Indian Motorcycle) Install Genuine Indian Motorcycle Parts Parts Replace Worn or Damaged Wheel Bearing(s) Replace...
  • Page 526 BRAKES NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 9.62 © Copyright Polaris Inc.
  • Page 527 ELECTRICAL CHAPTER 10 ELECTRICAL STARTING / CHARGING................10.5 .
  • Page 528 ELECTRICAL ............. . . 10.36 STATOR REMOVAL / INSTALLATION .
  • Page 529 ELECTRICAL ..............10.74 WCM REMOVAL / INSTALLATION .
  • Page 530 ELECTRICAL ..............10.114 TESTING FOR A SHORT TO VOLTAGE .
  • Page 531 ELECTRICAL S S T T A A R R T T I I N N G G / / C C H H A A R R G G I I N N G G Battery Label 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 All electrical system and component service can be performed with the engine in the frame.
  • Page 532 ELECTRICAL WARNING CAUTION Battery electrolyte is poisonous. It contains sulfuric WIRE ROUTING acid. Serious burns can result from contact with skin, Make sure that all wires are routed correctly away eyes or clothing. Antidote: from moving parts, hot exhaust, or sharp edges. •...
  • Page 533 ELECTRICAL B B A A T T T T E E R R Y Y 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 L L E E C C T T R R I I C C A A L L This motorcycle is equipped with a maintenance free PART NUMBER TOOL DESCRIPTION...
  • Page 534 ELECTRICAL 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 – – S S T T A A R R T T I I N N G G / / STARTING SYSTEM SPECIFICATIONS C C H H A A R R G G I I N N G G ITEM...
  • Page 535 ELECTRICAL 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 S S T T A A R R T T E E R R M M O O T T O O R R / / S S O O L L E E N N O O I I D D C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
  • Page 536 ELECTRICAL S S T T A A T T O O R R C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION 88 in-lbs (10 N·m) Stator Fastener —...
  • Page 537 ELECTRICAL R R E E G G U U L L A A T T O O R R / / R R E E C C T T I I F F I I 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 ITEM DESCRIPTION...
  • Page 538 ELECTRICAL B B A A T T T T E E R R Y Y B B O O X X C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
  • Page 539 ELECTRICAL B B A A T T T T E E R R Y Y S S E E R R V V I I C C E E 5. Remove the antenna by disconnecting its electrical connector and removing it from the 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 / / I I N N S S T T A A L L L L A A T T I I O O N N upper battery tray.
  • Page 540 ELECTRICAL 9. Remove the positive terminal fastener 12. Lift the battery from the battery box. 10. Remove the battery strap fastener 13. Installation is performed by the reversing the removal procedure. TORQUE Battery Strap Fastener: 35 in-lbs (4 N·m) TORQUE Battery Terminal Fastener: 48 in-lbs (5.4 N·m) 11.
  • Page 541 ELECTRICAL B B A A T T T T E E R R Y Y B B O O X X 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 542 ELECTRICAL 2023+ 10. On the rear subframe, disconnect the electrical connectors 1. Remove battery. See Battery Removal / Installation page 10.13. 2. Remove ECM. See ECM Removal / Installation page 4.47. 3. If applicable, remove carbon canister. See Carbon Canister Removal / Installation page 4.29. 4.
  • Page 543 ELECTRICAL INDIAN MOTORCYCLE RECOMMENDED AGM BATTERY 14. Installation is performed by reversing the TESTING PROCEDURE: removal procedure. 1. Test battery using the battery tester PU-50296. TORQUE Subframe Fastener: 2. If the tester indicates a test result other than “Good Battery,” follow the steps below before replacing 74 ft-lbs (100 N·m)
  • Page 544 ELECTRICAL AGM BATTERY CHARGING RECOMMENDATIONS AGM BATTERY CHARGING RECOMMENDATIONS – DEEPLY DISCHARGED (BELOW 3 VOLTS) The battery will self-discharge when disconnected from a vehicle, and will discharge at a faster rate when NOTICE connected. Listed below are the recommended If the automatic charger's manual does not include battery charging schedules.
  • Page 545 ELECTRICAL AGM BATTERY MAINTENANCE TIPS 1. If the motorcycle will not be driven for more than 2 weeks, maintaining the battery with the BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438) is recommended. 2. To help prolong battery life, if a power source is not available to use the 12V Battery Charge Port, it is recommended to remove the battery from vehicles stored ONE month or longer.
  • Page 546 4. Test using the Indian Motorcycle recommended AGM battery testing procedure. See BATTERY CHARGING AND MAINTENANCE page 10.17.
  • Page 547 ELECTRICAL S S T T A A R R T T I I N N G G S S Y Y S S T T E E M M T T E E S S T T S S 4. Connect digital multimeter to battery and keep it connected for duration of test.
  • Page 548 ELECTRICAL 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 L L O O W W C C H H A A R R T T 1 1 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.22 ©...
  • Page 549 ELECTRICAL 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 L L O O W W C C H H A A R R T T 2 2 NOTE These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive ammeter clamp and a DMM.
  • Page 550 ELECTRICAL 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 L L O O W W C C H H A A R R T T 3 3 SYMPTOM POSSIBLE CAUSE Starter clutch malfunction.
  • Page 551 ELECTRICAL G G E E A A R R 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 7.
  • Page 552 ELECTRICAL C C L L U U T T C C H H S S W W I I T T C C H H C C I I R R C C U U I I T T T T E E S S T T S S T T A A R R T T E E R R S S O O L L E E N N O O I I D D P P O O S S I I T T I I V V E E C C I I R R C C U U I I T T T T E E S S T T The symptom of a faulty clutch switch circuit is: WARNING...
  • Page 553 ELECTRICAL S S T T A A R R T T E E R R 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 554 ELECTRICAL S S T T A A R R T T E E R R M M O O T T O O R R S S E E R R V V I I C C E E S S A A F F E E 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 WARNING Always disconnect the battery (negative terminal first) before servicing the starter motor.
  • Page 555 ELECTRICAL G G E E A A R R 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 R R E E M M O O V V A A L L / / S S T T A A R R T T E E R R M M O O 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 R R E E P P L L A A C C E E M M E E N N T T WARNING...
  • Page 556 ELECTRICAL 5. Installation is performed by reversing the removal procedure. TORQUE Starter Motor Fasteners: 88 in-lbs (10 N·m) TORQUE Battery Cable to Starter Motor Nut: 88 in-lbs (10 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.30 ©...
  • Page 557 ELECTRICAL C C H H A A R R G G I I N N G G S S Y Y S S T T E E M M S S E E R R V V I I C C E E 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 H H A A R R G G I I N N G G S S Y Y S S T T E E M M NOTE The battery must be fully charged and in good condition to obtain accurate readings.
  • Page 558 ELECTRICAL C C U U R R R R E E N N T T D D R R A A I I N N I I N N S S P P E E C C T T I I O O N N 5.
  • Page 559 ELECTRICAL S S T T A A T T O O R R A A C C V V O O L L T T A A G G E E O O U U T T P P U U T T T T E E S S T T 6.
  • Page 560 ELECTRICAL S S T T A A 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 3.
  • Page 561 ELECTRICAL S S T T A A T T O O R R W W I I N N D D I I N N G G S S T T O O G G R R O O U U N N D D I I N N S S P P E E C C T T I I O O N N 4.
  • Page 562 ELECTRICAL S S T T 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 9.
  • Page 563 ELECTRICAL R R E E C C T T I I F F I I E E R R / / R R E E G G U U L L A A T T O O R R C C O O N N N N E E C C T T O O R R D D I I O O D D E E L L E E A A K K A A G G E E T T E E S S T T I I N N S S P P E E C C T T I I O O N N IMPORTANT...
  • Page 564 ELECTRICAL R R E E G G U U L L A A T T O O R R / / R R E E C C T T I I F F I I 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 2.
  • Page 565 If the key fob is not detected or is not available and you cannot remember your PIN, please see your INDIAN MOTORCYCLE dealer. Please read the entire procedure before beginning. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.39...
  • Page 566 ELECTRICAL • After starting the engine, the Wireless Control Programming the Key Fob: Module (WCM) will verify that the key fob is within Programming the key fob can only be done by the range again when shifting from neutral into gear. dealer and must be done using Digital Wrench®...
  • Page 567 ELECTRICAL K K E E Y Y F F O O B B A A U U T T H H E E N N T T I I C C A A T T I I O O N N K K E E Y Y F F O O B B 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 Four things must occur for the WCM to authenticate 1.
  • Page 568 Does antenna test within specification? SPECIFICATION YES — Replace VCM Capacitance: 3.4 nF (± 2 %) NO — Contact Indian Motorcycle Technical Service. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.42...
  • Page 569 ELECTRICAL K K E E Y Y F F O O B B B B A A T T T T E E R R Y Y R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 570 ELECTRICAL A A L L A A R R M M 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 5. Install the battery cover back on to the key fob. Chief / Chief Bobber / Super Chief models have 6.
  • Page 571 ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M GENERAL PRECAUTIONS 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 •...
  • Page 572 ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M S S E E R R V V I I C C E E I I G G N N I I T T I I O O N N C C O O I I L L 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 1.
  • Page 573 ELECTRICAL 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 I I G G N N I I T T I I O O N N 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 B B A A S S I I C C S S T T E E S S T T L L E E A A D D A A D D A A P P T T E E R R K K I I T T Before troubleshooting the ignition system, ensure that the engine STOP/RUN switch is in the RUN position,...
  • Page 574 ELECTRICAL 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 PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION Rear heated Oxygen Sensor Control GY / WH —...
  • Page 575 ELECTRICAL PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION Tail Light Power ETC Motor (+) DG / YE PK / RD CPS Positive Signal – – CPS Negative Signal – – Intake Air Temperature Sensor Output – – OG / DG Manifold Absolute Pressure Sensor Output –...
  • Page 576 ELECTRICAL PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION Rear Coil Signal BK / WH ECM GROUND FRONT HEATED OXYGEN SENSOR GY / WH – – CONTROL – – – – 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.50 ©...
  • Page 577 ELECTRICAL E E C C M M R R E E P P L L A A C C E E M M E E N N T T E E C C M M 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 Although the need for ECM replacement is unlikely, a This procedure will require Digital Wrench®...
  • Page 578 ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M T T E E S S T T F F L L O O W W C C H H A A R R T T 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.52 ©...
  • Page 579 ELECTRICAL B B A A T T T T E E R R Y Y V V O O L L T T A A G G E E I I N N S S P P E E C C T T I I O O N N T T E E S S T T 1 1 S S P P A A R R K K I I N N S S P P E E C C T T I I O O N N T T E E S S T T 2 2 1.
  • Page 580 ELECTRICAL I I G G N N I I T T I I O O N N C C O O I I L L P P O O W W E E R R / / G G R R O O U U N N D D S S I I G G N N A A L L T T E E S S T T •...
  • Page 581 ELECTRICAL I I G G N N I I T T I I O O N N C C O O I I L L 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 4 4 Ignition Coil Primary Winding 1.
  • Page 582 ELECTRICAL C C H H A A S S S S I I S S E E L L E E C C T T R R I I C C A A L L 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 Keep the following notes in mind when diagnosing an electrical problem:...
  • Page 583 ELECTRICAL 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 H H E E A A D D L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S TORQUE ITEM DESCRIPTION...
  • Page 584 ELECTRICAL T T A A I I L L L L I I G G H H T T / / L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T C C O O M M P P O O N N E E N N T T S S SIDE MOUNT DESCRIP- TORQUE...
  • Page 585 ELECTRICAL CENTER MOUNT DESCRIP- TORQUE TORQUE ITEM ITEM DESCRIPTION TION Center Light Mount Turn Signal 18 ft-lbs (25 N·m) — Fastener Rear Light — License Plate Light Mount (RH) 18 ft-lbs (25 Turn Signal License Plate Light 17 in-lbs (2 N·m) N·m) Fastener Fastener...
  • Page 586 ELECTRICAL F F U U S S E E B B O O X X MAIN FUSE BOX J-CASE 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.60 © Copyright Polaris Inc.
  • Page 587 ELECTRICAL ITEM DESCRIPTION Fuse Box Cover Fuse Box Latch H H A A R R N N E E S S S S 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 NOTICE 2022 Model Shown ITEM...
  • Page 588 ELECTRICAL ITEM DESCRIPTION Cable Tie Routing Clip 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.62 © Copyright Polaris Inc.
  • Page 589 ELECTRICAL NOTICE ABS equipped harness shown. ITEM DESCRIPTION Cable Tie Routing Clip 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.63 © Copyright Polaris Inc.
  • Page 590 ELECTRICAL ITEM DESCRIPTION Silencer Clip Routing Clip Edge Clip 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.64 © Copyright Polaris Inc.
  • Page 591 ELECTRICAL ITEM DESCRIPTION Cable Tie Routing Clip 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.65 © Copyright Polaris Inc.
  • Page 592 ELECTRICAL ITEM DESCRIPTION Cable Tie Routing Clip 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.66 © Copyright Polaris Inc.
  • Page 593 ELECTRICAL The electrical harness routes through the frame backbone and exits near the seat base. There is a recess on the right hand cradle where the harness routes into. 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.67 ©...
  • Page 594 ELECTRICAL F F U U S S E E B B O O X X F F U U S S E E A A P P P P L L I I C C A A T T I I O O N N C C H H A A R R T T 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.68 ©...
  • Page 595 ELECTRICAL MAIN FUSE BLOCK CIRCUIT WIRE COLOR FUNCTION Ignition Coil Feed Ignition Coil Fuse 7.5A Engine Breaker Output RD/DB Run / Stop Switch Power RD/DB Engine Fuse Engine Relay Power VT/PK Output Main Fuse Output Main Fuse Output Engine Relay Engine Relay Control GY/BK Engine Breaker output...
  • Page 596 ELECTRICAL Fuel Pump Relay Control Fuel Pump Power VT/YE Main 2 Fuse Output Tender Fuse 10A Accessory Constant Fuse GY/RD Output — — Spare Fuse 10A — — Switched Power Relay RD/BU Load Switch 1 Fuse 10A VCM Accessory Power PK/GN Main Fuse Output OG/YE...
  • Page 597 ELECTRICAL J-CASE CIRCUIT WIRE COLOR FUNCTION ABS Main Fuse Output ABS Main Fuse Input Primary Fuse Output Primary Primary Fuse Input Secondary Fuse Output Secondary Secondary Fuse Input 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.71 ©...
  • Page 598 ELECTRICAL V V E E H H I I C C L L E E C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( V V C C M M ) ) V V E E H H I I C C L L E E C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( V V 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 V V E E H H I I C C L L E E C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( V V C C M M ) ) O O V V E E R R V V I I E E W W...
  • Page 599 ELECTRICAL V V C C M M P P I I N N O O U U T T FUNCTION Power 500K CAN High LH Heated Grips Output Aux Light Switch Indicator Light Low Beam Aux Light Switch Output Horn Power Heat Grip Switch Decrease —...
  • Page 600 ELECTRICAL W W 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 W W I I R R E E L L E E S S S S C C O O N N T T R R O O L L M M O O D D U U L L E E ( ( W W C C M M ) ) W W C C M M O O V V E E R R V V I I E E W W 1.
  • Page 601 ELECTRICAL W W C C M M P P I I N N O O U U T T FUNCTION Power 500K CAN High — 500K CAN LOW — Ignition Switch Signal K15 Signal Switched Power Control Security LED Feed 21 kHz B 21 kHz A Ground...
  • Page 602 ELECTRICAL C C E E L L L L M M O O D D E E M M C C E E L L L L M M O O D D E E M M R R E E P P L L A A C C E E M M E E N N T T C C E E L L L L M M O O D D E E M M O O V V E E R R V V I I E E W W 1.
  • Page 603 ELECTRICAL PERFORM DIGITAL WRENCH CELL MODEM ACTIVATION 3. Clear all pairings from Headset and re-pair with (USA AND CANADA ONLY) display This procedure can only be done by the dealer and 4. Pair Headset with another Bluetooth enabled must be done using Digital Wrench® II. device and check for proper functionality For instructions, Click HERE...
  • Page 604 ELECTRICAL T T I I P P O O V V E E R R M M O O D D U U L L E E T T I I P P O O V V E E R R M M O O D D U U L L E E C C O O N N N N E E C C T T O O R R M M A A P P Connector Pinout Function Wire Color...
  • Page 605 ELECTRICAL H H E E A A D D L L I I G G H H T T S S E E R R V V I I C C E E H H O O R R N N S S E E R R V V I I C C E E H H E E A A D D L L I I G G H H T T R R E E P P L L A A C C E E M M E E N N T T H H O O R R N N 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 IMPORTANT...
  • Page 606 ELECTRICAL T T A A I I L L L L A A M M P P S S E E R R V V I I C C E E L L E E D D T T A A I I L L / / B B R R A A K K E E L L I I G G H H T T O O P P E E R R A A T T I I O O N N The multiple LED tail / brake lamp functions much like a conventional incandescent tail / brake lamp.
  • Page 607 ELECTRICAL L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T R R E E M M O O V V A A L L / / L L I I C C E E N N S S E E P P L L A A T T E E B B R R A A C C K K E E T T 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...
  • Page 608 ELECTRICAL 2. Disconnect electrical connector 3. Remove license plate bracket by removing its fasteners 4. Installation is performed by reversing the removal procedure. TORQUE License Plate Bracket Fastener: 88 in-lbs (10 N·m) 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.82 ©...
  • Page 609 ELECTRICAL T T U U R R N N S S I I G G N N A A L L / / H H A A Z Z A A R R D D S S Y Y S S T T E E M M S S E E R R V V I I C C E E T T U U R R N N S S I I G G N N A A L L O O P P E E R R A A T T I I O O N N Turn Signal Auto Cancel Functionality Verify function of the following components for correct...
  • Page 610 ELECTRICAL F F R R O O N N T T T T U U R R N N S S I I G G N N A A L L R R E E M M O O V V A A L L / / CHIEF BOBBER / SUPER CHIEF 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 611 ELECTRICAL F F R R O O N N T T T T U U R R N N S S I I G G N N A A L L 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 - - 6.
  • Page 612 ELECTRICAL R R E E A A R R T T U U R R N N S S I I G G N N A A L L 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 1.
  • Page 613 ELECTRICAL I I N N S S T T R R U U M M E E N N T T A A T T I I O O N N 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...
  • Page 614 ELECTRICAL LAMP INDICATES CONDITION also illuminates with the security light and/or power switch when the key fob battery is low, and with the TPMS lamp when the TPMS sensor battery is low. ABS Not Activated The indicator remains on until the anti-lock system activates, which occurs when vehicle speed exceeds 6 MPH (10 km/h).
  • Page 615 ELECTRICAL 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 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 - - 2.
  • Page 616 ELECTRICAL U U S S B B C C H H A A R R G G E E P P O O R R T T O O V V E E R R V V I I E E W W 5.
  • Page 617 ELECTRICAL U U S S B B C C H H A A R R G G E E P P O O R R T T R R E E P P L L A A C C E E M M E E N N T T U U S S B B C C H H A A R R G G E E P P O O R R T T T T E E S S T T I I N N G G 1.
  • Page 618 ELECTRICAL C C H H A A S S S S I I S S H H A A R R N N E E S S S S 12. Remove ignition bracket by removing its fasteners H H A A R R N N E E S S S S 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 1.
  • Page 619 ELECTRICAL 18. Remove detonation sensor by removing its fastener 24. On the left side of the unit, remove the wire form guide fastener 19. at the front of the engine, disconnect voltage regulator electrical connectors 25. Disconnect air temperature sensor electrical connector 26.
  • Page 620 ELECTRICAL 34. Remove J-case fasteners 42. Remove fastener securing ground cable to rear of engine. 35. Remove harness retention feature 43. Remove harness retention feature from frame 2& 36. Disconnect charge port electrical connector 37. Disconnect rear brake pressure switch electrical connector 38.
  • Page 621 ELECTRICAL H H A A R R N N E E S S S S P P I I N N O O U U T T WIRE COLOR FROM PORT PORT FUNCTION Ignition Switch VT / YE Handlebar Signal AUX Light Switch Fog Lights DG / BK...
  • Page 622 ELECTRICAL Rear Wheel Splice Ground Speed Sensor Splice Start Solenoid Ground Splice Start Solenoid Ground Rear Lighting Splice Ground Rear 12V Splice Ground Switched Splice Fusebox Ground ABS Main Fuse J-Case Output WH / BK ECM 2 Handlebar 2 PPS 1 Return Front Fuel Front Injector WH / GY...
  • Page 623 ELECTRICAL VCM Accessory Headlight Splice 0071 PK / GN Power Out VCM Accessory Splice 0071 PK / GN Power Out VCM Accessory Splice 0071 PK / GN Handlebar 2 Power Out VCM Accessory Splice 0071 PK / GN Power Out Heated Grips VCM Accessory Splice 0071...
  • Page 624 ELECTRICAL Headlight Low Beam YE / BK ECM 2 Handlebar 2 PPS 2 Return BN / GN ECM 2 TMAP MAP Sensor BN / WH ECM 2 ETC Motor TPS Return LH Aux Light Fog Lights DG / RD Feed PPS 2 Output YE / GN ECM 2...
  • Page 625 ELECTRICAL Splice 0132D Handlebar 1 250K CAN HIGH Splice 0132E Splice 0132D 250K CAN HIGH Splice 0132E Handlebar 1 250K CAN HIGH Speedo Splice 0132E 250K CAN HIGH Splice 0133A ECM1 CANB HIGH Diag Splice 0133A CANB HIGH Splice 0133A Splice 0133B CANB HIGH Splice 0133B...
  • Page 626 ELECTRICAL Accessory Splice 0153 Charge Port Constant Fuse GY / RD Output Accessory Diag Splice 0153 Constant Fuse GY / RD Output PPS 1 +5V WH / RD ECM 2 Handlebar 2 Reference BN / PK ECM 1 TMAP TMAP Power Chassis Ground Horn Horn Ground...
  • Page 627 ELECTRICAL Side Stand Splice 0179 BK / WH ECM Ground Switch Splice 0179 BK / WH ECM 2 ECM Ground Splice 0179 BK / WH ECM 1 ECM Ground Splice 0179 BK / WH ECM 2 ECM Ground Ambient Air Splice 0179 BK / WH ECM Ground...
  • Page 628 ELECTRICAL Front Heated Oxygen Sensor GY / DB ECM 1 Front O2 Output Throttle Position OG / YE ECM 2 ETC Motor sensor 1 output Front heated BG WJ ECM 1 Front O2 sensor return Fuel Sender Fuel Pump BK / BU ECM 1 Ground Rear heated...
  • Page 629 ELECTRICAL Main 2 Fuse Splice 0272 Fusebox Output Main 2 Fuse Splice 0272 Fusebox Output Main 2 Fuse Splice 0272 Fusebox Output J-Case Stud Battery Unfused Starter Solenoid Left Heated Handlebar 3 Grips Output 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.103 ©...
  • Page 630 ELECTRICAL R R I I D D E E C C O O M M M M A A N N D D D D I I S S P P L L A A Y Y D D I I S S P P L L A A Y Y C C O O N N N N E E C C T T O O R R P P I I N N O O U U T T WIRE FUNCTION WIRE COLOR...
  • Page 631 ELECTRICAL WIRE FUNCTION WIRE COLOR FUNCTION COLOR VBUS VBUS – – – – White D – White D – Green Green – – – – Black Ground Black Ground 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual 10.105 ©...
  • Page 632 ELECTRICAL R R I I D D E E C C O O M M M M A A N N D D D D I I A A G G N N O O S S T T I I C C S S / / 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: Black Screen / Will Not Power On STEP ACTION...
  • Page 633 ELECTRICAL S S W W I I T T C C H H T T E E S S T T I I N N G G REAR B B R R A A K K E E P P R R E E S S S S U U R R E E S S W W I I T T C C H H T T E E S S T T 1.
  • Page 634 ELECTRICAL S S I I D D E E S S T T A A N N D D S S W W I I T T C C H H T T E E S S T T 1. Inspect side stand. Be sure that when the side stand is fully retracted (UP) that the switch plunger is extended and that when the side stand is extended (down) the plunger is depressed.
  • Page 635 ELECTRICAL B B R R E E A A K K O O U U T T W W I I R R I I N N G G D D I I A A G G R R A A M M S S B B R R E E A A K K O O U U T T D D I I A A G G R R A A M M S S Physical copies of the breakout diagrams can be located in the last few pages of the service manual.
  • Page 636 ELECTRICAL S S T T A A T T I I C C A A N N D D D D Y Y N N A A M M I I C C T T E E S S T T I I N N G G There are many methods for testing a DC circuit.
  • Page 637 ELECTRICAL C C O O N N N N E E C C T T O O R R P P R R O O B B I I N N G G G G U U I I D D E E L L I I N N E E S S For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.
  • Page 638 ELECTRICAL T T E E S S T T I I N N G G C C O O N N T T I I N N U U I I T T Y Y / / R R E E S S I I S S T T A A N N C C E E Testing using the Ohmmeter function of your DMM is one of the first things you will do when troubleshooting an electrical issue.
  • Page 639 ELECTRICAL T T E E S S T T I I N N G G F F O O R R A A S S H H O O R R T T T T O O G G R R O O U U N N D D 9.
  • Page 640 ELECTRICAL T T E E S S T T I I N N G G F F O O R R A A S S H H O O R R T T T T O O V V O O L L T T A A G G E E T T E E S S T T I I N N G G F F O O R R I I N N T T E E R R M M I I T T T T E E N N T T C C O O N N D D I I T T I I O O N N S S There are three possible short to voltage causes: Intermittent conditions are very difficult to diagnose,...
  • Page 641 ELECTRICAL T T E E S S T T I I N N G G P P A A R R A A S S I I T T I I C C D D R R A A W W T T E E S S T T I I N N G G C C U U R R R R E E N N T T F F L L O O W W ( ( A A M M P P E E R R A A G G E E ) ) Performing a current flow test requires the meter leads IMPORTANT...
  • Page 642 ELECTRICAL T T E E S S T T I I N N G G V V O O L L T T A A G G E E D D R R O O P P 5. If current drain exceeds specifications inspect wiring and components for short to ground.
  • Page 643 WIRING DIAGRAMS APPENDIX A WIRING DIAGRAMS 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual © Copyright Polaris Inc.
  • Page 644 ELECTRICAL NOTES 9941445 R03 - 2022-2024 Indian Chief / Chief Bobber / Super Chief / Sport Chief Service Manual © Copyright Polaris Inc.
  • Page 645 INDEX 2022 Model Primary Cover (2023)..........5.10 Specifications ............1.5 Rear Brake ............9.11 2023 Model Rear Caliper............9.28 Specifications ............1.8 Rear Master Cylinder..........9.25 2024 Model Rear Wheel ............8.74 Specifications ............1.12 Rear Wheel and Suspension ........8.72 Rear Wheel and Suspension (Sport Chief) ....8.73 Regulator / Rectifier..........
  • Page 646 INDEX Front Brakes (Sport Chief)........9.41 Brake System, Front Brake Rear Brakes ............9.38 Assembly View ............9.8 Brake Bleeding Precautions........9.37 Assembly View (Sport Chief) ........9.10 Brake System, Front Brake Pads Brake Disc, Front Removal / Installation..........9.44 Replacement (Sport Chief)........9.47 Removal / Installation (Sport Chief) ......9.48 Brake System, Front Caliper Assembly View .............9.26 Brake Disc, Rear...
  • Page 647 INDEX Removal...............6.18 Removal / Installation (2023) ........5.34 Camshaft Clutch Switch Carrier Assembly..........3.47 Circuit Test............10.26 Carrier Disassembly ..........3.45 Removal / Installation........... 10.28 Carrier Installation ..........3.50 Test..............10.107 Carrier Removal............3.44 Coil, Ignition Inspection ............3.46 Removal / Installation........... 10.46 Compression Test Removal - In Bike...........3.51 Synchronization ............3.47 Engine..............
  • Page 648 INDEX Removal...............3.92 Service Notes ............3.88 Special Tools ............3.88 Connector Map ........... 10.48 Specifications ............3.89 Connectors ............4.46 Stud Replacement ..........3.97 Disconnect ............4.46 Warpage Measurement ..........3.94 Pinout Chart ............10.48 Cylinder / Piston Pinout Testing ............4.46 Troubleshooting............3.99 Reflash Procedure ..........10.51 Cylinder Head Removal / Installation..........4.47 Assembly.............3.84 ECM Connector Map ..........4.31...
  • Page 649 INDEX Exhaust Front Suspension Assembly View ........... 3.103 Assembly View .............8.16 Heat Shield Clamp..........3.102 Assembly View (Sport Chief) ........8.18 Joints ..............3.102 Front Wheel Muffler Removal Assembly View ..........8.20, 8.22 Muffler Installation..........3.104 Bearing Inspection ..........8.32 Removal / Installation........... 3.105 Inspection ............8.32 Removal / Installation..........8.29 Exhaust Emission Control ..........1.17...
  • Page 650 INDEX Removal / Installation........7.39, 10.88 Removal / Installation (Sport Chief) ......10.89 Gear Position ............10.29 USB Charge Port..........10.90 Gear Position Sensor Intake Manifold Test..............10.25 Removal / Installation..........4.13 Gear Ratios .............. 6.4 General Information Engine..............3.27 Gross Vehicle Weight Rating (GVWR) ......1.16 Key Fob Battery Replacement..........
  • Page 651 INDEX Muffler Assembly View (2023)..........5.10 Removal............. 3.104 Installation (2022)..........5.24 Installation (2023)..........5.26 Removal (2022) .............5.17 Removal (2023) .............5.18 Primary Drive Noise Emission Control ..........1.17 Service Notes ............5.3 Service Specifications ..........5.3 Special Tools ............5.3 Troubleshooting............5.42 Primary Drive Gear ..........5.13 O-rings Installation ............5.40 Fuel Injector ............4.51...
  • Page 652 INDEX Removal...............3.78 Removal...............5.20 Shift Shaft Seal Replacement ............5.23 Shifting Troubleshooting............5.42 Saddle Bag Shock Components............7.15 Analysis ...............8.63 Seat Shock Absorber Assembly View .............7.11 Inspection ............8.85 Assembly View (Sport Chief) ........7.14 Removal / Installation..........8.85 Removal / Installation..........7.27 Shock Absorber Stud Removal / Installation (Sport Chief) ......7.29 Removal / Installation..........8.86 Sensor Diagnostics ...........4.45 Shock, Rear...
  • Page 653 INDEX Piston ..............3.89 Assembly View (Sport Chief) ........8.73 Sprocket, Drive Bushing / Bearing Replacement .......8.89 Inspection ............8.79 Inspection ............8.69 Removal / Installation..........8.78 Installation ............8.90 Sprocket, Driven Removal...............8.87 Inspection ............8.80 Installation ............8.81 Removal...............8.80 Sprocket, Rear Inspection ............8.68 Tail Light Assembly View ........... 10.58 Stake Nut Installation ............6.43 Operation Overview ..........
  • Page 654 INDEX Removal...............8.43 Assembly View ........... 10.11 Removal (Sport Chief) ..........8.56 Troubleshootin Cylinder / Piston ...........3.99 Troubleshooting Brake System ............9.60 Overview ............10.74 Crankshaft ............6.44 Cylinder Head / Valves ..........3.86 Wheel Final Drive ............8.93 Inspection ............8.101 Troubleshooting..........8.103 Front Wheel & Suspension ........8.59 Key Fob .............

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Chief bobber 2022-2024Super chief 2022-2024Sport chief 2022-2024
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