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Indian Motorcycle N17CCDAAAH Service Manual
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Indian Motorcycle N17CCDAAAH Service Manual

2017-2024
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2017-2024 Indian Motorcycle (Full-Size)
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most
recent version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by Indian Motorcycle 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 9941443 R04)
© Copyright 2023 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 N17CCDAAAH

  • Page 1 Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by Indian Motorcycle 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.
  • 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 3 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 2017-2024 Indian Motorcycle (Full-Size) 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...
  • Page 7 ............. .1.68 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual...
  • Page 8 Individual Serial No. Digit * Model Year: H = 2017; J = 2018; K = 2019; L = 2020; M = 2021; N=2022; P = 2023; R = 2024 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 9 T T I I R R E E I I N N F F O O R R M M A A T T I I O O N N L L A A B B E E L L See Manufacturer Label page 1.3 for tire information. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 10 862 lbs. (391 kg) Chieftain Dark 896 lbs. (406 kg) 944 lbs. (428 kg) fuel/fluids) Classic / Dark Horse 831 lbs. Horse (377 kg) 856 lbs. (388 kg) Chieftain 860 lbs. Vintage (391 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 11 489 lbs. (222 kg) 441 lbs. (200 kg) Capacity (riders, Classic / Dark Chieftain cargo, Horse 554 lbs. (251 kg) accessories) 404 lbs. (183 kg) Chieftain Dark Vintage Horse 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 12 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 6th Gear 2.789:1 ELECTRICAL Stator 710W @ 2000 RPM 610W @2000 RPM (Chief/Chief Dark Horse) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 13 180/65B16 81H Dunlop 180/60R16 80H Dunlop Elite 3 Multi-Compound American Elite Front Brakes Dual / 4 Piston Caliper / Floating Rotor Rear Brakes Single / 2 Piston Caliper / Floating Rotor 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 14 Horse: 745 lbs. lbs. (355 kg) lbs. (371 kg) fluids) (338 kg) Chieftain Dark Elite: 823 lbs (373 kg) Vintage: 818 Horse: 802 lbs. lbs. (371 kg) (364 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 15 Horse: 483 lbs. lbs. (258 kg) lbs (250 kg) (riders, cargo, (219 kg) Chieftain Dark Elite: 530 lbs accessories) Vintage: 410 Horse: 551 lbs. (240 kg) lbs. (186 kg) (250 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 16 5th Gear 3.243:1 6th Gear 2.789:1 ELECTRICAL Stator 710W @ 2000 RPM 610W @2000 RPM (Chief/Chief Dark Horse) Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.10 © Copyright...
  • Page 17 180/60R16 80H Dunlop Elite 3 Multi-Compound Dunlop American Elite Front Brakes Dual / 4 Piston Caliper / Floating Rotor Rear Brakes Single / 2 Piston Caliper / Floating Rotor 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.11 © Copyright...
  • Page 18 Limited: 834 lbs 944 lbs. (428 kg) fuel/fluids) lbs. (352 kg) lbs. (370 kg) (378 kg) Vintage: 850 lbs. Chieftain Dark (385 kg) Horse 834 lbs. (378 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.12 © Copyright...
  • Page 19 441 lbs. (200 kg) Capacity (riders, Horse: 483 lbs. lbs. (258 kg) (250 kg) cargo, (219 kg) Chieftain Dark accessories) Vintage: 410 lbs. Horse: 551 lbs. (186 kg) (250 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.13 © Copyright...
  • Page 20 5th Gear 3.243:1 6th Gear 2.789:1 ELECTRICAL Stator 710W @ 2000 RPM 610W @2000 RPM (Chief/Chief Dark Horse) Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.14 © Copyright...
  • Page 21 180/60R16 80H Dunlop Elite 3 Multi-Compound Dunlop American Elite Front Brakes Dual / 4 Piston Caliper / Floating Rotor Rear Brakes Single / 2 Piston Caliper / Floating Rotor 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.15 © Copyright...
  • Page 22 758 lbs (344 kg) 789 lbs (358 kg) Chieftain: 789 lbs 893 lbs. (405 kg) (without fuel/ lbs. (334 kg) (358 kg) Dark Horse: 868 fluids) lbs (394 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.16 © Copyright...
  • Page 23 Vintage: 259 lbs. Dark Horse: 389 lbs. (145 kg) accessories) (117 kg) lbs. (176 kg) Springfield: 384 Limited: 389 lbs. lbs. (174 kg) (176 kg) Elite: 383 lbs. (174 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.17 © Copyright...
  • Page 24 Transmission 30-Tooth Rear Wheel 66-Tooth Ratio 2.2:1 Overall Gear Ratio 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 6th Gear 2.789:1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.18 © Copyright...
  • Page 25 14.4 volts/42 amp Headlight Non-Serviceable LED Non-Servicable LED Position Lamp Non-Serviceable LED (Head Dress) integrated into headlight INT’L = N/A Auxiliary Light Non-Serviceable LED Tail/Brake Light Non-Serviceable LED 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.19 © Copyright...
  • Page 26 ROADMASTER DARK MODEL YEAR 2020 ROADMASTER ROADMASTER ELITE HORSE Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Light Non-Serviceable LED Speedometer Non-Serviceable LED Indicator Lights Non-Serviceable LED 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.20 © Copyright...
  • Page 27 180/60R16 80H Dunlop Elite 3 Multi-Compound Vintage: 180/65B16 81H Dunlop American Elite Dual / 4 Piston Caliper / Floating Rotor Front Brakes Single / 2 Piston Caliper / Floating Rotor Rear Brakes 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.21 © Copyright...
  • Page 28 Springfield Dark 823 lbs (373 kg) Chieftain / Roadmaster: 909 fuel/fluids) (377 kg) Horse: 783 lbs. Limited / Dark lbs. (412 kg) (355 kg) Horse: 823 lbs (373 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.22 © Copyright...
  • Page 29 Vintage Dark (255 kg) Dark Horse / accessories) Horse: 605 lbs. Elite: 556 lbs. Limited: 495 lbs. (274 kg) (252 kg) (225 kg) Springfield: 556 lbs. (252 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.23 © Copyright...
  • Page 30 1.103:1 5th Gear Ratio 0.943:1 6th Gear Ratio 0.811:1 Gear Shift 1 Down/5 Up Pattern Final Drive Belt Drive, 152-Tooth Type Transmission 30-Tooth Rear Wheel 66-Tooth Ratio 2.2:1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.24 © Copyright...
  • Page 31 Non-Servicable LED integrated into headlight Position Lamp assembly INT’L = N/A Auxiliary Light H8 35W Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.25 © Copyright...
  • Page 32 Auxiliary Light Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Non-Serviceable LED Light Speedometer Non-Serviceable LED Indicator Non-Serviceable LED Lights 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.26 © Copyright...
  • Page 33 Metzeler Cruisetec Metzeler Cruisetec R16 (I) 80H Metzeler Cruisetec Dual / 4 Piston Caliper / Floating Rotor Front Brakes Single / 2 Piston Caliper / Floating Rotor Rear Brakes 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.27 © Copyright...
  • Page 34 829 lbs (376 kg) 823 lbs (373 kg) Chieftain / Limited / Roadmaster: 909 lbs. fuel/fluids) Dark Horse: 783 lbs. Dark Horse: 823 lbs (412 kg) (355 kg) (373 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.28 © Copyright...
  • Page 35 Capacity (riders, Dark Horse: 602 lbs. Limited: 562 lbs. (216 kg) cargo, accessories) (273 kg) (255 kg) Dark Horse / Elite: 556 lbs. (252 Limited: 495 lbs. (225 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.29 © Copyright...
  • Page 36 1.103:1 5th Gear Ratio 0.943:1 6th Gear Ratio 0.811:1 Gear Shift 1 Down/5 Up Pattern Final Drive Belt Drive, 152-Tooth Type Transmission 30-Tooth Rear Wheel 66-Tooth Ratio 2.2:1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.30 © Copyright...
  • Page 37 Non-Servicable LED integrated into headlight Position Lamp assembly INT’L = N/A Auxiliary Light H8 35W Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.31 © Copyright...
  • Page 38 Auxiliary Light Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Non-Serviceable LED Light Speedometer Non-Serviceable LED Indicator Non-Serviceable LED Lights 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.32 © Copyright...
  • Page 39 180/60-R16 (I) 80H Type/Size Dark Horse: 180/60- Metzeler Cruisetec Metzeler Cruisetec Metzeler Cruisetec R16 (I) 80H Metzeler Cruisetec Dual/4 Caliper/Floating Rotor Front Brakes Single/2 Caliper/Floating Rotor Rear Brakes 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.33 © Copyright...
  • Page 40 829 lbs (376 kg) Chieftain / Limited / Roadmaster: 909 lbs. fuel/fluids) Dark Horse: 783 lbs. 823 lbs (373 kg) Dark Horse: 823 lbs (412 kg) (355 kg) (373 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.34 © Copyright...
  • Page 41 (216 kg) cargo, accessories) Dark Horse: 602 lbs. 562 lbs. (255 kg) (255 kg) Dark Horse / (273 kg) Elite: 556 lbs. (252 Limited: 495 lbs. (225 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.35 © Copyright...
  • Page 42 1.103:1 5th Gear Ratio 0.943:1 6th Gear Ratio 0.811:1 Gear Shift 1 Down/5 Up Pattern Final Drive Belt Drive, 152-Tooth Type Transmission 30-Tooth Rear Wheel 66-Tooth Ratio 2.2:1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.36 © Copyright...
  • Page 43 Headlight Non-Serviceable LED Position Lamp Non-Servicable LED Auxiliary Light Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Non-Serviceable LED Light 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.37 © Copyright...
  • Page 44 Auxiliary Light Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Non-Serviceable LED Light Speedometer Non-Serviceable LED Indicator Non-Serviceable LED Lights 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.38 © Copyright...
  • Page 45 180/60-R16 (I) 80H Type/Size Dark Horse: 180/60- Metzeler Cruisetec Metzeler Cruisetec Metzeler Cruisetec R16 (I) 80H Metzeler Cruisetec Dual/4 Caliper/Floating Rotor Front Brakes Single/2 Caliper/Floating Rotor Rear Brakes 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.39 © Copyright...
  • Page 46 829 lbs (376 kg) Chieftain / Limited / Roadmaster: 909 lbs. fuel/fluids) Dark Horse: 783 lbs. 823 lbs (373 kg) Dark Horse: 823 lbs (412 kg) (355 kg) (373 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.40 © Copyright...
  • Page 47 (216 kg) cargo, accessories) Dark Horse: 602 lbs. 562 lbs. (255 kg) (255 kg) Dark Horse / (273 kg) Elite: 556 lbs. (252 Limited: 495 lbs. (225 kg) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.41 © Copyright...
  • Page 48 1.103:1 5th Gear Ratio 0.943:1 6th Gear Ratio 0.811:1 Gear Shift 1 Down/5 Up Pattern Final Drive Belt Drive, 152-Tooth Type Transmission 30-Tooth Rear Wheel 66-Tooth Ratio 2.2:1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.42 © Copyright...
  • Page 49 Headlight Non-Serviceable LED Position Lamp Non-Servicable LED Auxiliary Light Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Non-Serviceable LED Light 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.43 © Copyright...
  • Page 50 Auxiliary Light Non-Serviceable LED Tail/Brake Non-Serviceable LED Light Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Front Fender Non-Serviceable LED Light Speedometer Non-Serviceable LED Indicator Non-Serviceable LED Lights 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.44 © Copyright...
  • Page 51 180/60-R16 (I) 80H Type/Size Dark Horse: 180/60- Metzeler Cruisetec Metzeler Cruisetec Metzeler Cruisetec R16 (I) 80H Metzeler Cruisetec Dual/4 Caliper/Floating Rotor Front Brakes Single/2 Caliper/Floating Rotor Rear Brakes 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.45 © Copyright...
  • Page 52 • weight of all riders’ apparel and items in or on apparel • weight of any accessories and their contents • weight of any additional cargo on the motorcycle 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.46 © Copyright...
  • Page 53 3. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. 4. Removal or puncturing of any part of the intake system. 5. Lack of proper maintenance. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.47 © Copyright...
  • Page 54 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 55 Commercially Available PU-50105 PF-52135 Engine Stand Adapter Crankcase Tool Spanner Socket (Stem) PF-51240 PF-51234 PV-43508 Clutch Shaft Holding Tool Crankshaft Rotation Tool Output Shaft Seal Tool PF-51232 PF-51239 PF-51243 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.49 © Copyright...
  • Page 56 PV-50567 PV-48656 PU-43506-A F F R R A A M M E E / / B B O O D D Y Y Body Panel Tool Kit PV-49955 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.50 © Copyright...
  • Page 57 PV-48909 available) Fork Spring Compressor Fork Spring Compressor Adapter Fork Seal Tool PV-49463 PV-49464 PV-49494 Fork Oil Level Tool Damper Rod Holder Cartridge Shaft Tool PV-59000A PV-49453 PV-49452 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.51 © Copyright...
  • Page 58 PU-51324 Swingarm Bushing Tool PF-51237 B B R R A A K K E E S S Brake Lever Pressure Test Tool Vacuum Brake Bleeder PV-50104 Commercially Available 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.52 © Copyright...
  • Page 59 E E L L E E C C T T R R I I C C A A L L Battery Tester MultiLink XP Electrical Tester Kit PU-50296 PU-52792 PV-43526 USB to Serial Adapter Relay Bypass Tool PU-49466 PU-50621 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.53 © Copyright...
  • Page 60 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 1.54 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.54 © Copyright...
  • Page 61 Cam Chain Tensioner Chain Guide Fastener 15 ft-lbs (20 N·m) Cam Chain Tensioner Fastener Camshaft Sprocket Fastener 52 ft-lbs (70 N·m) Connecting Rod Fastener 22 ft-lbs (30 N·m) + 90° 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.55 © Copyright...
  • Page 62 Oil Pressure Switch (2023+) 9 ft-lbs (13 N·m) Oil Pressure Switch Adapter 15 ft-lbs (20 N·m) Oil Pump Pickup Fastener 88 in-lbs (10 N·m) Oxygen Sensor 14 ft-lbs (19 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.56 © Copyright...
  • Page 63 Oil Pressure Switch (2023+) 9 ft-lbs (13 N·m) Oxygen Sensor 14 ft-lbs (19 N·m) 88 in-lbs (10 N·m) Seat Fastener 44 in-lbs (5 N·m) Side Stand Switch Fastener 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.57 © Copyright...
  • Page 64 88 in-lbs (10 N·m) Stator Fastener Stopper Plate Fastener 62 in-lbs (7 N·m) Torque Compensator Fastener 83 ft-lbs (112 N·m) Torque Compensator Locking Plate Fastener 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.58 © Copyright...
  • Page 65 18 ft-lbs (24 N·m) Floorboard Pivot Fastener Floorboard Support Fastener 35 ft-lbs (48 N·m) Foot Peg Blank Fastener 35 ft-lbs (48 N·m) Foot Peg Mounting Fastener 35 ft-lbs (48 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.59 © Copyright...
  • Page 66 Seat Fastener (Dark Horse) 18 ft-lbs (24 N·m) Seat Bracket Fastener (2019 Chieftain) 35 in-lbs (4 N·m) Strap Fastener 88 in-lbs (10 N·m) 88 in-lbs (10 N·m) Seat Fastener 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.60 © Copyright...
  • Page 67 Drive Sprocket Lock Plate Fastener 88 in-lbs (10 N·m) Fairing Support Fastener 12 ft-lbs (16 N·m) 18 ft-lbs (24 N·m) Fork Lock Fastener Fork Cartridge Fastener 17 ft-lbs (23 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.61 © Copyright...
  • Page 68 55 ft-lbs (75 N·m) Upper Pushrod Fastener, Rear Suspension (2020+) 96 ft-lbs (130 N·m) 53 in-lbs (6 N·m) Valve Stem Nut Final Spoke Torque 69 in-lbs (8 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.62 © Copyright...
  • Page 69 35 in-lbs (4 N·m) Cell Modem Fastener Chassis Lug Joint Fastener 88 in-lbs (10 N·m) 88 in-lbs (10 N·m) Coil Ground to Bracket Fastener 88 in-lbs (10 N·m) Console Panel Fastener 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.63 © Copyright...
  • Page 70 VCM Mounting Plate Fastener 88 in-lbs (10 N·m) Windshield Mounting Fastener 35 in-lbs (4 N·m) 35 in-lbs (4 N·m) Windshield Motor Nut 35 in-lbs (4 N·m) Windshield Cowl Panel Fastener 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.64 © Copyright...
  • Page 71 2-4 1/2 1 25/32 5/16-18 2-12 1 59/64 5/16-24 2 1/4-4 1/2 2 1/32 3/8-16 2 1/2-4 2 1/4 3/8-24 2 3/4-4 2 1/2 7/16-14 2 3/4 7/16-20 25/64 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.65 © Copyright...
  • Page 72 35/64 in = .5469 in [14 mm = .5512 in] 9/16 in = .5625 in 37/64 in = .5781 in [15 mm = .5906 in] 19/32 in = .5938 in 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.66 © Copyright...
  • Page 73 C to F: 9 ( C + 40) ¸ 5 - 40 = F to C: 5 ( F + 40) ¸ 9 - 40= DEGREES F DEGREES C 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.67 © Copyright...
  • Page 74 = Imperial US quarts x.833 quarts US quarts x.946 = liters = US quarts liters x 1.057 US gallon x 3.785 = liter = US gallon liter x .264 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 1.68 © Copyright...
  • Page 75 MAJOR MAINTENANCE PROCEDURES ............. . .2.34 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual...
  • Page 76 Roadmaster / : 41 PSI (282 kPa) — Tire Tread Depth (Minimum) .063 in (1.6 mm) — Valve Lash (Int. / Ex.) NOT ADJUSTABLE (Lash is self-adjusting via hydraulic lifters) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 77 Fork Oil (Chieftain / Indian Motorcycle Fork Oil 18.8 oz (557 cc) per leg Roadmaster / Springfield) Fuel 91 Octane (Recommended) 5.5 gal (20.8 L) / Reserve 1.0 gal (3.8 L) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 78 2884182 quart 2880187 Synthetic 15W-60 Engine Lubricant (Scout / Thunderstroke / Challenger Engines) 55 gal drum 2880188 quart 2880012 Semi-Synthetic 20W-40 Engine Lubricant (Thunderstroke Engines) 55 gal drum 2880013 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 79 IMPORTANT Indian Motorcycle recommends performing a Engine Oil & Filter change every 12 months regardless of milage. XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Indian Motorcycle dealer perform these services.
  • Page 80 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 81 Inspect; adjust if necessary, lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 82 Inspect; adjust if necessary, lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 83 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 84 Inspect; adjust if necessary, lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.10 © Copyright...
  • Page 85 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.11 © Copyright...
  • Page 86 Inspect; adjust if necessary, lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.12 © Copyright...
  • Page 87 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.13 © Copyright...
  • Page 88 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.14 © Copyright...
  • Page 89 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.15 © Copyright...
  • Page 90 Lubricate with proper lubricant as directed Sidestand Steering Bearings Inspect Suspension Linkage, Rear Inspect Swing Arm and Rear Axle Inspect Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.16 © Copyright...
  • Page 91 Inspect tread depth, sidewall cracking, wear patterns Tires / Wheels When the vehicle goes beyond 50,000 miles, return to the 500 mile chart and start the interval process over. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.17 © Copyright...
  • Page 92 Do not operate for extended (484–805 km) periods above 3/4 throttle. 500 Miles Perform the break-in maintenance (805 km) procedure outlined in the Periodic Maintenance Interval Table located in this chapter. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.18 © Copyright...
  • Page 93 3. Installation of new filter is performed by reversing the removal procedure. TORQUE Air Filter Fasteners : 62 in-lbs (7 N·m) Airbox Cover Fasteners : 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.19 © Copyright...
  • Page 94 Do not overfill. 12. Reinstall the dipstick securely. 13. With the motorcycle in an upright, centered position, start the engine and idle for 30 seconds. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.20 © Copyright...
  • Page 95 E E N N G G I I N N E E O O I I L L VISCOSITY: Indian Motorcycle engineering has validated the use of 15W60 oil across MY14+ 111 & 116 C.I. engine platforms. The use of 15W60 has been shown to improve cold-start performance and cold-weather shifting.
  • Page 96 5. 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. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.22 © Copyright...
  • Page 97 M M I I N N I I M M U U M M T T R R E E A A D D D D E E P P T T H H ( ( A A L L L L M M O O D D E E L L S S ) ) Front Tire Minimum Tread Depth .063 in (1.6 mm) Rear Tire Minimum Tread Depth .063 in (1.6 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.23 © Copyright...
  • Page 98 REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) 2021+ SPRINGFIELD DARK HORSE FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa) REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.24 © Copyright...
  • Page 99 REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) 2021+ ROADMASTER DARK HORSE / LIMITED FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa) REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.25 © Copyright...
  • Page 100 14 in-lbs (2 N·m) 4. Wipe away any fluid spills. Check for signs of brake fluid leaks around hoses, fittings, reservoir and brake calipers. Check for deterioration of hoses. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.26 © Copyright...
  • Page 101 Rear Master Cylinder Cover Fasteners: 7 in-lbs (1 N·m) 4. Wipe away any fluid spills. Check for signs of brake fluid leaks around hoses, fittings, reservoir, and brake calipers. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.27 © Copyright...
  • Page 102 If the correctly rated fuse continues to blow, something is wrong and needs to be corrected. Substituting a higher amperage fuse can lead to extensive electrical system and vehicle damage. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.28 © Copyright...
  • Page 103 Measure distance = 25 ft. 10 in. (7.62 m) Headlight Center With the headlight switched to HIGH beam, the center of highest intensity (appears as a diamond shape). 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.29 © Copyright...
  • Page 104 2. To adjust the headlight horizontally, turn the left adjustment fastener out (counter-clockwise) to adjust the beam to the left. Turn the right adjustment fastener out (counter-clockwise) to adjust the beam to the right. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.30 © Copyright...
  • Page 105 3. The time listed on the PU-50296 battery tester printout is an estimate. The recommended automatic charger will indicate when the battery is fully charged on its display. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.31 © Copyright...
  • Page 106 4. Wait for the charger to complete the charge cycle before disconnecting it. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.32 © Copyright...
  • Page 107 Carefully remove the tape to Dash Column expose the connector and length of wire. Be sure to properly secure the wire and connector before operating the vehicle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.33 © Copyright...
  • Page 108 Steering Head / Front Wheel Inspection Steering Head / Front Wheel Inspection page 8.12 Swingarm Inspection Swingarm Inspection page 8.12 Rear Shock Preload Inspection Rear Shock Preload Inspection page 8.13 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.34 © Copyright...
  • Page 109 Rear Brake Pad Inspection page 9.9 Battery Battery page 9.4 Battery Inspection Battery Inspection page 10.19 Battery Removal Battery Removal page 10.12 Battery Installation Battery Box Installation page 10.15 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.35 © Copyright...
  • Page 110 MAINTENANCE NOTES 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 2.36 © Copyright...
  • Page 111 ..............3.36 OIL COOLER INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 112 ......... .3.95 TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 113 ................3.122 MUFFLER INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 114 1. With the engine at room temperature, grasp the spark plug boot and rotate back and forth slightly to release from the spark plug. DO NOT pull on the wire or spark plug wire may be damaged. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 115 4. Install spark plug wire boots securely over the achieved. plugs. Spark Plug Type: DCPR8E Spark Plug Gap: .034 in (0.9 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 116 • Carbon or foreign material on valve seat • Worn or damaged piston and/or piston rings • Leaking exhaust or intake valves • Leaking head gasket • Valve timing incorrect • Non-OEM camshafts or faulty gauge 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 117 See Engine Compression Test page 3.6. 2. If compression increases substantially, inspect cylinder, piston, and rings. 3. If compression does not increase, inspect valves and valve seats. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 118 4. Remove the two fasteners securing the baffle plate to the intake air boot. 5. Disconnect the multi-plug from the throttle body. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 119 7. Using an 8 mm socket, remove the lower fastener securing the airbox to the mounting plate. 8. Push the rubber harness seal through to the back side of the airbox and remove from the motorcycle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 120 8. Install the air filter adapter plate and seal into the airbox. Press the hose fitting on the adapter plate into the breather hose until the plate is fully seated. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.10 © Copyright...
  • Page 121 31 in-lbs (4 N·m) Airbox Cover Fasteners: 88 in-lbs (10 N·m) 10. Install the air filter element and torque fasteners to specification. TORQUE Air Filter Fasteners: 62 in-lbs (7 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.11 © Copyright...
  • Page 122 Oil Pump Drive Pushrods Output Shaft Seal Transmission/All Torque Compensator Internal Transmission Assembly Parts Valve Covers Starter, Starter One-Way Clutch, Starter Torque Limit Clutch Crankshaft Position Sensor Timing Wheel 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.12 © Copyright...
  • Page 123 Fastener, Front Engine Mount — M8 x 1.25 x 20 (QTY.2) 45 ft-lbs (60 N·m) 18 ft-lbs (24 N·m) Fastener, Engine Mount — M10 x 1.5 x 60 (QTY.2) 45 ft-lbs (60 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.13 © Copyright...
  • Page 124 Fastener, Engine Mount — M10 x 1.5 x 60 (QTY.2) 75 ft-lbs (102 N·m) 45 ft-lbs (60 N·m) Fastener, Engine Mount — M12 x 1.75 x 120 (QTY.1) 75 ft-lbs (102 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.14 © Copyright...
  • Page 125 18. Remove both ends of the breather hose from the assemblies. See Floorboard (Driver), Removal valve covers. page 7.23. 12. Remove highway bars, if equipped. See Highway Bar Removal page 7.29. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.15 © Copyright...
  • Page 126 23. Using a 4 mm hex wrench, remove the two fasteners securing the sidestand switch and move switch out of the way. See Sensors — Powertrain Management page 4.15. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.16 © Copyright...
  • Page 127 ABS bracket. 2. Place a platform jack beneath the engine and raise enough to support crankcase (Jack should just be touching the crankcase). 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.17 © Copyright...
  • Page 128 11. Remove the starter motor. See Starter Motor, 8. Disconnect the stator from the regulator. Removal / Installation page 10.31. 12. Remove CPS. See Sensors — Powertrain Management page 4.15. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.18 © Copyright...
  • Page 129 18. Move the ABS Module / bracket and hydraulic brake lines far enough away from the RH side of the engine so that the engine can be lowered slightly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.19 © Copyright...
  • Page 130 21. Using a pick tool, remove the two spacers from the RH side of the engine between the frame panel and engine mounts. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.20 © Copyright...
  • Page 131 3. Position the engine on a platform jack to the left of right-hand frame panel and the engine crankcase. the motorcycle and slide into position so the engine is orientated correctly front to back. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.21 © Copyright...
  • Page 132 15. If applicable, install the mounting bracket and charcoal canister to the back of the ABS module TORQUE bracket and reconnect vapor hoses. Grounding Wire Fastener: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.22 © Copyright...
  • Page 133 TORQUE Brake Line Mounting Fasteners: 80 in-lbs (9 N·m) 18. Install the starter motor. See Starter Motor, Removal / Installation page 10.31. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.23 © Copyright...
  • Page 134 Bar Installation page 7.29. 30. Install front fender. See Front Fender Installation page 7.34. 31. Install the left-hand and right-hand floorboard assemblies. See Floorboard (Driver), Installation page 7.24. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.24 © Copyright...
  • Page 135 If the engine is making irregular noises that appear to be coming from rotating parts, check the lubrication side oil pressure. Check the oil pressure before engine disassembly, and recheck the oil pressure after a repair. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.25 © Copyright...
  • Page 136 .006"-.010" (.15 mm-.25 mm) .015" (.381 mm) Oil Pump End Clearance .0014"-.0032" (.036 mm-.081 mm) .008" (.203 mm) Gerotor Tip Clearance .003"-.005" (.076 mm-.127 mm) .007" (.178 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.26 © Copyright...
  • Page 137 22 ft-lbs (30 N·m) Fastener, Oil Filter Adapter - M6 x 1.0 x 40 (QTY.3) Oil Cooler Assembly 88 in-lbs (10 N·m) Backing Ring, O-ring Oil Filter Adapter Assembly 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.27 © Copyright...
  • Page 138 O O I I L L 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 A A S S S S E E M M B B L L Y Y V V I I E E W W Fastener, Oil Filter Adapter - M6 x 1.0 x 40 (QTY.3) O-ring, Oil Cooler 88 in-lbs (10 N·m) Oil Filter Adapter Assembly 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.28 © Copyright...
  • Page 139 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 OIL COOLER FILTER ADAPTER INTERNAL BYPASS • Chieftain Dark Horse • Chief Classic • Chieftain • Chief Vintage • Roadmaster • Chief Dark Horse • Springfield 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.29 © Copyright...
  • Page 140 88 in-lbs (10 N·m) 2018–2020: 11 ft-lbs (15 N·m) Oil Pressure Switch 2021–2023: 9 ft-lbs (13 N·m) 2023+: Adapter, Oil Pressure Switch 15 ft-lbs (20 N·m) Dipstick, Oil – 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.30 © Copyright...
  • Page 141 6. Start engine and check oil pressure at 3000 rpm. 7. Compare reading to oil system specifications. 8. If oil pressure is outside of specification, refer to the troubleshooting section page 3.25. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.31 © Copyright...
  • Page 142 , and drive pin from oil pump input shaft. 6. Remove the oil pump / snorkel tube assembly from the LH crankcase. 4. Remove the oil pump snorkel tube fasteners 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.32 © Copyright...
  • Page 143 7. Install oil pump drive pin , sprocket , washer and external snap-ring 8. Assemble engine crankcase. See Crankcase Assembly page 6.43. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.33 © Copyright...
  • Page 144 ENGINE / COOLING / EXHAUST 9. Install engine in frame. See Engine Installation page 3.21. 10. Verify engine oil pressure after assembly. See Oil Pressure page 3.31. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.34 © Copyright...
  • Page 145 4. Remove the upper oil cooler fastener and lift the lower cooler mounts off of the rubber isolators. 5. Remove the oil cooler assembly from the vehicle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.35 © Copyright...
  • Page 146 TORQUE Oil Cooler Line Fasteners: 88 in-lbs (10 N·m) 4. Run the engine to cycle oil through the oil cooler and check oil level. Top off if necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.36 © Copyright...
  • Page 147 • Cleanliness of parts is critical to engine life and accurate parts inspection. Use clean solvent to clean all disassembled parts. Dry parts with compressed air and lubricate before engine inspection and engine assembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.37 © Copyright...
  • Page 148 At 1 mm Lift Max Lobe Lift (7.20 mm) (7.55 mm) INTAKE (7.20 mm) (8.40 mm) EXHAUST Max Valve Lift (12.8 mm) (13.32 mm) INTAKE (12.8 mm) (14.8 mm) EXHAUST 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.38 © Copyright...
  • Page 149 111 c.i. =0.504" (12.8 Exhaust Valve Maximum Lift Valve Spring 116 c.i. =0.583” (14.8 2017-2022: 1.929 - 2.007" (49.00 - Spring Installed Height 51.00 mm) 2023+: 1.96” (50.00 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.39 © Copyright...
  • Page 150 Timing Chain Tensioner Timing Gear, Crankshaft Snap Ring, Tensioner Arm Timing Gear, Camshaft (Intake) Tensioner Arm, Timing Chain Timing Chain Timing Chain Guide Fastener 71 in-lbs (8 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.40 © Copyright...
  • Page 151 Fastener - M8 x 1.25 x 30 (QTY.3) / M8 x 1.25 x 40 (QTY.1) Camshaft, Exhaust (Front) 15 ft-lbs (20 N·m) Bearing Carrier, Camshaft (QTY.6) Camshaft, Intake (Center) External Snap ring Camshaft, Exhaust (Rear) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.41 © Copyright...
  • Page 152 Pushrod Tube 62 in-lbs (7 N·m) Dowel, Lifter Guide Pushrod Fastener, Lifter Block - M6 x 1.0 x 25 (QTY.3 per cylinder) Lifter 88 in-lbs (10 N·m) Lifter Block 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.42 © Copyright...
  • Page 153 Fastener, Outer Valve Cover - M6 x 12 x 15 (QTY.3) Valve Spring 88 in-lbs (10 N·m) Cylinder Head Temperature Sensor (CHT) Retainer, Valve Spring 71 in-lbs (8 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.43 © Copyright...
  • Page 154 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 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.44...
  • Page 155 It may be necessary to rotate the crankshaft slight forward or back to properly align holes. 6. Torque cam chain cover fasteners following the specified torque sequence. TORQUE Cam Chain Cover Fasteners: 10 ft-lbs (13 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.45 © Copyright...
  • Page 156 5. Inspect tensioner arm for excessive wear marks from timing chain, cracks or fatigue. 6. Inspect the tensioner arm spring for cracks or fatigue. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.46 © Copyright...
  • Page 157 Tensioner Fastener: 15 ft-lbs (20 N·m) 6. With a new gasket and both mating surfaces clean, install the cam chain cover. See Cam Chain Cover, Removal / Installation page 3.45. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.47 © Copyright...
  • Page 158 3. Install the cam cover. See Cam Chain Cover, Removal / Installation page 3.45. 10. Pull the camshaft sprocket, crankshaft sprocket and cam chain off as an assembly. 11. Collect the woodruff key from the crankshaft. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.48 © Copyright...
  • Page 159 14. Install clutch assembly and clutch rack. See Clutch Installation page 5.44 15. If applicable, Install torque compensator. See Torque Compensator Installation page 5.57 16. Install primary cover. See Primary Cover Installation (2017-2020) page 5.27 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.49 © Copyright...
  • Page 160 ENGINE / COOLING / EXHAUST 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.50 © Copyright...
  • Page 161 3. Starting with the front lifter block, remove the three fasteners and the lifter block. 6. Repeat steps 3–5 to remove the rear lifters. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.51 © Copyright...
  • Page 162 7. Install new gaskets into lifter blocks and install lifter blocks and fasteners finger tight. 8. Torque lifter block fasteners to specification. TORQUE Lifter Block Fasteners: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.52 © Copyright...
  • Page 163 5. Remove the camshaft carrier assembly from the vise and remove camshaft fasteners. Care should be taken so camshafts don’t fall out of the carrier during this process. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.53 © Copyright...
  • Page 164 7. Camshaft carrier bearings can be removed using a suitable press or bearing driver. Pressure must be applied from the backside of the carrier plate and bearings pressed through the front. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.54 © Copyright...
  • Page 165 2. Inspect height of each cam lobe. Exhaust cam lobes and intake cam lobes 3. Measure O. D. of each camshaft journal. Exhaust journals and Intake journals 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.55 © Copyright...
  • Page 166 4. If replacing camshaft carrier bearings, press or drive new bearings into the carrier from the front side until seated against shoulder. 5. Install the bearing retainer plate with the countersunk fastener holes facing out. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.56 © Copyright...
  • Page 167 Install the LH and RH exhaust camshafts so the timing marks line up as shown. 13. Torque exhaust camshaft fasteners to specification. TORQUE Exhaust Camshaft Fasteners: 52 ft-lbs (70 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.57 © Copyright...
  • Page 168 3. Install the three fasteners and torque to specification. TORQUE Camshaft Carrier Fasteners: 15 ft-lbs (20 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.58 © Copyright...
  • Page 169 3. Support motorcycle securely in an upright position. Clamp front tire securely in a wheel vise. 4. Drain engine oil. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.59 © Copyright...
  • Page 170 IMPORTANT Do not bend or kink flexible brake line during floorboard removal. Master cylinder assembly should be kept in an upright position and properly supported at all times. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.60 © Copyright...
  • Page 171 • Seat Removal / Installation - (Dark Horse) page 7.28 2. Using an 8mm socket, remove the three fasteners securing the air filter element to the adapter plate and remove element. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.61 © Copyright...
  • Page 172 8. Using an 8 mm socket, remove the lower fastener securing the air box to the mounting plate. 5. Disconnect the multi-plug from the throttle body. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.62 © Copyright...
  • Page 173 2. Locate the fuel pump power fuse. 5. Wrap a clean shop towel around fuel line fitting. 3. Pull the fuel pump relay and crank the engine over for 5 seconds to release pressure. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.63 © Copyright...
  • Page 174 Do not use anything other than fingers to remove the quick connection. The use of tools can damage the connection. CAUTION Always wear eye protection 7. Cover fuel fittings to keep debris out. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.64 © Copyright...
  • Page 175 10. Lift the rear of the fuel tank and slide rearward to 4. Remove console cover fasteners and the plastic release from the front isolators. dart 11. Lift the tank off of the motorcycle and store safely. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.65 © Copyright...
  • Page 176 3. Clean out spark plug wells with compressed air to remove any loose dirt or debris. 4. Using a 3” extension and a 5/8” spark plug socket, remove spark plugs. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.66 © Copyright...
  • Page 177 2020+ 3. Leave electrical connector in place, remove fuel injectors from intake. 1. Disconnect fuel injector electrical connectors. IMPORTANT Disengage Red CPA connection lock before disconnecting injector. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.67 © Copyright...
  • Page 178 2. Ensure indents on gear faces align with each other as shown. If they do not, repeat crankshaft locking procedure and align them. 3. Loosen, but DO NOT REMOVE four screws 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.68 © Copyright...
  • Page 179 8. Remove the exhaust camshaft fasteners 6. Remove and retain two fasteners and Camshaft Chain Guide 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.69 © Copyright...
  • Page 180 11. Remove the camshaft bearing carrier assembly 14. Install special tool spacer (has dowel hole) onto the intake camshaft and spacers onto the exhaust camshafts. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.70 © Copyright...
  • Page 181 It will be necessary to rotate the camshaft (clockwise) with a wrench to seat the pin. 17. Rotate the camshaft using a suitable wrench while pressing on the retaining pin until it seats. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.71 © Copyright...
  • Page 182 (clockwise) with a wrench to seat the pin. 23. Rotate the camshaft using a suitable wrench while pressing on the retaining pin until it seats at the line marked “B”. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.72 © Copyright...
  • Page 183 The camshaft ends are slip-fit to the inner bearings and should slide in by hand. Press the camshaft carrier assembly into the inner bearings until carrier is fully seated on the inner cam chain cover. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.73 © Copyright...
  • Page 184 5. Install crankshaft and camshaft sprocket fasteners and washers and torque to specification. TORQUE Camshaft / Crankshaft Sprocket Fasteners: 52 ft-lbs (70 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.74 © Copyright...
  • Page 185 Cam Chain Cover Fasteners: specification. 10 ft-lbs (13 N·m) TORQUE Tensioner Fastener: 15 ft-lbs (20 N·m) 11. Clean gasket mating surfaces and install cam chain cover using a new gasket. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.75 © Copyright...
  • Page 186 4. Connect throttle body electrical connector route the throttle body wiring to the holder. 2. Install throttle body gasket aligned into the notches of the bracket as shown. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.76 © Copyright...
  • Page 187 Pull gently on quick connector once seated to ensure a proper connection has been 4. Install fuel rail fasteners and torque to made. specification. TORQUE Fuel Rail Fasteners: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.77 © Copyright...
  • Page 188 4. Install the console cover and torque fasteners to specification. TORQUE Console Cover Fasteners: 88 in-lbs (10 N·m) 5. Slide tank forward until fully seated on forward isolators. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.78 © Copyright...
  • Page 189 TORQUE Fuel Tank Mounting Fasteners: 18 ft-lbs (24 N·m) 11. Install the fuel pump relay. 8. Install the outer isolators and washers onto the rear tank mount. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.79 © Copyright...
  • Page 190 See Priming The Fuel System page 4.32 TORQUE Baffle Plate Fasteners: 31 in-lbs (4 N·m) airbox Retainer Fastener: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.80 © Copyright...
  • Page 191 8. Install the three air filter adapter plate fasteners and torque to specification. TORQUE airbox Cover Fasteners: 88 in-lbs (10 N·m) TORQUE Air Filter Adapter Plate Fasteners: 31 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.81 © Copyright...
  • Page 192 If master cylinder is not kept upright, brake system must be bled of air. TORQUE Brake Master Cylinder Mounting Screws 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.82 © Copyright...
  • Page 193 6. Reinstall the dipstick securely. 7. With the motorcycle in an upright, centered position, start the engine and idle for 30 seconds. d. Thread the dipstick until fully seated. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.83 © Copyright...
  • Page 194 10. Dispose of used filter and oil properly. 11. Check for leaks around drain plug and oil filter. NOTICE Recycle used oil and oil filter in accordance with local regulations. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.84 © Copyright...
  • Page 195 3. Using an 8mm socket, remove the fasteners securing the inner valve covers to the cylinder head. 4. Remove inner valve covers and gaskets. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.85 © Copyright...
  • Page 196 2. Reference the torque sequence at the beginning of this section and torque inner valve cover fasteners to specification. TORQUE Inner Valve Cover Fasteners: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.86 © Copyright...
  • Page 197 2. Remove inner and outer valve covers. See Valve Cover Removal page 3.85. 3. Alternately loosen cylinder head nuts to relieve valve spring pressure. Remove nuts and washers. 4. Remove cylinder heads and head gaskets 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.87 © Copyright...
  • Page 198 Check for excessive radial movement. 4. Replace rocker arm assembly if pad or push rod cup show signs of wear, cracks, nicks or burrs. 3. Remove the valves 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.88 © Copyright...
  • Page 199 2. Inspect cylinder head for distortion with a straight edge and feeler gauge. Check in different directions and locations on the cylinder head. For cylinder head service limits, Service Specifications - Cylinder Head / Valves. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.89 © Copyright...
  • Page 200 4. Insert valves into their original locations in cylinder head. 5. Inspect that each valve moves up and down smoothly without binding in guide. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.90 © Copyright...
  • Page 201 Wear, settling of valve seat Narrow with both 30 stone and 60 stone Contact area too narrow Use 45 stone None Contact area free of pitting Correct and damage, centered in seat, proper width. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.91 © Copyright...
  • Page 202 Do not grind seats more than necessary to provide proper seat width and contact point on valve face. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.92 © Copyright...
  • Page 203 2. Install valve in head before installing seal. Hold valve against seat wipe off the portion that extends above the guide. 3. Apply Indian Motorcycle engine oil to valve guide seal and install seal on valve, rotating the seal as you install it.
  • Page 204 6. Set cylinder head in place on cylinder and press down over the push rod tubes until fully seated. 7. Apply assembly lube to the tops of the valve stems. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.94 © Copyright...
  • Page 205 Correct Engine Oil Level Collapsed Hydraulic Lifter Bleed Air from Lifter(s) / Run at high idle for 10 minutes Engine Noise Valve Train Area Broken or Weak Valve Replace Spring(s) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.95 © Copyright...
  • Page 206 Worn Camshaft / Rocker Replace Arms — Ignition / Fuel Injection Refer to Fuel Delivery / EFI System or Electrical chapter Oiling Problem Oil Overfilled Correct Engine Oil Level 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.96 © Copyright...
  • Page 207 5. Apply shop air pressure to the tester and adjust according to the manufacturer’s instructions. 6. Record the cylinder leakage value. Max Cylinder Leakage: 7. For any cylinder leakage above 30%, inspect for the following conditions: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.97 © Copyright...
  • Page 208 Crankshaft Locking Pin PF-52135 Engine Case Splitting Tool PF-51234 Straightedge, Feeler Commercially Gauge Available Protective Sleeves For Commercially Pistons / Studs Available Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris.service-solutions.com/ 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.98 © Copyright...
  • Page 209 0.02 - 0.060 mm Ring Land (1.2 mm ring 0.11 mm (0.0043") (0.0008 - 0.0024") thickness) 0.03 - 0.17 mm Oil Control Ring 0.26 mm (0.010") (0.001 - 0.0067") 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.99 © Copyright...
  • Page 210 Reference Connecting Rod Installation Bearing Cap, Connecting Rod Ring, Compression (top 2 rings) Bearing, Connecting Rod (52 mm) Gasket, Cylinder Base Circlip, Wristpin Cylinder Wristpin Gasket, Cylinder Head Piston 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.100 © Copyright...
  • Page 211 Front piston is installed closest to the camshaft side of the engine. Wrist pin circlip. Install the circlip with the gap positioned at 12 o’clock. Oil Control Ring Compression Ring No. 2 Compression Ring No. 1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.101 © Copyright...
  • Page 212 C C Y Y L L I I N N D D 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. Visually inspect cylinder bores for scratches and wear. 2. Inspect gasket surfaces for scratches or other damage that may cause an oil leak. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.102 © Copyright...
  • Page 213 • If the piston-to-cylinder clearance exceeds the service limit, measure a new piston and re-calculate the clearance. If the piston-to-cylinder clearance exceeds the service limits with a new piston, the cylinder must be replaced. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.103 © Copyright...
  • Page 214 4. Rotate rings in piston grooves. Rings should rotate freely in grooves. 5. Clean carbon deposits from piston. 6. Spread rings only wide enough to remove them from piston. Spreading rings too wide will damage them. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.104 © Copyright...
  • Page 215 If piston-to-cylinder clearance exceeds service limits with a new piston, cylinder must be replaced. 8. Replace parts that exceed service limit. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.105 © Copyright...
  • Page 216 2. Measure piston pin O.D. at three locations. Record largest measurement. 3. Calculate piston pin-to-piston clearance. Subtract pin O.D. from pin hole I.D. 4. Measure connecting rod small end I. D. at two locations. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.106 © Copyright...
  • Page 217 6. Install remaining circlip with end gap facing up (12:00 position.) 7. Make sure both piston circlips are seated properly in the groove. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.107 © Copyright...
  • Page 218 1. Use a stud extractor to remove 10 mm studs 2. Clean threads in cases thoroughly. 3. Install studs and torque them to specification. TORQUE Cylinder Studs: 25 ft-lbs (34 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.108 © Copyright...
  • Page 219 Installation page 3.94. gaskets or sealing surfaces during the assembly process. 7. Apply a small amount of engine oil to inside surfaces of a piston ring compressor band. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.109 © Copyright...
  • Page 220 Broken or Weak Valve Replace Spring(s) Engine Noise Worn Camshaft or Rocker Replace Valve Train Area Rocker Arm Bearing Replace Damage Cam Bearings Worn or Replace Damaged 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.110 © Copyright...
  • Page 221 Worn Camshaft / Rocker Replace Arms — Ignition / Fuel Injection Refer to Fuel Delivery / System EFI or Electrical chapter Oiling Problem Oil Overfilled Correct Engine Oil Level 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.111 © Copyright...
  • Page 222 Fastener, Head Pipe Trim Cover — M6 x 1.0 x 20 80 in-lbs (9 N·m) (QTY.4) Nut, Head Pipe — M8 x 1.25 (QTY.4) 15 ft-lbs (20 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.112 © Copyright...
  • Page 223 Fastener, Rear Head Pipe Hanger — M8 x 1.25 x 20 18 ft-lbs (24 N·m) (QTY.4) Clamp, Worm Drive 26 in-lbs (3 N·m) Clamp, Worm Drive 26 in-lbs (3 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.113 © Copyright...
  • Page 224 Step 5: Torque rear lower nut to 88 in-lbs (10 N·m). Step 6: Final Torque 15 ft-lbs (21 N·m) in sequence : Front upper, front lower, rear upper, rear lower. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.114 © Copyright...
  • Page 225 1. Using a flat head screwdriver, loosen (do not remove) the rear heat shield clamps 2. Loosen the forward muffler clamps between the head pipe / cross over pipe and muffler. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.115 © Copyright...
  • Page 226 3. Remove left and right muffler assemblies page 3.115. 4. Remove cross over pipe support fastener from left hand side of the motorcycle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.116 © Copyright...
  • Page 227 8. Slide the rear head pipe and cross over pipe assembly back to remove from the front head pipe. 9. Remove the cross over pipe from the rear head pipe. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.117 © Copyright...
  • Page 228 It is not necessary to remove the hydraulic line from the master cylinder during this operation. 3. Locate the front oxygen sensor connector , at the front motor mount, and disconnect. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.118 © Copyright...
  • Page 229 80 in-lbs (9 N·m) 6. Reconnect front and rear oxygen sensors and secure wires with cable ties. 3. Install the cross over pipe / rear head pipe page 3.120 assembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.119 © Copyright...
  • Page 230 Step 5: Torque rear lower nut to 88 in-lbs (10 N·m). Step 6: Final Torque 15 ft-lbs (21 N·m) in sequence : Front upper, front lower, rear upper, rear lower. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.120 © Copyright...
  • Page 231 Heat Shield Clamps: 26 in-lbs (3 N·m) 10. Install left and right muffler assemblies page 3.122. TORQUE Exhaust Clamps: 40 ft-lbs (54 N·m) 8. Reconnect rear oxygen sensor. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.121 © Copyright...
  • Page 232 Heat Shield Clamps: 26 in-lbs (3 N·m) 6. Start engine and listen for exhaust leaks. 3. Tighten left and right muffler clamps specification. TORQUE Muffler Clamps: 40 ft-lbs (54 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 3.122 © Copyright...
  • Page 233 .........4.48 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual...
  • Page 234 ............. . .4.75 FUEL SYSTEM TROUBLESHOOTING, PART 4 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 235 Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 236 91 Octane Minimum Octane Relay Bypass PU-49466 Injector Resistance 11.4 - 12.6 Ohms Smartlink Module Kit PU-47471 USB to Serial Adapter PU-50621 Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris.service-solutions.com/ 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 237 2. Inspect condition of ventilation hose along its length and at both ends. 3. Be sure hoses are not restricted, kinked, or cracked. 4. Replace hose if worn or damaged. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 238 ITEM PART DESCRIPTION Fuel Tank Vent Line Evaporative Emissions Carbon Canister Purge Line (Canister to Purge Valve) Purge Valve Purge Line (Purge Valve to Throttle Body) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 239 Be sure fuel lines are routed properly and do not come in contact with sharp or hot objects, or anything that may cause wear or damage. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 240 Carefully inspect the connections of the failed circuit before doing any other troubleshooting steps. Wire terminals should be corrosion free and fully seated into the connectors. Connector should snap together and lock. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 241 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 ( ( 4 4 9 9 S S T T A A T T E E M M O O D D E E L L S S ) ) ITEM PART DESCRIPTION Fuel Line (Pump to Fuel Rail) Fuel Vent Line, Upper (from tank) Fuel Vent Line, Lower (to atmosphere) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 242 Fuel Vent Line, Lower (from canister) Purge Valve Fuel Vent Line, Lower (to canister) Fuel Vent Line, Upper (to engine) Fuel Vent Line, Upper (from tank) Fuel Line (Pump to Fuel Rail) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.10 © Copyright...
  • Page 243 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M 2017–2020 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.11 © Copyright...
  • Page 244 Fastener, Fuel Tank — M8 x 1.25 x 35 (QTY.2) 18 ft-lbs (24 N·m) 24 in-lbs (3 N·m) (2017–2021) Nut, Fuel Pump — M5 x 0.8 (QTY.10) 44 in-lbs (5 N·m) (2022+) Fuel Pump Access Panel — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.12 © Copyright...
  • Page 245 44 in-lbs (5 N·m) (2022+) Fuel Pump Access Panel – Seal, Access Panel – Fuel Pump – Fastener, Fuel Tank — M8 x 1.25 x 35 (QTY.2) 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.13 © Copyright...
  • Page 246 Cover, Airbox 88 in-lbs (10 N·m) Fastener, Air Filter Element — M5 x 0.8 x 10 (QTY.3) Retainer Plate, Air Filter 62 in-lbs (7 N·m) Gasket, Airbox Cover 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.14 © Copyright...
  • Page 247 CHT (Cylinder Head Temperature) Sensor — Located on the rear face of the 71 in-lbs (8 N·m) front cylinder head Fuel Injectors — Located at the cylinder head intake ports — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.15 © Copyright...
  • Page 248 Ignition coil — Located behind the horn assembly on the RH side of the engine 88 in-lbs (10 N·m) TMAP — (Temperature / Manifold Absolute Pressure) Sensor — Located on the 20 in-lbs (2 N·m) back side of the intake manifold 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.16 © Copyright...
  • Page 249 7. Rotate the air box mounting flange up as shown and remove the intake manifold from the engine. 8. INSTALLATION is performed by reversing the removal procedure. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.17 © Copyright...
  • Page 250 (located on pump) *Fuel pump malfunction (Pump should run for about 2 seconds the instant that the key switch and Engine Stop switch are turned ON. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.18 © Copyright...
  • Page 251 5. Wrap a clean shop towel around fuel line fitting and squeeze both release buttons. CAUTION Do not use anything other than fingers to remove the quick connection. The use of tools can damage the connection. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.19 © Copyright...
  • Page 252 3. Depressurize the fuel system. See Fuel System Depressurization page 8. Remove console cover fasteners and the plastic dart 4. Disconnect the vent line from the fuel tank. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.20 © Copyright...
  • Page 253 14. Lift the rear of the fuel tank and slide rearward to release from the front isolators. 15. Lift the tank off of the motorcycle and store safely. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.21 © Copyright...
  • Page 254 3. Disconnect the fuel tank vent line by sliding the connection. rubber elbow off of the fitting. 5. Remove fuel pump access panel nuts in an alternating or “star” pattern. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.22 © Copyright...
  • Page 255 1. Refer to Maintenance chapter for tank vent tab is released, gently pull the fuel pump electrical inspection and hose routing information. See Fuel connector to remove. Tank Vent Inspection (49 State) page 4.5. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.23 © Copyright...
  • Page 256 4. Verify that the float arm moves freely through it’s full range of motion. 5. Press a new sealing gasket into the bottom of the fuel pump access panel. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.24 © Copyright...
  • Page 257 "click" when pressing into place. Pull gently on quick connector once seated to ensure a proper connection has been made. 9. Install the console cover. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.25 © Copyright...
  • Page 258 FUEL DELIVERY / EFI 10. Prime the fuel system, check for leaks, and verify fuel pump operation. See Priming The Fuel System page 4.32 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.26 © Copyright...
  • Page 259 5. Install the console cover and torque fasteners to specification. TORQUE Console Cover Fasteners: 88 in-lbs (10 N·m) 6. Slide tank forward until fully seated on forward isolators. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.27 © Copyright...
  • Page 260 13. Prime the fuel system and verify fuel pump operation. See Priming The Fuel System page 4.32 9. Install the outer isolators and washers onto the rear tank mount. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.28 © Copyright...
  • Page 261 (terminals A &C) and compare to the table. LEVEL SENSOR ARM APPROXIMATE POSITION RESISTANCE LIMITS Full (Top of Range) 97–103 Ω Empty (Bottom of 445–455 Ω Range) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.29 © Copyright...
  • Page 262 8. When a CPS signal is received by the ECM (engine is cranking or running) the ECM maintains the ground on Pin 42 (Gray wire), keeping the pump powered. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.30 © Copyright...
  • Page 263 4. Insert one meter lead in pin socket (4) and other meter lead in pin socket (7) of relay block. 5. Read fuel pump current draw on meter and compare to specification. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.31 © Copyright...
  • Page 264 Fuel level in tank must be high enough to submerge pickup screen on fuel pump. 10. Once system is pressurized, carefully check all fuel connections, joints and lines for leaks. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.32 © Copyright...
  • Page 265 AFR. The locations of sensors and other EFI system related components are outlined in this chapter. See Sensors — Powertrain Management page 4.15. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.33 © Copyright...
  • Page 266 RH WARMER THERMISTOR NOT USED YE/VT REAR BRAKE SWT OUTPUT NOT USED OG/WH TIPOVER SENSOR DB/OG CLUTCH SWT OUTPUT OG/BN MAP SENSOR OUTPUT NOT USED VT/RD TPS 2 SIGNAL 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.34 © Copyright...
  • Page 267 ETC MOTOR (-) BK/WH ECM GROUND NOT USED BK/WH ECM GROUND REAR COIL SIGNAL VT/PK ENG RELAY PWR OUTPUT NOT USED VT-PK ENG RELAY PWR OUTPUT FRONT COIL SIGNAL 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.35 © Copyright...
  • Page 268 Manifold Absolute Pressure Signal Out of Range P0106 Sensor Abnormal Rate of Change P0109 Pneumatic Fault P1106 Voltage Too High P0113 Intake Air Temperature Sensor Voltage Too Low P0112 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.36 © Copyright...
  • Page 269 Cruise Control Set/Decel Switch Switch Stuck P1591 Cruise Control Resume/Accel Switch Stuck P1592 Switch ECU Memory EEPROM Read / Write Failure P1602 Circuit Fault P0336 Crankshaft Position Sensor Plausibility Fault P0335 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.37 © Copyright...
  • Page 270 Driver Circuit Open/Grounded P1714 Left Turn Indicator Driver 2367 Driver Circuit Short to B+ P1715 Circuit Driver Circuit Grounded P1716 Right Turn Indicator Driver Driver Circuit Open/Grounded P1710 2369 Circuit 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.38 © Copyright...
  • Page 271 Signal Out of Range (Not Plausible) P0221 Abnormal Rate of Change P0220 Calibration / Adaption Failure P1220 Condition Exists (engine disabled due to extended 520267 Kickstand Switch P181C kickstand) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.39 © Copyright...
  • Page 272 Motor Lock C0020 520260 ABS Motor Off Stick C1020 On Stick C1021 ABS Fail Safe Relay On/Off Stick C1034 520261 Drop C1038 ABS Source Voltage 520262 Raise C1039 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.40 © Copyright...
  • Page 273 Right Fog Lamp 520292 Grounded Circuit C1079 Open Circuit / Short to B+ C122A 520293 Horn Grounded Circuit C122B Open Circuit / Short to B+ C1222 520294 Windshield Motor Driver 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.41 © Copyright...
  • Page 274 Operator Switch Status (pOSS1) Abnormal Update Rate P1063 520329 Out of Calibration P1064 520330 Immobilizer Abnormal Update Rate P106A Voltage Too High P1327 520331 Knock Sensor Positive Line 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.42 © Copyright...
  • Page 275 U0405 524079 Cruise Control Input Message Counter not incremented U1405 524080 Counter Open Circuit P1075 Secondary Air Control Valve 524083 Shorted to Battery P1076 Shorted to Ground P1077 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.43 © Copyright...
  • Page 276 These may include the sensor connector, the ECM connector, and any wiring between the two, such as jumper harnesses where applicable. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.44 © Copyright...
  • Page 277 6. Install the upper and lower side covers. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.45 © Copyright...
  • Page 278 3. Remove the four fasteners securing the ECM to the battery box. 4. Reverse the removal procedure to install. 5. Torque ECM fasteners to specification. TORQUE ECM Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.46 © Copyright...
  • Page 279 The TMAP sensor is a non-serviceable item. If it is TMAP Sensor Fastener: faulty, it must be replaced 44 in-lbs (5 N·m) IMPORTANT This sensor should only be tested using Digital Wrench Diagnostic Software. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.47 © Copyright...
  • Page 280 6. If Step 5 continuity is good, measure the resistance through the sensor and compare to specification. METER TEST SPECIFICATIONS (±10%) COMPONENT SETTING CONNECTIONS CYLINDER HEAD 30.5 K Ohms +/- 13% @ 25 C (77 OHMS Pin #8 to #15 TEMPERATURE SENSOR 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.48 © Copyright...
  • Page 281 For models with a passenger seat, remove passenger seat fastener. 3. Depressurize the fuel system. See Fuel System Depressurization page 4.19 4. Disconnect the vent / EVAP line from the fuel tank. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.49 © Copyright...
  • Page 282 CAUTION Always wear eye protection NOTICE Cleaning the area with compressed air prevents sand, grit, and dirt from entering the intake runner as the injector is removed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.50 © Copyright...
  • Page 283 10. Remove the upper two fasteners securing the baffle plate to the intake. 13. Remove four throttle body fasteners and remove throttle body. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.51 © Copyright...
  • Page 284 16. Wrap a clean shop towel around fuel line fitting. NOTICE Listen for an audible “click” to confirm the Fuel Line Plug Tool is fully engaged. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.52 © Copyright...
  • Page 285 When removing fuel rail from injectors, wrap a rag around both ends of the fuel rail to collect fuel. 20. Leave electrical connector in place, remove fuel injectors from intake. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.53 © Copyright...
  • Page 286 Verify that the new top and bottom o-rings are installed in the correct position. IMPORTANT Verify that both of the new o-rings have been lubricated and installed correctly onto the injectors. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.54 © Copyright...
  • Page 287 Verify that the new top and bottom o-rings are installed in the correct position. IMPORTANT Verify that both of the new o-rings have been lubricated and installed correctly onto the injectors. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.55 © Copyright...
  • Page 288 Use care not to fold or displace upper o-ring from seating surface. 5. Install fuel rail fasteners into the intake manifold until finger tight. NOTICE For ease of installation, install the front cylinder fuel rail fastener first. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.56 © Copyright...
  • Page 289 The use of tools can damage the connection. NOTICE Use a rag to contain the small amount of fuel that may drain from the fuel line after the special tool is removed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.57 © Copyright...
  • Page 290 Use a small amount of lubricant around the outside of the breather hose when installing to the air box housing. NOTICE Make sure that the harness seal is fully seated in the air box cutout. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.58 © Copyright...
  • Page 291 16. Install the upper two fasteners securing the baffle plate to the intake. Torque fasteners to specification. TORQUE Air Filter Fasteners: 62 in-lbs (7 N·m) TORQUE Upper Intake Fasteners: 9 in-lbs (1 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.59 © Copyright...
  • Page 292 24. Connect the motorcycle to Digital Wrench. Verify no fail codes and no MIL lights are present. Field Test the motorcycle to verify proper operation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.60 © Copyright...
  • Page 293 FUEL DELIVERY / EFI 25. Install the upper side covers. 26. Install Trunk (if equipped). See Trunk Installation, Roadmaster page 7.37 27. Install Saddlebags (if equipped). 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.61 © Copyright...
  • Page 294 Crankshaft Position Sensor: 1050 Ohms @ 20°C (68° 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.62 © Copyright...
  • Page 295 4. Slide connector off of retaining clip. Do not remove crankshaft position sensor from vehicle. disconnect connector. 5. Cut zip tie retaining starter cable. 8. Clean headpipe if there is excessive residue. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.63 © Copyright...
  • Page 296 Torque fastener to specification. 4. Replace zip tie retaining starter cable. TORQUE Crankshaft Position Sensor Retaining Fastener: 5. Slide voltage regulator connector onto retaining 88 in-lbs (10 N·m) clip. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.64 © Copyright...
  • Page 297 TORQUE Voltage Regulator Fasteners: 88 in-lbs (10 N·m) 7. Reconnect crankshaft position sensor connector. 8. Replace zip tie retaining crankshaft position sensor connector to wiring harness. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.65 © Copyright...
  • Page 298 Sensors that have been over-tightened or under-tightened may set a diagnostic trouble code and cause the MIL to illuminate. Use a properly calibrated torque wrench during installation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.66 © Copyright...
  • Page 299 520331 Detonation face of the P1328 Positive Line: Voltage too low “Knock” Sensor front cylinder P132A Negative Line: Voltage too high 520332 P132B Negative Line: Voltage too low 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.67 © Copyright...
  • Page 300 9. Using a multi meter with a low voltage AC frequency scale, connect the meter leads to the connector pins of the detonation sensor. 10. Allow the signal to stabilize to 0 Hz. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.68 © Copyright...
  • Page 301 IMPORTANT Once the systems is repaired and functioning normally, connect to Digital Wrench to clear active and historic codes. Retest to verify the condition is no longer present. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.69 © Copyright...
  • Page 302 3. Toggle to turn cylinder deactivation on or off. Press and hold hand right-hand trigger to save settings. • CYLdeAC ON: rear cylinder can deactivate • CYLdeAC OFF: rear cylinder cannot deactivate 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.70 © Copyright...
  • Page 303 Green CAN Low wire at the specified module connectors below (while unplugged): • VCM = 60Ω • ECM = 120Ω • Speedometer = 120Ω • ABS Module = 60Ω • Diagnostic Connector = 60Ω 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.71 © Copyright...
  • Page 304 Battery Voltage Battery Unplug connections - inspect Loose, corroded, or ECM and wiring harness Inspect cylinder head & valves wet connector(s) Valve springs, valve, Valve train problems head 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.72 © Copyright...
  • Page 305 ECM or wiring harness Seal intake or exhaust leaks Clean air inlet tract and throttle Inlet and Exhaust body Intake tract / Throttle body 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.73 © Copyright...
  • Page 306 Fuel pressure regulator Test / Replace Air temperature sensor Test / Replace TMAP sensor Test / Replace Plugged vent hose Clear Low battery voltage ECM Test batt./Charging system 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.74 © Copyright...
  • Page 307 PIN, Calibration I.D. Attach Battery Charger number, or calibration During Re-Flash, and Re- authorization code Charge Battery When Re- Flash Is Completed Enter Authorization Code Sent With Accessory Kit 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.75 © Copyright...
  • Page 308 FUEL DELIVERY / EFI NOTES 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 4.76 © Copyright...
  • Page 309 ............5.31 CLUTCH PINION SHAFT INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 310 TROUBLESHOOTING, CLUTCH / PRIMARY / SHIFT ............5.61 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual...
  • Page 311 PF-52135 • Oil additives of any kind are not recommended by Crankshaft Rotation Socket PF-51239 Indian Motorcycle. Using oil additives or oil of the Engine Stand Adapter PF-51240 wrong viscosity can have a detrimental affect on clutch performance, operation, and service life.
  • Page 312 Coil Type, QTY 3 — (2021–2022) 82.5 lbf @ Installed Height Spring Coil Type, QTY 3 — (2023+) 74.4 lbf @ Installed Height Clutch Lever Free Play (Cable) .50-1.50 mm (.020-.060") 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 313 Cable Guide Fastener: 80 in-lbs (9 N·m) 7. Adjust cable free play. Push the rubber boot up to expose the lower cable end and inspect for damage or frayed wires. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 314 7. Tighten the lower cable guide fastener to specification. TORQUE Clutch Cable Jam Nut: 48 in-lbs (5 N·m) 2. Inspect the lower cable end for damage or frayed wires. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 315 7. Lubricate and attach lower end of cable to clutch arm on primary cover. 8. Adjust clutch lever free play See Clutch Level Free Play. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 316 Free Play page 5.9 or Clutch Lever Free Play out of lever. (2021+) page 5.9. 7. Disconnect the clutch cable from the wire guide 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 317 4. Hold cable and loosen the jam nut. 48 in-lbs (5 N·m) 5. Turn adjuster nut in or out until clutch free play is correct. 7. Slide adjuster boot back over adjuster assembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 318 1. Check all shift pedal and linkage fasteners to be sure they are tight. Torque fasteners to specification. See Shift Pedal Adjustment page 5.11. 2. Lubricate shift pedal pivot bushing and all pivots with all-purpose lubricant. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.10 © Copyright...
  • Page 319 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. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.11 © Copyright...
  • Page 320 Fastener, Primary Cover - M8 x 1.25 x 35 (QTY.7) 15 ft-lbs (20 N·m) Fastener, Primary Cover - M8 x 1.25 x 75 (QTY.7) 15 ft-lbs (20 N·m) Primary Cover Gasket, Primary Cover 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.12 © Copyright...
  • Page 321 Bearing, Shaft (Shift Shaft / Clutch Pinion Shaft) End Bearing, Pinion Shaft Pinion Shaft, Clutch Lever, Clutch Fastener, Clutch Lever - M6 x 1.0 x 25 (QTY.1) 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.13 © Copyright...
  • Page 322 88 in-lbs (10 N·m) Locking Plate Compensator Spring Retainer Compensator Spring Cup Compensator Spring Compensator Slider Compensator Gear Washer Compensator Sleeve Stator Rotor Stator Fastener (QTY.3) 88 in-lbs (10 N·m) Stator 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.14 © Copyright...
  • Page 323 83 ft-lbs (112 N·m) Locking Plate Fasteners (QTY.2) 88 in-lbs (10 N·m) Locking Plate Adapter Primary Drive Gear Stator Rotor Stator Fasteners (QTY.3) 88 in-lbs (10 N·m) Stator 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.15 © Copyright...
  • Page 324 Plate, Friction C (QTY.5) Plate, Seperator (QTY.4) Plate, Friction B (QTY.1) Seat, Judder Spring Spring, Judder Clutch Hub Thrust Washer Clutch Basket Gear Bearing, Needle Collar, Clutch Bearing 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.16 © Copyright...
  • Page 325 88 in-lbs (10 N·m) Cold Start Cover Fastener — Cold Start Cover Cold Start Cover O-ring — Primary Cover Fastener 15 ft-lbs (20 N·m) Primary Cover — Primary Cover Gasket — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.17 © Copyright...
  • Page 326 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 TORQUE ITEM DESCRIPTION — Lift Rack Bearing M7 — 62 in-lbs (7 N·m) Pinion Shaft Retention Fastener Bearing M12 — — Shaft Seal — Pinion Shaft 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.18 © Copyright...
  • Page 327 PART DESCRIPTION Primary Drive Gear Fastener (QTY.1) 50 ft-lbs (68 N·m) + 38 Degrees Adapter Primary Drive Gear Stator Rotor Stator Fasteners (QTY.3) 88 in-lbs (10 N·m) Stator 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.19 © Copyright...
  • Page 328 Washer 62 in-lbs (7 Outer Basket Stopper Plate — N·m) Assembly Fastener Stopper Plate — Needle Bearing — Clutch Spring Clutch Adapter — — Clutch Seat — Spring 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.20 © Copyright...
  • Page 329 Cold Start Cover O-ring — 88 in-lbs (10 N·m) Cable Mount Bracket Fastener — Cable Mount Bracket Primary Cover Fastener 15 ft-lbs (20 N·m) Primary Cover — Primary Cover Gasket — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.21 © Copyright...
  • Page 330 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 TORQUE ITEM DESCRIPTION Bearing M7 — 62 in-lbs (7 N·m) Pinion Shaft Retention Fastener Bearing M12 — — Shaft Seal — Pinion Shaft 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.22 © Copyright...
  • Page 331 TORQUE (IF APPLICABLE) ITEM PART DESCRIPTION Primary Drive Gear Fastener (QTY.1) 83 ft-lbs (112 N·m) Adapter Primary Drive Gear Stator Rotor Stator Fasteners (QTY.3) 88 in-lbs (10 N·m) Stator 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.23 © Copyright...
  • Page 332 62 in-lbs (7 Stopper Plate — Washer N·m) Fastener Outer Basket Stopper Plate — — Assembly Clutch Spring — Needle Bearing — Clutch Seat — Clutch Spacer — Spring 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.24 © Copyright...
  • Page 333 5. Release the clutch cable end from the clutch arm. 6. Remove the external snap ring from the clutch cable and withdraw from the mounting boss. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.25 © Copyright...
  • Page 334 2. Install washer and E-clip 3. Slide the pinion shaft out through the bottom of the primary cover. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.26 © Copyright...
  • Page 335 IMPORTANT The clutch shaft must engage the clutch rack so that the clutch arm is angled approximately 60° off of the primary cover mating surface when fully seated. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.27 © Copyright...
  • Page 336 CLUTCH / PRIMARY / SHIFT 6. Torque the primary cover fasteners to specification following the torque sequence. TORQUE Primary Cover Fasteners: 15 ft-lbs (20 N·m) Primary Cover Torque Sequence 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.28 © Copyright...
  • Page 337 Primary Cover Installation (2017-2020) page 5.27. 9. After installing primary cover, be sure shift shaft returns freely to the centered position after rotating up or down. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.29 © Copyright...
  • Page 338 6. Remove shift lever fastener 7. Slide shift level off its splines. 8. Remove primary cover fasteners 3. Remove pinion shaft retention fastener 9. Remove primary cover and gasket. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.30 © Copyright...
  • Page 339 2. Secure pinion shaft with its fastener TORQUE Pinion Shaft Retention Fastener: 62 in-lbs (7 N·m) 3. Install lift rack and make sure marks previously made line back up. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.31 © Copyright...
  • Page 340 6. Apply a small amount of grease to lip seal and apply engine oil to outside of seal. 7. Drive seal into place with a seal driver slightly smaller than O.D. of seal. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.32 © Copyright...
  • Page 341 1. Apply engine oil to the bearings. 2. Temporarily install pinion shaft into primary cover. 3. Turn shaft by hand. Replace bearings that feel rough, notched, or loose. 9. Remove primary cover and gasket. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.33 © Copyright...
  • Page 342 6. Install clutch cable to pinion shaft 2. Install new inner primary cover gasket. 7. Install clutch cable retention bracket by removing its fastener TORQUE Cable Mount Bracket Fastener: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.34 © Copyright...
  • Page 343 6. Rotate the detent lever so the spring is relaxed. Using a 10 mm socket, remove the fastener securing the detent lever to the engine case and remove lever. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.35 © Copyright...
  • Page 344 10. Inspect coil spring for tension. The spring should apply enough tension on the shift ratchet mechanism to keep it engaged with the shift star. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.36 © Copyright...
  • Page 345 5. Install the primary cover. See Primary Cover roller fastener . Install detent roller arm with Installation (2017-2020) page 5.27. spring. Torque fastener to specification. TORQUE Detent Roller Fastener: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.37 © Copyright...
  • Page 346 Failure to correctly install the clutch rack will cause improper operation. 2021 MODELS CORRECT Snap ring is facing outward. INCORRECT Snap ring is facing inward. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.38 © Copyright...
  • Page 347 6. A new stake nut must be installed upon assembly. tension has relaxed. Remove fasteners and springs. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.39 © Copyright...
  • Page 348 Seperator Plate A (TOP) Seperator Plate B (BOTTOM) Spring, Judder Clutch Seat, Judder Clutch 7. Remove Friction Plate A , Seperator Plate A Friction Plate B and Seperator Plate A 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.40 © Copyright...
  • Page 349 5. Rotate hub bearing. Check for smooth rotation. Inner race should have no detectable radial movement. 6. Lubricate bearing with engine oil. Clutch Hub 7. Inspect spline teeth for wear, cracks or damage. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.41 © Copyright...
  • Page 350 15. Inspect lifter bearing visually for any signs or wear or discoloration. Rotate bearing inner race with your finger and check for smooth movement and no play. 16. Replace clutch rack assembly if necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.42 © Copyright...
  • Page 351 5. Place an oiled Separator Plate B into clutch basket. NOTICE If friction plates are new, soak them in clean engine oil for a few minutes before installing. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.43 © Copyright...
  • Page 352 5. Install clutch rack assembly. See Clutch Rack, Removal / Installation page 5.38. 6. Install primary cover. Primary Cover Installation (2017-2020) page 5.27. 7. Check engine oil and fill to proper level. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.44 © Copyright...
  • Page 353 2. Using an internal snap ring pliers, remove snap ring and clutch rack CORRECT Snap ring is facing outward. INCORRECT Snap ring is facing inward. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.45 © Copyright...
  • Page 354 , Belleville washer , and flat washer . Discard the stake nut. IMPORTANT A new stake nut must be installed upon assembly. 5. Remove clutch assembly from clutch shaft. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.46 © Copyright...
  • Page 355 8. Remove the friction and separator plates. Reference Clutch page 5.20. 3. Alternately loosen the pressure plate fasteners until spring tension has released. 4. Remove stopper plate 5. Remove clutch springs and retaining rings 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.47 © Copyright...
  • Page 356 15. Inspect lifter bearing visually for any signs or wear or discoloration. Rotate bearing inner race with your finger and check for smooth movement and no play. 16. Replace clutch rack assembly if necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.48 © Copyright...
  • Page 357 Stopper Plate Fastener: NOTICE 62 in-lbs (7 N·m) Use care while installing to prevent damage to friction plates and separator plates 3. Apply engine oil to hub bearing 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.49 © Copyright...
  • Page 358 125 ft-lbs (170 N·m) 3. Stake the nut. 4. Install clutch rack. See Clutch Rack, Removal / Installation page 5.45. 5. Install primary cover. See Primary Cover Installation page 5.27. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.50 © Copyright...
  • Page 359 A new stake nut must be installed upon assembly. 5. Remove clutch assembly from input shaft. IMPORTANT Make sure to retrieve the clutch spacer after removing the clutch. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.51 © Copyright...
  • Page 360 8. Remove thrust washer 3. Alternately loosen the pressure plate fasteners until spring tension has released. 4. Remove stopper plate 5. Remove clutch springs and retaining rings 6. Remove outer hub 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.52 © Copyright...
  • Page 361 12. Measure thickness of friction plates in several places. Thickness should be the same at each place. Replace plates that fail inspection. Friction Plate Thickness (Minimum): .126 in (3.2 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.53 © Copyright...
  • Page 362 2. Install pressure plate NOTICE Use care while installing to prevent damage to friction plates and separator plates 3. Apply engine oil to hub bearing 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.54 © Copyright...
  • Page 363 5. Install primary cover. See Primary Cover fasteners Installation page 5.27. IMPORTANT Alternately tighten the clutch spring fasteners in a star pattern until fully seated. TORQUE Stopper Plate Fastener: 62 in-lbs (7 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.55 © Copyright...
  • Page 364 2. Measure free length of torque compensator spring stack. 4. Remove the spring pack , upper torque compensator ramp and torque compensator drive gear from the crankshaft. Compensator Spring Stack Height: 1.437–1.476 in (36.5–37.5 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.56 © Copyright...
  • Page 365 10. Fill engine oil to proper level. 4. Load the three Belleville spring packs into the spring retainer cup and fit the drive plate and fastener into the spring retainer cup. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.57 © Copyright...
  • Page 366 TORQUE Primary Drive Gear Fastener: 83 ft-lbs (112 N·m) 7. Install primary cover. See Primary Cover Installation (2017-2020) page 5.27. 8. Fill engine oil to proper level. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.58 © Copyright...
  • Page 367 TORQUE Primary Drive Gear Fastener (2021-2022) : 50 ft-lbs (68 N·m) + 38 Degrees TORQUE Primary Drive Gear Fastener (2023+) : 83 ft-lbs (112 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.59 © Copyright...
  • Page 368 6. Check engine oil and add as necessary. See threaded holes on flywheel Engine Oil Level Check page 2.22 6. Grasp the two fasteners and lift the flywheel off of the stator. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.60 © Copyright...
  • Page 369 Pressure plate worn, Pressure plate Replace warped or distorted Clutch plate(s) worn, Driven plates and / or Replace warped or distorted drive plates Replace Weak clutch springs Clutch springs 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.61 © Copyright...
  • Page 370 Adjust or replace Clutch plates bind or drag Clutch plates / hubs Adjust / repair / replace when clutch is disengaged Gear/bearing wear/damage Transmission components Inspect / replace 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 5.62 © Copyright...
  • Page 371 ............... .6.41 CRANKSHAFT INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 372 TROUBLESHOOTING ..................6.47 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual...
  • Page 373 Clutch Shaft Holding Tool PF-51232 Crankshaft Locking Pin PF-52135 Crankshaft Rotation Socket PF-51239 Drive Sprocket Seal Installer PF-51243 Engine Stand Adapter PF-51240 Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris.service-solutions.com/ 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 374 Crankshaft End Play (2019 0.080–0.450 mm (0.003–0.018”) ONLY) Balance Shaft Journal O.D., Left (Primary 24.980 - 24.992 mm / Side) / Journal O.D., Right 24.969 - 24.979 mm (Cam Side) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 375 Gear Ratio: 2nd Gear 1.86: 1 Gear Ratio: 3rd Gear 1.38: 1 Gear Ratio: 4th Gear 1.10: 1 Gear Ratio: 5th Gear 0.94: 1 Gear Ratio: 6th Gear (Overdrive) 0.81: 1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 376 Bearing, Transmission Input Shaft Serviceable Crankcase, Right-Hand Crankcase, Left-Hand Fastener, Piston Cooling Jet — M5 x 0.8 x 10 (QTY.2) Bearing, Shift Shaft 62 in-lbs (7 N·m) Bearing, Transmission Output Shaft 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 377 Reference Connecting Rod Installation page 6.38 Bearing, Crankshaft Main (Left-Hand) — Non- Bearing Caps, Connecting Rod Serviceable Bearings, Connecting Rod (big end) Wrist Pin, Piston Circlip, Wrist Pin Piston 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 378 Items 1, 3, 4, 11, 13 & 15 use Long fasteners. All other items use Short fasteners. Torque case fasteners to specification following the torque sequence. TORQUE Crankcase Fasteners: 22 ft-lbs (30 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 379 Bearing, 6th Gear Slider, Gear Dog Gear Dog, 5th & 6th Gear, 6th — Drive Gear, 4th — Drive Gear, 2nd — Drive Snap Ring (not used on 2019-2020 engines) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 380 Gear Dog Gear, 3rd — Driven Bearing Gear, 5th — Driven Gear, 6th — Driven Gear, 4th — Driven Gear, 2nd — Driven Bearing, 2nd Gear Output Shaft, Transmission 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.10 © Copyright...
  • Page 381 Bearing, 6th Gear Slider, Gear Dog Gear Dog, 5th & 6th Gear, 6th — Drive Gear, 4th — Drive Gear, 2nd — Drive Snap Ring (not used on 2019-2020 engines) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.11 © Copyright...
  • Page 382 Gear Dog Gear, 3rd — Driven Bearing Gear, 5th — Driven Gear, 6th — Driven Gear, 4th — Driven Gear, 2nd — Driven Bearing, 2nd Gear Output Shaft, Transmission 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.12 © Copyright...
  • Page 383 Bearing, Shift Drum — Primary Side Gear Dog Shift Fork, 1st & 3rd Slider, Gear Dog Shift Fork, 2nd & 4th Shift Fork, 5th & 6th Shift Drum Shift Rail 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.13 © Copyright...
  • Page 384 Fastener, Bearing Retainer Plate — M5 x 0.8 x 12 (QTY.3) Washer 65 in-lbs (7.3 N·m) Snap-Ring, Balance Shaft Split Gear Bearings, Balance Shaft Gear, Balance Shaft (Outer) — Non-Serviceable Balance Shaft Springs, Pre-Load — Non-Serviceable 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.14 © Copyright...
  • Page 385 TRANSMISSION / CRANKSHAFT G G E E A A R R T T R R A A I I N N 1st Gear 2nd Gear 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.15 © Copyright...
  • Page 386 TRANSMISSION / CRANKSHAFT 3rd Gear 4th Gear 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.16 © Copyright...
  • Page 387 TRANSMISSION / CRANKSHAFT 5th Gear 6th Gear 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.17 © Copyright...
  • Page 388 6. Rotate right and left balance shaft bearings by hand while observing bearing rotation. Bearings should run smooth and quiet and shaft should be a snug fit in bearing. 7. Visually inspect bearings for damage. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.18 © Copyright...
  • Page 389 6. Place the woodruff key into the end of the balance shaft. 7. Place a pin punch, or other suitable tool, through hole and preload split gear teeth so they are aligned. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.19 © Copyright...
  • Page 390 TRANSMISSION / CRANKSHAFT 12. Install the spacer onto the crankshaft. 13. Install the inner cam cover. See Inner Cam Chain Cover Installation page 6.21. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.20 © Copyright...
  • Page 391 4. Tighten inner cam chain cover fasteners following the specified torque sequence. TORQUE Inner Cam Chain Cover Fasteners: 15 ft-lbs (20 N·m) 5. Install camshaft carrier assembly. Camshaft Carrier Installation page 3.58. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.21 © Copyright...
  • Page 392 One-Way Clutch Hub I.D. (Balance Shaft Gear): 68.38 mm ±.013 mm One-Way Clutch Hub O.D. (Flywheel): 51.71 mm ±.007 mm 5. Replace gear if wear or damage is evident. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.22 © Copyright...
  • Page 393 6. Install inner cam chain cover. See Inner Cam bore followed by the limiter clutch assembly Chain Cover Installation page 6.21. 7. Check engine oil and fill to proper level. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.23 © Copyright...
  • Page 394 Position Switch Replacement page 10.123. NOTICE If applicable, collect the two switch contact pins and springs from the end of the shift drum so they do not get lost. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.24 © Copyright...
  • Page 395 1– 2 threads are exposed on the other side. 25. Install M6 fasteners and M12 fastener into threaded spacers and torque to specification. TORQUE Main Plate Mounting Fasteners (All): 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.25 © Copyright...
  • Page 396 28. Alternately turn the case splitting tool in until resistance is felt, then work around the upper case with a mallet until the cases are completely apart. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.26 © Copyright...
  • Page 397 Rotate rails and forks away from the shift drum. 4. Lift the shift drum out of the bearing. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.27 © Copyright...
  • Page 398 Bushing, 6th Gear — O.D. 38.955 — 38.980 mm Input Shaft, 2nd Gear Journal 27.987 — 28.0 mm (Press Fit) Gear, 2nd — I.D. (Press Fit) 27.884 — 27.909 mm 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.28 © Copyright...
  • Page 399 37.010 — 37.026 mm Bushing, 1st Gear — I.D. 28.015 — 28.040 mm Bushing, 1st Gear — O.D. 36.965 — 36.990 mm Output Shaft, 1st Gear Journal 27.987 — 28.0 mm 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.29 © Copyright...
  • Page 400 12. Inspect right side shift drum bearing. 13. Temporarily install shift drum in right hand case bearing and inspect fit. Spin drum to check for smooth bearing operation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.30 © Copyright...
  • Page 401 Crankshaft Inspection page 6.37. NOTICE Connecting rod bearings and main bearings are easily damaged. Be careful not to cause damage to these parts when servicing items within the crankcase. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.31 © Copyright...
  • Page 402 If rod caps are installed incorrectly and tightened, the precision mating surfaces will be damaged. Replace the connecting rod assembly if mating surfaces are damaged. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.32 © Copyright...
  • Page 403 See Service Specifications page 6.4. 5. Visually inspect connecting rod upper and lower ends for scoring, damage, or excessive wear. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.33 © Copyright...
  • Page 404 5. If service limits are exceeded, install new rod bearings and recheck oil clearance. 6. If service limits are still exceeded, determine if crankshaft or connecting rods need to be replaced. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.34 © Copyright...
  • Page 405 RED Paint Mark RED (“R” Stamp) Orange ( - 159 ) RED Paint Mark WHITE (“W” Stamp Blue ( - 027 ) 1.482 — 1.488 mm or not marked) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.35 © Copyright...
  • Page 406 RED Paint Mark RED (“R” Stamp) Orange ( - 159 ) RED Paint Mark WHITE (“W” Stamp Blue ( - 027 ) 1.482 — 1.488 mm or not marked) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.36 © Copyright...
  • Page 407 Be sure to compare measurements to specifications for the proper color (or non- marked) connecting rod or crankshaft. Measure O. D. of crankshaft rod journal in four places and compare to specifications. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.37 © Copyright...
  • Page 408 TORQUE Connecting Rod Fasteners: 22 ft-lbs (30 N·m) + 90° TORQUE I-18-06 Connecting Rod Fasteners: 46 ft-lbs (62 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.38 © Copyright...
  • Page 409 2. Inspect alignment of bearing lubrication hole in left crankcase half and in right case half. Holes must be aligned with their respective oil passage in crankcase. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.39 © Copyright...
  • Page 410 3. Install bearing retainers as required and torque to specification. specification. 4. Install scavenge filter screen assembly. See Lubrication System Assembly View page 3.30. 5. Install new oil passage o-ring 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.40 © Copyright...
  • Page 411 4. Place crankshaft into left crankcase half. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.41 © Copyright...
  • Page 412 , shift forks 12. Assemble crankcase. See Crankcase Assembly and rails into the left crankcase. Make certain page 6.43. both shafts are fully seated and rotate freely. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.42 © Copyright...
  • Page 413 6. Install case assembly adapter , nut washer onto main plate. 4. Remove the drive sprocket spacer and o-ring from the right-hand crankcase prior to installation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.43 © Copyright...
  • Page 414 Installation page 8.77. 18. Install the balance shaft driven gear and drive gear. See Balance Shaft Installation page 6.19. 19. Install the starter drive. See Starter Drive Installation page 6.23. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.44 © Copyright...
  • Page 415 29. Install cylinders. See Cylinder Installation page 3.109. 30. Install cylinder heads. See Cylinder Head Installation page 3.94. 31. Install engine in frame. See Engine Installation page 3.21. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.45 © Copyright...
  • Page 416 3. Torque stake nut to specification. 4. Stake the stake nut using round side of punch. Do not crack or tear staking lip. Do not use a sharp chisel to stake the nut. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.46 © Copyright...
  • Page 417 Refer to Engine / Cooling Sprocket / Exhaust chapter PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Hard to Shift Improper Clutch Clutch Refer to Clutch / Primary Operation / Shift chapter 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.47 © Copyright...
  • Page 418 Replace shift forks Shift Forks Bent or Distorted Shift Shift Fork Rails Replace shift fork rails Fork Rails Worn Engagement Dogs Transmission Gears Replace necessary parts on Transmission Gears 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 6.48 © Copyright...
  • Page 419 ..............7.36 TRUNK REMOVAL, ROADMASTER 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 420 ............7.68 RIDE COMMAND SYSTEM INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 421 S S P P E E C C I I A A L L T T O O O O L L S S PART NUMBER TOOL DESCRIPTION PV-49955 Body Panel Tool Kit Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris.service-solutions.com/ 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 422 Strut Cover Fastener Caliper Cover Acorn Nut 18 ft-lbs (24 N·m) 18 ft-lbs (24 N·m) Rear Fender Upper Fastener Front Fender Fastener 88 in-lbs (10 N·m) 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 423 18 ft-lbs (24 N·m) 18 ft-lbs (24 N·m) Strut Cover Fastener Front Fender Fastener 18 ft-lbs (24 N·m) 18 ft-lbs (24 N·m) Rear Fender Upper Fastener 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 424 18 ft-lbs (24 N·m) Fastener — M12 x 1.75 x 120 (QTY.3) Fastener, Engine Bracket — M8 x 1.25 x 20 (QTY.2) 75 ft-lbs (102 N·m) 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 425 Fastener, Brake Pedal Pad — M6 x 1.0 x 15 (QTY.2) Retaining Pin, Pushrod 88 in-lbs (10 N·m) Shifter Toe Pedal Passenger Foot Peg Support Bracket 88 in-lbs (10 N·m) Passenger Foot Peg Floorboard Pan Floorboard Pad 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 426 Fastener, Right Hand Sprocket Cover — M6 x 1.0 x 15 (QTY.3) 40 (QTY.2) 88 in-lbs (10 N·m) 88 in-lbs (10 N·m) Side Cover, Right Hand Upper Side Cover, Left Hand Lower Rubber Isolator 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 427 Fastener, Passenger to Driver Seat - M x 88 in-lbs (10 N·m) 1.0 x 15 (QTY.4) (except Dark Horse) Washer (QTY.1) (except Dark Horse) – Washer (QTY.1) (except Dark Horse) – 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 428 18 ft-lbs (24 N·m) Fastener, Strap - M6 x 1.0 x 25 (QTY.2) 88 in-lbs (10 N·m) Fastener (QTY.4) 18 ft-lbs (24 N·m) Washer (QTY.1) – Washer (QTY.1) – 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.10 © Copyright...
  • Page 429 Fastener, Bracket - M6 x 1.0x12 (QTY.2) 35 in-lbs (4 N·m) Strap - Passenger Seat – Fastener, Strap - M6 x 1.0 x 25 (QTY.2) 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.11 © Copyright...
  • Page 430 Fastener, Trunk Back - M6 x 1.0 x 20 (QTY.2) 12 in-lbs (1 N·m) Luggage Rack Washer, Cup Washer, Upper Washer, Lower Fastener, Luggage Rack - M6 x 1.0 x 20 (QTY.4) 12 in-lbs (1 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.12 © Copyright...
  • Page 431 Fastener, Luggage Rack 84 in-lbs (9 N·m) Plate Latch, Hoop Latch, Hoop 35 in-lbs (4 N·m) Fastener, Bezel 12 in-lbs (1 N·m) Fastener, Taillight 12 in-lbs (1 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.13 © Copyright...
  • Page 432 A A N N T T E E N N N N A A A A S S S S E E M M B B L L Y Y V V I I E E W W Antenna Bracket Fastener Antenna 88 in-lbs (10 N·m) Antenna Fastener Antenna Cable 18 in-lbs (2 N·m) Antenna Cable Fastener Antenna Bracket 18 in-lbs (2 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.14 © Copyright...
  • Page 433 L L O O W W E E R R F F A A I I R R I I N N G G A A S S S S E E M M B B L L Y Y V V I I E E W W ( ( R R O O A A D D M M A A S S T T E E R R ) ) Fastener, Inner to Outer Fairing - (QTY.10) Fastener, Clamp - M6 x 1.0 x 16 - (QTY 6) 12 ft-lbs (16 N·m) 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.15 © Copyright...
  • Page 434 Fastener, Headlight Bracket — M6 x 1.0 x 40 (QTY.3) See Fairing Installation (Frame / Body Fastener, Fairing — NOTE: Fasteners differ in size chapter) Speaker Grill, Right-Hand — Speaker Grill, Left-Hand — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.16 © Copyright...
  • Page 435 See Fairing Installation (Frame / Body Fastener, Fairing — NOTE: Fasteners differ in size chapter) Speaker Grill, RH — Speaker Grill, LH — Fastener, Speaker 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.17 © Copyright...
  • Page 436 See Fairing Installation (Frame / Body Fastener, Fairing — NOTE: Fasteners differ in size chapter) Speaker Grill, RH — Speaker Grill, LH — Fastener, Speaker 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.18 © Copyright...
  • Page 437 45 in-lbs (5 N·m) Fastener, Latch Asm. - M6 x 1.0 x 20 (QTY.4) 65 in-lbs (7 N·m) Actuator, Lock (QTY.2) Seal, Saddlebag Lock (QTY.2) Lock Cylinder (QTY.2) Handle, Latch (QTY.2) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.19 © Copyright...
  • Page 438 65 in-lbs (7 N·m) Fastener, Saddlebag Wire Cover 15 in-lbs (2 N·m) Fastener, Saddlebag Wire Guide M6 1.0x15 (QTY.2) 18 ft-lbs (24 N·m) Grommet Limiter Hinge, Lid (QTY.4) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.20 © Copyright...
  • Page 439 12 in-lbs (1 N·m) Fastener - M6 x 1.0 x 16 (QTY.2) 35 in-lbs (4 N·m) Clip, Speed Nut (QTY.2) Cover, Rear Nacelle (QTY.1) Spacer, Nacelle Bezel (QTY.1) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.21 © Copyright...
  • Page 440 INSTALLATION is performed by reversing the re- moval procedure. Using a mild soapy water solu- tion on the rubber grommets will make it easier to press the side covers into position. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.22 © Copyright...
  • Page 441 CAUTION Do not bend or kink flexible brake line during floorboard removal. Master cylinder assembly should be kept in an upright position and properly supported at all times. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.23 © Copyright...
  • Page 442 5. Remove the two fasteners securing the LH floorboard to the frame and remove floorboard assembly. TORQUE Shift Rod Fastener: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.24 © Copyright...
  • Page 443 35 ft-lbs (48 N·m) 4. Lower the master cylinder assembly onto the floorboard bracket and torque the jam nut specification. TORQUE Master Cylinder Jam Nut: 35 ft-lbs (48 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.25 © Copyright...
  • Page 444 3. Remove the passenger seat fastener 3. INSTALLATION is performed by reversing the removal procedure. 4. Torque passenger foot peg bracket fasteners specification. TORQUE Passenger Foot Peg Fasteners: 35 ft-lbs (48 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.26 © Copyright...
  • Page 445 NOTICE 18 ft-lbs (24 N·m) It may be necessary to lift the seat skirt to access the side fasteners on some models. 4. Remove the passenger seat fastener 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.27 © Copyright...
  • Page 446 9. Torque the seat fasteners to specification. TORQUE Seat Fasteners (All): 4. INSTALLATION is performed by reversing the 18 ft-lbs (24 N·m) removal procedure. TORQUE Seat Fasteners (All): 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.28 © Copyright...
  • Page 447 Upper Highway Bar Fasteners: 18 ft-lbs (24 N·m) Lower Highway Bar Fasteners: 35 ft-lbs (48 N·m) 3. Carefully maneuver the highway bar out from the frame / fender area. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.29 © Copyright...
  • Page 448 2. Remove fasteners from clamps securing the inner fairing assembly to the highway bars. 3. Remove the inner fairing assembly and associated clamps from the highway bars. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.30 © Copyright...
  • Page 449 2. Position the inner fairing assembly over the highway bar so the clamps line up with the fastener holes. 3. Install the upper and lower clamp fasteners finger tight. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.31 © Copyright...
  • Page 450 FRAME / BODY 8. Alternately tighten outer fairing fasteners to specified torque. TORQUE Inner to Outer Fairing Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.32 © Copyright...
  • Page 451 4. Remove the three fasteners from each side of Once fender has been removed from the the fender. motorcycle, make sure the fender is stored safely until it is reinstalled. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.33 © Copyright...
  • Page 452 TORQUE Front Fender Fasteners: 18 ft-lbs (24 N·m) 3. Route the fender light wire harness into the fairing / nacelle and reconnect. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.34 © Copyright...
  • Page 453 18 ft-lbs (24 N·m) until it is reinstalled. 3. Turn the handlebar all the way to the left and right to verify proper operation and freedom of movement. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.35 © Copyright...
  • Page 454 2. Disconnect the trunk harness multi-plug 3. Lift the trunk latches to unlock the trunk from the mount. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.36 © Copyright...
  • Page 455 5. If applicable, install the mounting fasteners into left and right locking levers. 6. Install saddlebags, if equipped. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.37 © Copyright...
  • Page 456 It will be necessary to replace the adhesive with a suitable alternative (e.g. double sided tape) when the bezel is reinstalled. 5. Remove the two fasteners from the lock actuator bracket and disconnect electrical connector. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.38 © Copyright...
  • Page 457 • Press bezel into place on the trunk bin with constant and even pressure and hold for 30 seconds. 5. Install trunk liner. 6. Operate lock and latch assembly to verify proper operation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.39 © Copyright...
  • Page 458 It will be necessary to replace the adhesive with a suitable alternative (e.g. double sided tape) when the bezel is reinstalled. 8. Remove assembly from the unit. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.40 © Copyright...
  • Page 459 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 1 1 + + ) ) 1. Installation is performed by reversing the removal procedure. TORQUE Trunk Latch Fasteners: 65 in-lbs (7 N·m) TORQUE Lock Actuator Fasteners: 12 in-lbs (1 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.41 © Copyright...
  • Page 460 NOTICE There is enough slack in the antenna wire to remove fender, turn it over and clip the cable ties. CAUTION Be careful not to damage painted surfaces. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.42 © Copyright...
  • Page 461 6. Install forward fender fasteners on both sides of the fender and torque to specification. TORQUE Forward Fender Fasteners 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.43 © Copyright...
  • Page 462 12. Install upper side panels. See Side Cover (Upper), Removal / Installation page 7.22. 13. Install seat as outlined in this chapter. 14. Install saddlebags, if equipped. 15. Connect antenna cable to mast. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.44 © Copyright...
  • Page 463 Remove the upper spacer from between the mid- casting and the engine. 13. Remove fasteners from the mid casting. 15. Move the front casting toward the right hand side of the motorcycle to release dowels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.45 © Copyright...
  • Page 464 IMPORTANT The upper engine spacer will not be installed during the initial torque and measurement stage of this procedure. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.46 © Copyright...
  • Page 465 Upper, Left-Hand Down Tube Fasteners TORQUE 45 ft-lbs (60 N·m) Lower Mid-Cast Fastener 75 ft-lbs (102 N·m) TORQUE Lower, Left-Hand Down Tube Fasteners & 45 ft-lbs (60 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.47 © Copyright...
  • Page 466 9. If the gap is correct, the upper spacer can be installed and the upper fastener torqued to specification. TORQUE Upper Engine Mount Fastener: 75 ft-lbs (102 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.48 © Copyright...
  • Page 467 88 in-lbs (10 N·m) 4. Remove the bezel from the speedometer and lift the speedometer head out of the rubber grommet. TORQUE Bracket to Console Cover Fasteners: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.49 © Copyright...
  • Page 468 3. Remove two fasteners securing the console cover to the fuel tank and lift console back and set on protected fuel tank. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.50 © Copyright...
  • Page 469 Some of the connectors are unmarked and interchangeable. 12. Disconnect all multi-plugs between the switch cube and chassis harness and route through the front portion of the nacelle. 13. Remove nacelle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.51 © Copyright...
  • Page 470 4. Secure harness to the front portion of the nacelle using the newly installed cable ties. 5. Position the headlamp bucket in front of the nacelle and reconnect the headlamp bulb. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.52 © Copyright...
  • Page 471 15. Verify that all controls are operating correctly and the handlebar turns freely from lock to lock. NOTICE Verify that the rubber grommets securing the auxiliary light / turn signal harness have been slid into place. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.53 © Copyright...
  • Page 472 When removing the five windshield fasteners be sure to capture the T-nuts as they are not captive. NOTICE Some fasteners are longer than others, make sure to note placement of fasteners when removing. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.54 © Copyright...
  • Page 473 6. Remove two fasteners and head light bezel. 7. Remove three fasteners and withdraw the head light assembly far enough to disconnect electrical connector. 8. Remove fairing assembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.55 © Copyright...
  • Page 474 8. Lift the inner fairing assembly off of the triple clamp studs and route wire through the access hole. 4. Using a side-cutter, carefully clip the four cable ties securing the wiring harness to the inner fairing. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.56 © Copyright...
  • Page 475 11. Install the outer fairing assembly. See Outer Fairing Installation - (Chieftain Dark Horse) page 7.58 12. Install the instrument cluster. See Instrument Panel Removal / Installation - (Chieftain Dark Horse) page 7.59 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.57 © Copyright...
  • Page 476 TORQUE TORQUE Head Light Bracket Fasteners: 12 in-lbs (1 N·m) Inner Fairing Fasteners: 12 ft-lbs (16 N·m) 5. Install the LH and RH speaker grills. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.58 © Copyright...
  • Page 477 CAUTION Do not use alcohol on seal for installation. TORQUE Windshield Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.59 © Copyright...
  • Page 478 • Gently pull outward and remove Bezel. NOTICE When removing the five windshield fasteners be sure to capture the T-nuts as they are not captive. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.60 © Copyright...
  • Page 479 . Pull speaker grills bottom NOTICE out and then downward to remove. Some fasteners are longer than others, make sure to note placement of fasteners when removing. 8. Remove fairing assembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.61 © Copyright...
  • Page 480 4. Disconnect all multi plugs in harness holder bracket. IMPORTANT Use a marker or tape to index each multi-plug before disconnecting. Some of the connectors are unmarked and interchangeable. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.62 © Copyright...
  • Page 481 4. Verify that no wires or connectors have been pinched between the inner fairing and the triple clamp and torque mounting nuts to specifications. TORQUE Inner Fairing Mounting Nuts: 12 ft-lbs (16 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.63 © Copyright...
  • Page 482 12 in-lbs (1 N·m) NOTICE Some fasteners are longer than others, make sure to note placement of fasteners when removing. TORQUE Inner Fairing Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.64 © Copyright...
  • Page 483 35 in-lbs (4 N·m) 6. Install the four fasteners into the top of the fairing assembly and torque to specification. TORQUE Upper Fairing Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.65 © Copyright...
  • Page 484 4. Disconnect Power Button, Speedometer, Tach and Display harnesses. 5. Remove Display bracket hardware from top and bottom of display. 8. Pull up on dash tabs to disengage display bracket pins 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.66 © Copyright...
  • Page 485 FRAME / BODY 9. Pivot display bracket back and out to remove display. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.67 © Copyright...
  • Page 486 7. Connect Power Button, Speedometer, Tach and Display harnesses 8. Route USB wire thru storage box grommet and install storage box. TORQUE Ride Command Display fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.68 © Copyright...
  • Page 487 Refer to image below to make sure the Lift Arm hardware stack is in the correct order. 10. Install Outer Fairing and Windshield. See Outer Fairing Installation - (Chieftain / Roadmaster) page 7.64. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.69 © Copyright...
  • Page 488 FRAME / BODY NOTES 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 7.70 © Copyright...
  • Page 489 ............8.41 BRAKE DISC REMOVAL / INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 490 ..............8.89 SHOCK ABSORBER INSTALLATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 491 ..................8.131 TROUBLESHOOTING 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 492 3. If the drive belt or sprocket is being replaced due to damage, replace belt and both sprockets as a set if drive system has more than 5000 miles (8000 Km) of use. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 493 D D R R I I V V E E B B E E L L T T F F R R E E Q Q U U E E N N C C Y Y T T E E N N S S I I O O N N D D A A T T A A NOTICE Due to the low frequency levels produced by Indian Motorcycle drive belts, it is recommended to use a commercially available CLAVIS optical sensor or equivalent to achieve the most accurate tension measurement.
  • Page 494 (least deflection) to use as a reference. 7. Push up on gauge until O-ring just touches tool body. See Drive Belt Specifications page 8.5 drive belt deflection specifications. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 495 23 Hz (± 1 Hz) Horse / Vintage Tension: Springfield / 18 Hz (± 1 Hz) Chieftain / Chieftain Dark Horse / Roadmaster 2020+ Models Tension: 18 Hz (± 1 Hz) All Models 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 496 1. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 2. Make note of adjuster locations 3. Raise the rear of the motorcycle so the rear tire can be freely rotated. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 497 Rinse and dry thoroughly. 2. Inspect front and rear sprocket teeth for wear or damage from foreign material. 3. Closely inspect drive belt condition. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 498 2020-2022 IMPORTANT Sidestand fasteners must be replaced any time the sidestand is removed. The nut is a crushed lock and therefor it can not be reused. 2023+ 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.10 © Copyright...
  • Page 499 6. Torque to specification and wipe off any excess grease. TORQUE Sidestand Pivot Fastener: 37 ft-lbs (50 N·m) 7. Cycle the sidestand to be sure it moves freely, and returns to the fully retracted position. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.11 © Copyright...
  • Page 500 See Steering / Suspension chapter. 8. Verify axle nut is tight. 9. Replace any worn or damaged parts. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.12 © Copyright...
  • Page 501 RECOMMENDED SUSPENSION SAG Chief Classic / Chief Vintage / Chief Dark 35 mm Horse Springfield / Chieftain Dark Horse / Chieftain / 45 mm Roadmaster (All 2020+ Models) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.13 © Copyright...
  • Page 502 6. Recheck the preload measurement after adjusting. 7. Tighten the lock nut securely against the adjuster nut. 8. Install the seat as outlined in Frame / Body chapter. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.14 © Copyright...
  • Page 503 • Park the motorcycle with the sidestand down on a firm, level surface. Remove all riders and cargo. • DO NOT exceed 150 PSI (1034 kPa) in the shock. • Use the INDIAN MOTORCYCLE Air Pump and Gauge (P/N PV-48909). Follow the instructions on the following pages.
  • Page 504 PAINTED TRUNK SELECT PRESSURE CORRESPONDING TO TOTAL CARGO AND OCCUPANT WEIGHT. REMOVE ALL PASSENGERS AND CARGO BEFORE SETTING/ CHECKING SHOCK PRESSURE. SET PRESSURE WITH BIKE ON SIDE STAND. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.16 © Copyright...
  • Page 505 7. Remove the hose from the air fitting and reinstall the cap. 8. Repeat the preload inspection to verify proper preload. See Rear Shock Preload Inspection page 8.13. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.17 © Copyright...
  • Page 506 (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.18 © Copyright...
  • Page 507 Tighten loose spokes or replace bent, broken or missing spokes. Inspect spokes after first 500 miles, then again every 5,000 miles. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.19 © Copyright...
  • Page 508 • Refer to MAINTENANCE chapter for front end components service. • Refer to Steering / Suspension chapter for TIRE REMOVAL, REPAIR, & BALANCING • Refer to Brakes chapter for BRAKE SYSTEM service and repairs. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.20 © Copyright...
  • Page 509 (5.20") Oil level must be measured Chief: 599 cc (599 ml) Fork Oil Capacity (per leg, and adjusted to Chieftain: 557 cc (557 Set Level dry) specification. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.21 © Copyright...
  • Page 510 Brake Lever Clamp Fastener 96 in-lbs (11 N·m) Grip Retainer Fastener 35 in-lbs (4 N·m) Right-Hand Switch Cube 12 in-lbs (1 N·m) Fastener Left-Hand Switch Cube 12 in-lbs (1 N·m) Fastener 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.22 © Copyright...
  • Page 511 Outer cube fasteners 12 in-lbs (1 N·m) Inner cube fasteners — Rear Switch Cover — Front Switch Cover LH Handlegrip — RH Throttle Handlegrip — Throttle alignment slot — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.23 © Copyright...
  • Page 512 Outer cube fasteners 12 in-lbs (1 N·m) Inner cube fasteners — Rear Switch Cover — Front Switch Cover LH Grip Assembly — Grip Fastener 53 in-lbs (6 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.24 © Copyright...
  • Page 513 PART DESCRIPTION 12 in-lbs (1 N·m) Outer cube fasteners 12 in-lbs (1 N·m) Inner cube fasteners — Rear Switch Cover — Front Switch Cover RH Grip Assembly — 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.25 © Copyright...
  • Page 514 H H A A N N D D L L E E B B A A R R A A S S S S E E M M B B L L Y Y V V I I E E W W Riser Fastener (QTY.2) Spacer 60 ft-lbs (81 N·m) Riser Cap Fastener (QTY.4) Washer 18 ft-lbs (24 N·m) Tighten front fastener then rear. Isolator 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.26 © Copyright...
  • Page 515 Metal Slide Cylinder Assembly Washer Oil Seal Inner Fork Tube Snap Ring Bushing Dust Seal Oil Lock Cap Assembly Fork Cover Top Triple Clamp Nut 72 ft-lbs (98 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.27 © Copyright...
  • Page 516 A Service Kit is required to upfit a 16” to 19” front wheel. The service kit will include all the triple clamp parts required for adequate clearance. See the polaris parts for specific kit details. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.28...
  • Page 517 A Service Kit is required to upfit a 16” to 19” front wheel. The service kit will include all the triple clamp parts required for adequate clearance. See the polaris parts for specific kit details. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.29...
  • Page 518 F F R R O O N N T T W W H H E E E E L L A A S S S S E E M M B B L L Y Y V V I I E E W W - - C C A A S S T T ( ( 1 1 6 6 & & 1 1 7 7 I I N N C C H H ) ) Outer Bearing Spacer Seal Pulse Wheel / Brake Disc Fastener (QTY.6 per disc) Wheel Bearing 22 ft-lbs (30 N·m) Inner Bearing Spacer ABS Pulse Wheel Brake Disc 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.30 © Copyright...
  • Page 519 F F R R O O N N T T W W H H E E E E L L A A S S S S E E M M B B L L Y Y V V I I E E W W - - C C A A S S T T ( ( 1 1 9 9 I I N N C C H H ) ) Pulse Wheel / Brake Disc Fastener (QTY.6 per Disc) Seal 22 ft-lbs (30 N·m) Wheel Bearing ABS Pulse Wheel Inner Bearing Spacer Brake Disc 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.31 © Copyright...
  • Page 520 F F R R O O N N T T W W H H E E E E L L A A S S S S E E M M B B L L Y Y V V I I E E W W - - S S P P O O K K E E D D Outer Bearing Spacer Seal Pulse Wheel / Brake Disc Fastener (QTY.6) Wheel Bearing 22 ft-lbs (30 N·m) Inner Bearing Spacer ABS Pulse Wheel Brake Disc 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.32 © Copyright...
  • Page 521 5. Noting harness routing and connector locations, removal procedure. disconnect all fairing electrical connectors and remove inner fairing support. Chief Classic / Chief Vintage / Chief Dark Horse / Springfield: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.33 © Copyright...
  • Page 522 Riser Fasteners: 60 ft-lbs (81 N·m) Chieftain Dark Horse: 16. Install the inner fairing support and torque nuts to specification. TORQUE Inner Fairing Support: 12 ft-lbs (16 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.34 © Copyright...
  • Page 523 Front Master Cylinder Service (2017) page 9.36. CAUTION Keep brake reservoir in an upright position to prevent air from entering the system. Bleeding is required if air enters the system. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.35 © Copyright...
  • Page 524 TORQUE Riser Fasteners: 60 ft-lbs (81 N·m) 14. Install the inner fairing support and torque nuts to specification. TORQUE Inner Fairing Support: 12 ft-lbs (16 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.36 © Copyright...
  • Page 525 6. Pull lever slightly until slotted opening in lever is clear of perch and slide cable barrel end down and out of lever. 7. Note routing of clutch cable through frame. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.37 © Copyright...
  • Page 526 10. Install the side stand bumper and fastener. Torque to specification. TORQUE Side Stand Bumper: 88 in-lbs (10 N·m) 11. Adjust clutch cable free play. See Clutch Lever Free Play (2017-2020) page 5.9. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.38 © Copyright...
  • Page 527 Axle Pinch Fasteners: 2. Remove the front fender. See Front Fender 18 ft-lbs (24 N·m) Removal page 7.33. 8. Install front fender. See Front Fender Installation page 7.34. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.39 © Copyright...
  • Page 528 (side to side) (B) and compare to specifications. 4. Visually inspect wheel for cracks. 5. Replace wheel if it fails visual or measured inspection. Do not attempt to straighten cast or wheels. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.40 © Copyright...
  • Page 529 (or remove it) by hand. Replace the wheel if outer race of a new bearing does not fit tightly in the bore. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.41 © Copyright...
  • Page 530 Installation page 8.41. 4. Remove front wheel. See Front Wheel, Removal / 13. Install the front wheel. See Front Wheel, Removal / Installation page 8.39. Installation page 8.39. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.42 © Copyright...
  • Page 531 12. Slide fork legs down and remove. 10. If disassembling the fork tube(s), loosen the fork cap(s) prior to loosening the lower triple clamp fasteners. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.43 © Copyright...
  • Page 532 6. Rotate tube until cap is unscrewed completely Wear eye / face protection. Be sure spring is from fork tube. engaged properly with pegs of tool as you compress the spring in the following steps. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.44 © Copyright...
  • Page 533 15. Hold cartridge through top of fork inner tube with octagonal end of Cartridge Shaft Tool (PV-49452). Loosen cartridge fastener. 10. Hold nut and remove fork cap from cartridge shaft. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.45 © Copyright...
  • Page 534 20. Push inner and outer tube together, then pull apart quickly to produce a slide hammer motion to remove the inner tube. 21. Separate the tubes. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.46 © Copyright...
  • Page 535 Cartridge can be cleaned by adding clean fork oil to slider and pumping the cartridge rod in the clean oil bath. Discard fork oil used to flush the cartridge. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.47 © Copyright...
  • Page 536 5. Lubricate the surface of the inner fork tube and slide backing washer and new oil seal down tube and into outer fork leg. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.48 © Copyright...
  • Page 537 20. Bleed cartridge by moving shaft up and down to purge air. Begin with small strokes, increasing TORQUE stroke length until all air is removed and damping Cartridge Fastener: 17 ft-lbs (23 N·m) is smooth and consistent. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.49 © Copyright...
  • Page 538 29. Remove extension tool and hold damper rod up, 24. Draw excess oil out to the specified level. clear of spring. 30. Screw jamb nut fully onto damper rod until bottomed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.50 © Copyright...
  • Page 539 35. Slowly release spring pressure and remove fork Fork Cap to Outer Tube: leg from spring compressor. 16 ft-lbs (22 N·m) 36. Install special socket in compressor as outlined for disassembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.51 © Copyright...
  • Page 540 4. Torque the top fastener on the lower triple clamp 5. REPEAT torque process in steps 3 & 4. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.52 © Copyright...
  • Page 541 14. Inspect all fasteners for proper torque. Inspect hoses and wiring for proper routing. 15. Lower front end of motorcycle to the ground and test front suspension / fork operation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.53 © Copyright...
  • Page 542 3. Remove front wheel. See Front Wheel, Removal / Installation page 8.39. Chieftain Dark Horse: 4. Remove fairing assembly. See Outer Fairing Removal - (Chieftain Dark Horse) page 7.54. Chieftain / Roadmaster: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.54 © Copyright...
  • Page 543 14. Inspect bearings and bearing races. 3. Install NEW fork lock and Install two NEW fasteners . Torque fasteners to specification. TORQUE Fork Lock Fasteners: 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.55 © Copyright...
  • Page 544 10. Set upper triple clamp in place on stem. Install washer and nut and tighten top nut until it is finger tight. NOTICE Nut will be torqued after fork tubes are installed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.56 © Copyright...
  • Page 545 18. Repeat STEPS 15–17. 19. Install handlebar assembly. See Handlebar, Removal / Installation (All Models except Chieftain / Roadmaster) page 8.33 or Handlebar Removal / Installation (Chieftain / Roadmaster) page 8.35 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.57 © Copyright...
  • Page 546 Determine Cause / Correct Front Wheel Oscillates (Wobbles) Bent Front Rim Replace Damaged Front Wheel Bearings Replace Damaged or Incorrect Tire Replace Front Wheel Oscillates (Wobbles) Loose Axle Torque to specification 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.58 © Copyright...
  • Page 547 Damaged Wheel Bearings Replace Front Axle Bent Replace Brake Dragging Repair as Necessary (Hydraulic or Mechanical Problem) Brake Dragging (Bent Disc) Replace Improper Assembly After Repairs Correct as Necessary 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.59 © Copyright...
  • Page 548 Do not allow any motorcycle to leave your service area without tire valve caps securely installed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.60 © Copyright...
  • Page 549 31.946–31.972 mm (Right-Hand) Swing Arm Ball Bearing Bore O.D. (Left- – 41.967–41.992 mm Hand) Wheel bearing O.D. (approx) – 51.987–52.00 mm Wheel bearing I.D. (approx) – 19.998–20.00 mm 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.61 © Copyright...
  • Page 550 31.946–31.972 mm (Right-Hand) Swing Arm Ball Bearing Bore O.D. (Left- – 41.967–41.992 mm Hand) Wheel bearing O.D. (approx) – 51.987–52.00 mm Wheel bearing I.D. (approx) – 19.998–20.00 mm 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.62 © Copyright...
  • Page 551 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 ( ( 2 2 0 0 1 1 7 7 - - 1 1 9 9 M M O O D D E E L L S S ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.63...
  • Page 552 Nut — M18 x 1.5 (QTY.1) 2. Torque to 65 ft-lbs (88 N·m) 2& Axle Adjuster (RH) Nut — M8 x 1.25 (QTY.2) Axle Adjuster (QTY.2) Wheel Spacer (Right-Hand) Axle, Rear 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.64 © Copyright...
  • Page 553 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 ( ( 2 2 0 0 2 2 0 0 + + M M O O D D E E L L S S ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.65...
  • Page 554 Nut — M18 x 1.5 (QTY.1) 2. Torque to 65 ft-lbs (88 N·m) 2& Axle Adjuster (Right-Hand) Nut — M8 x 1.25 (QTY.2) Axle Adjuster (QTY.2) Wheel Spacer (Right-Hand) Axle, Rear 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.66 © Copyright...
  • Page 555 55 ft-lbs (75 N·m) (2017-19) Nut — (QTY.6) Gusset Plate, Swingarm Spherical Bearing Pushrod Gusset Plate, Swingarm Shock Assembly Gusset Plate, Fasteners — (QTY.4) 55 ft-lbs (75 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.67 © Copyright...
  • Page 556 Jam Nut, Shock Air Line 20 ft-lbs (27 N·m) Nut – (QTY.6) Gusset Plate, Swingarm Gusset Plate, Fasteners – (QTY.4) 96 ft-lbs (130 N·m) Pushrod Gusset Plate, Swingarm Shock Assembly 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.68 © Copyright...
  • Page 557 Spacer, Bearing — 130 mm Sprocket — 66T Damper, Cushion Drive Visual inspection for cracks or deformation is required Seal whenever the rear wheel is removed. Replace if damage is found. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.69 © Copyright...
  • Page 558 R R O O C C K K E E R R A A S S S S E E M M B B L L Y Y ( ( 2 2 0 0 1 1 7 7 - - 1 1 9 9 M M O O D D E E L L S S ) ) TORQUE (IF APPLICABLE) ITEM PART DESCRIPTION Bearing, Needle Bearing, Thrust Spherical Bearing Seal Rocker 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.70 © Copyright...
  • Page 559 R R O O C C K K E E R R A A S S S S E E M M B B L L Y Y ( ( 2 2 0 0 2 2 0 0 + + M M O O D D E E L L S S ) ) TORQUE (IF APPLICABLE) ITEM PART DESCRIPTION Bearing, Needle Seal Bearing, Thrust Rocker 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.71 © Copyright...
  • Page 560 Nut, Axle — M18 x 1.5 (QTY.1) Suspension Pivot 1. Torque to 15 ft-lbs (20 N·m) 2. Torque to 65 ft-lbs (88 N·m) Nut, Jamb — M27 x 1.5 (QTY.1) 75 ft-lbs (102 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.72 © Copyright...
  • Page 561 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 are tight. 1. Inspect belt tension and adjust if necessary. See 2. Install drive belt with the Indian Motorcycle script Drive Belt Inspection page 8.4. situated so that it reads correctly when viewed 2.
  • Page 562 9. Loosen both axle adjuster nuts evenly to move 88 in-lbs (10 N·m) wheel forward until belt is loose. 10. Pull belt off drive sprocket. 11. Remove two locking plate fasteners and locking plate 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.74 © Copyright...
  • Page 563 STEERING / SUSPENSION 12. Remove drive sprocket retaining nut and drive sprocket 13. Remove spacer , and O-ring from output shaft. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.75 © Copyright...
  • Page 564 Replace if worn or if surface is rough. 4. Inspect the machined sealing surface of the spacer sleeve . Replace the spacer sleeve if it is grooved or otherwise damaged. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.76 © Copyright...
  • Page 565 15. Install the exhaust system. See Head Pipe TORQUE Installation page 3.119. Drive Sprocket Nut: 16. Adjust belt tension and wheel alignment. See 180 ft-lbs (244 N·m) Drive Belt Adjustment page 8.8. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.77 © Copyright...
  • Page 566 Surface must be smooth, with no burrs or surface irregularities. 3. Lift the driven sprocket assembly off of the drive damper 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.78 © Copyright...
  • Page 567 The painted surface of the driven sprocket should be resting on a protective surface such as wood or shop rags to ensure the finished surface is not damaged while pressing the bearing out. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.79 © Copyright...
  • Page 568 7. Apply a thin coat of all-purpose grease to the outer race of the new driven sprocket bearing. 8. Place the new bearing into the bore on the driven sprocket so it is resting flat. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.80 © Copyright...
  • Page 569 2. Install sprocket assembly onto wheel hub making sure the cushion damper is properly engaged. 3. Install the RH wheel spacer into the sprocket roller bearing. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.81 © Copyright...
  • Page 570 5. Position a platform jack beneath the engine cases Move sensor aside so that it is not damaged. and raise until the rear tire is barely in contact with the ground. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.82 © Copyright...
  • Page 571 10. Raise the rear of the motorcycle until rear axle nut is accessible below the left muffler assembly. 14. Push wheel forward and slide drive belt to the right side off of the rear sprocket. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.83 © Copyright...
  • Page 572 2. Visually inspect wheel for cracks or other damage. 2. Axle diameter should be measured on bearing 3. Replace wheel if it fails visual or measured surfaces. inspection. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.84 © Copyright...
  • Page 573 Turn the inner race of the bearings. The bearings should turn smoothly and quietly. The inner race should be firm with minimal side to side movement and no detectable up and down movement. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.85 © Copyright...
  • Page 574 11. Install the brake disc. See Brake Disc Removal / Installation page 8.86. 12. Install driven sprocket. See Driven Sprocket Installation page 8.81. 13. Install the rear wheel. See Rear Wheel Removal / Installation page 8.82. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.86 © Copyright...
  • Page 575 2. Lubricate spring collars and loosen completely to relieve spring tension. 3. Remove shock absorber from swingarm assembly. 3. Remove lower spring keeper and slide spring off of shock. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.87 © Copyright...
  • Page 576 See Service Specifications page 8.61. 2017–19 Chieftain / Chieftain Dark Horse / Roadmaster / Springfield, All 2020+ models 10. Install the shock / spring assembly in a suitable spring compressor. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.88 © Copyright...
  • Page 577 5. Install the swingarm / shock absorber assembly. See Swingarm Installation page 8.94. 6. Set suspension ride height preload accommodate rider /cargo weight. See “REAR SHOCK PRELOAD INSPECTION”. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.89 © Copyright...
  • Page 578 Cover (Upper), Removal / Installation page 7.22 and Side Cover (Lower), Removal / Installation page 7.22. 6. Remove the seat. See Seat, Removal / Installation - Classic / Vintage / Chieftain page 7.26. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.90 © Copyright...
  • Page 579 15. Use an 8 mm hex wrench to thread the swingarm shaft out of the right side of the frame. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.91 © Copyright...
  • Page 580 4. Remove the pivot spacer from the LH side of the swingarm followed by internal snap-ring 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.92 © Copyright...
  • Page 581 10. Lower the arbor until its seated on the press plate and thread the nut down onto the bearing. 14. Inspect bearing bores for any galling or damage. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.93 © Copyright...
  • Page 582 Install the shock absorber air line into the LH frame 22. Install swingarm assembly. Swingarm section and torque nut to specification. Installation page 8.94. TORQUE Air Line Jam Nut: 20 ft-lbs (27 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.94 © Copyright...
  • Page 583 11. Connect the ABS wheel speed sensor located at the front of the swingarm. 12. Route the ABS wheel speed sensor harness as shown and install the p-clamp fastener . Torque to specification. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.95 © Copyright...
  • Page 584 19. If equipped, install the charcoal canister. See Evaporative Emission Control System (CA Models) page 4.6. 20. Test ride motorcycle to be sure rear suspension operates smoothly without binding or abnormal noises. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.96 © Copyright...
  • Page 585 Diagnose and Service Loose fasteners Torque to specification Bent rear axle Replace Damaged wheel bearings Replace Tire contact with object or chassis Determine point of contact and correct 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.97 © Copyright...
  • Page 586 Adjust Belt Excessive Wear, Binding Belt Tight Adjust Belt Suspension Broken Belt Belt weakened by foreign material Replace Belt, Replace Sprockets damage. Belt run excessively tight or loose. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.98 © Copyright...
  • Page 587 CAUTION Two of the biggest factors contributing to premature tire wear are overloading and under-inflation. Do not deviate from the specifications for loading or inflation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.99 © Copyright...
  • Page 588 MINIMUM TREAD DEPTH (ALL MODELS) Front Tire Minimum Tread Depth .063 in (1.6 mm) Rear Tire Minimum Tread Depth .063 in (1.6 mm) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.100 © Copyright...
  • Page 589 REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) 2021 SPRINGFIELD DARK HORSE FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa) REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.101 © Copyright...
  • Page 590 REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) 2021 ROADMASTER DARK HORSE / LIMITED FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa) REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.102 © Copyright...
  • Page 591 • Binding or improperly assembled front forks can also contribute to excessive tire cupping. If the front forks do not react as they should the tire acts as the sole suspension component and tread deflection increases. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.103...
  • Page 592 The TPMS display may indicate an increase in tire pressure while riding, a normal occurrence as tires warm up. Riding into colder conditions may result in a drop in tire pressure as tires cool down. Regardless of conditions, low tire pressures should always be corrected promptly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.104 © Copyright...
  • Page 593 3. Reverse the removal procedure for installation. Torque fastener to specification. TORQUE TPMS Sensor Fastener: 44 in-lbs (5 N·m) 4. Install tire. See Tire Installation - (Chieftain / Roadmaster) page 8.122. 5. Perform the TPMS sensor activation procedure. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.105 © Copyright...
  • Page 594 1. Press the power button to power up the motorcycle electrical system. 2. Press and hold RH and LH mode buttons simultaneously until the TMPS LEARN screens toggle on the screen. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.106...
  • Page 595 (7.6 cm) from the sidewall where the tape was placed on the front tire. You should hear a short audible “beep” acknowledging sensor activation. A value will appear on the screen indicating the successful reading of the front wheel. The display will switch to the rear wheel. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.107 © Copyright...
  • Page 596 You should hear a short audible “beep” acknowledging sensor activation. A value will appear on the screen indicating the successful reading of the rear wheel. The following screens will toggle indicating successful activation of both TPMS sensors. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.108 © Copyright...
  • Page 597 1. Press the power button to power up the motorcycle electrical system. 2. Press and hold RH and LH mode buttons simultaneously until the SETUP screen is displayed on the MFD. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.109...
  • Page 598 Activation tool is close at hand and powered up before initiating setup. 5. After a few seconds the following screen will appear, indicating that the TPMS sensors are ready to be activated with the Activation tool. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.110 © Copyright...
  • Page 599 You should hear a short audible “beep” acknowledging sensor activation. The MFD will display the following screen indicating successful activation of both TPMS sensors. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.111 © Copyright...
  • Page 600 Activation tool is held over the aluminum rim, the sensor signal may not be received. 1. Press the power button to power up the motorcycle electrical system. 2. Press the middle dropdown button on top of screen to open the settings menu. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.112 © Copyright...
  • Page 601 5. Press the “Vehicle” icon on the left hand side of screen. This screen indicates that the TPMS sensors are ready to be activated with the Activation tool. Press the green check to start the TPMS learn procedure. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.113...
  • Page 602 7. Move to the rear wheel and hold the Activation tool no more than 3 in (7.6 cm) from the sidewall where the tape was placed previously. You should hear a short audible “beep” acknowledging sensor activation. The screen will display a screen indicating successful activation of both TPMS sensors. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.114 © Copyright...
  • Page 603 90° and 270° from the valve stem as required. If the bead is broken 180° from the valve stem (sensor location) the TPMS sensor may be damaged and require replacement. See TPMS Overview page 8.104. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.115 © Copyright...
  • Page 604 90° and again at 270° from the , lift the lower tire bead up until the tire lever can valve stem as necessary. be positioned and the tire completely removed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.116 © Copyright...
  • Page 605 NOTICE Refer to manufacturer’s instructions for proper tire changer operation. Mount the tire and wheel assembly on the tire machine per the manufacturers instructions. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.117 © Copyright...
  • Page 606 NOTICE Refer to manufacturer’s instructions for proper tire changer operation. Mount the tire and wheel assembly on the tire machine per the manufacturers instructions. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.118 © Copyright...
  • Page 607 7. Lift the lower tire bead up until the tire lever can be positioned and the tire completely removed. 8. Work around the circumference of the rim until the tire can be lifted free of the rim. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.119 © Copyright...
  • Page 608 Do not scratch or damage sealing surfaces of rim. Loss of air pressure can cause a loss of control and an accident, resulting in serious injury or death. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.120 © Copyright...
  • Page 609 TORQUE orientation. Valve Stem Nut: 53 in-lbs (6 N·m) 1. Remove tire from wheel as outlined in this chapter. 6. Install tire as outlined in this chapter. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.121 © Copyright...
  • Page 610 Doing so can damage the tire. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.122 © Copyright...
  • Page 611 16. Install wheel assembly onto balance stand and spin. Observe the wheel assembly while it is spinning to make sure the tire is seated properly. 17. Adjust tire pressures to specifications. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.123 © Copyright...
  • Page 612 Never apply grease, oil, gasoline, spray type lubricants or anything other than rubber lubricant or a neutral soap and water solution to the tire bead. Doing so can damage the tire. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.124 © Copyright...
  • Page 613 “feel” of new tires or tire combination, and achieve optimum road grip. Inspect and adjust tire inflation pressure after tire cools down for at least three hours following “run- in”. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.125 © Copyright...
  • Page 614 Doing so can damage the tire. 9. Install valve core if it was removed. 10. Line up balance dot. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.126 © Copyright...
  • Page 615 16. Install wheel assembly onto balance stand and spin. Observe the wheel assembly while it is spinning to make sure the tire is seated properly. 17. Adjust tire pressures to specifications. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.127 © Copyright...
  • Page 616 / tire. Adhesive Weight P/N 1520253 8. Install wheel / tire assembly onto motorcycle. See Steering / Suspension chapter for front and rear wheel installation procedures. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.128 © Copyright...
  • Page 617 (hop) of the rim. 2. First, adjust radial runout by loosening spokes around any high spots, rotate wheel 1/2 turn and tighten spokes directly opposite the high spot. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.129 © Copyright...
  • Page 618 8. Place wheel assembly onto a truing stand for rim offset adjustment, final spoke tightening and wheel truing of wheel. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.130 © Copyright...
  • Page 619 Fork oil level incorrect Fill to specification Fork spring free length different Replace spring that does not meet between right & left specification Balance wheel Wheel assembly out-of-balance 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.131 © Copyright...
  • Page 620 STEERING / SUSPENSION NOTES 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 8.132 © Copyright...
  • Page 621 ...............9.31 ABS FRONT BRAKE BLEEDING 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 622 TROUBLESHOOTING ..................9.49 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual...
  • Page 623 Replace sealing washers whenever brake lines are removed. Always remove the master cylinder fluid reservoir cover and inspect the fluid level when brake pads are replaced. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 624 Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP CHILDREN AWAY FROM BATTERY. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 625 4. Assemble brake lever. TORQUE Brake Lever Pivot Fastener: 9 in-lbs (1 N·m) TORQUE Brake Lever Pivot Nut: 48 in-lbs (6 N·m) 4. Assemble brake lever. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 626 NOTICE Brake Fluid Replacement & Bleeding 2023 + models will have a rue pin instead of a cotter Precautions page 9.29. pin and flat washer. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 627 Floorboard (Driver), Installation page 7.24. 10. Depress brake pedal to verify proper operation and pedal feel. Bleed brakes if necessary. See Brake Fluid Replacement & Bleeding Precautions page 9.29. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 628 4. Install caliper cover. Torque to specification. TORQUE Caliper Cover Acorn Nuts: 18 ft-lbs (24 N·m) 2. Viewing the front brake pads from the rear of the calipers, locate the wear indicator grooves 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 629 2. Viewing the rear brake pads from behind the motorcycle and below the lip of the rear fender, locate the wear indicator grooves 3. Wear indicator grooves should be visible on both inboard and outboard brake pads. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 630 Fastener, Banjo — 10 x 1.25 18 ft-lbs (24 N·m) Washer, Copper Sealing (qty 2) Snap Ring, External Pivot Pin, Brake Lever Rubber Diaphragm Cover, Front Master Cylinder 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.10 © Copyright...
  • Page 631 31 ft-lbs (42 N·m) (QTY.2) Fastener, Banjo — 10 x 1.25 18 ft-lbs (24 N·m) Washer, Copper Sealing 88 in-lbs (10 N·m) Brake Pedal Pad Fastener Pedal Pad 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.11 © Copyright...
  • Page 632 88 in-lbs (10 N·m) 18 ft-lbs (24 N·m) Fastener, Bracket — (QTY.6) Retaining Strap 80 in-lbs (9 N·m) Brake Line, Front (ABS Module to Front Calipers) Routing Clip 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.12 © Copyright...
  • Page 633 Cover, Front Master Cylinder Rubber Diaphragm Brake Lever Clamp Fastener 70 in-lbs (8 N·m) Snap Ring, External Spring, Piston Return Cup, Primary Ring, Back Up Piston Cup, Secondary Dust Boot Pushrod 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.13 © Copyright...
  • Page 634 Brake Lever Clamp Fastener 70 in-lbs (8 N·m) 48 in-lbs (6 N·m) Brake Lever Pivot Nut Spring Retainer Seal, Primary Piston Seal, Secondary Snap Ring Dust Boot Plate, Front Master Cylinder 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.14 © Copyright...
  • Page 635 Cover, Rear Master Cylinder Rubber Diaphragm Reservoir, Rear Master Cylinder Cartridge, Rear Master Cylinder Push Cap Pushrod Dust Boot Washer Snap Ring, External Sight Glass O-Ring, Sight Glass 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.15 © Copyright...
  • Page 636 Cover, Rear Master Cylinder Rubber Diaphragm Reservoir, Rear Master Cylinder Plate, Rear Master Cylinder Sight Glass Spring Cup, Primary Piston Cup, Secondary Push Rod Snap Ring Dust Boot Connector 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.16 © Copyright...
  • Page 637 13 ft-lbs (17 N·m) Fastener, Bleeder Dust Seal 48 in-lbs (5 N·m) Caliper Body, Outboard Piston Seal Caliper Body, Inboard Piston Seal O-Ring, Caliper Passage Dust Seal Piston 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.17 © Copyright...
  • Page 638 Brake Pad, Outboard 13 ft-lbs (17 N·m) Caliper Body Pad Spring Rear Caliper Guide Pin Brake Pad, Inboard 115 in-lbs (13 N·m) Carrier, Caliper Piston Seal Dust Seal 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.18 © Copyright...
  • Page 639 BRAKES A A B B S S M M O O D D U U L L E E 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.19 © Copyright...
  • Page 640 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 , , F F R R O O N N T T 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.20...
  • Page 641 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 A A R R 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.21...
  • Page 642 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 required. • When the ABS lamp is illuminated, the anti-lock Change every 10,000 miles (16,000 km) or 2 years, brakes will not activate, but the conventional brake whichever comes first.
  • Page 643 The ABS Module Assembly is serviceable only as an assembly. The module itself is not rebuildable. Disconnect negative (-) battery cable from battery before servicing ABS brake lines or system components. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.23 © Copyright...
  • Page 644 • ABS module not programmed (partial ECUID present in Digital Wrench) When diagnosing this code, make sure the battery is fully charged and passes a load test prior to clearing and retesting. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.24 © Copyright...
  • Page 645 12. Reverse procedure to install. 13. Verify speed sensor air gap is within specification. Perform adjustment procedure if necessary. See Wheel Speed Sensor Air Gap Adjustment page 9.26. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.25 © Copyright...
  • Page 646 3. Remove Wheel Speed Sensor from bracket. 4. Withdraw the speed sensor and remove any existing shims. 5. Based on air gap measurement, add or remove shims to achieve the specified air gap. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.26 © Copyright...
  • Page 647 3. Attach Digital Wrench and check for ABS trouble codes. 6. Remove two starter solenoid fasteners IMPORTANT 2017 Models:Special Tests>Auxiliary Controller Reprogramming>Indian ABS 2018+ Models:On Digital Wrench - Special Tests > Vehicle Controller Update 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.27 © Copyright...
  • Page 648 What is the ohm reading between pin 2 (YE – CAN High) and pin 11 (DG – CAN Low)? Should be 61 ohms +/- 1 Perform an ohm reading of all the wheel speed sensor wires: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.28 © Copyright...
  • Page 649 It is extremely important to bleed the brakes properly after any brake system work has been performed or when inspection reveals spongy brakes. Keep these points in mind when bleeding hydraulic brakes: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.29 © Copyright...
  • Page 650 2. Attach a tight-fitting clear hose from the vacuum bleeder to the bleed screw and apply vacuum. 11. If pedal is not firm, repeat bleeding procedure and insect brake system. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.30 © Copyright...
  • Page 651 13. Close bleed screw. 14. Once both front calipers have been bled, repeat procedure again on left caliper, then right to ensure all air has been purged. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.31 © Copyright...
  • Page 652 9. If the minimum brake lever reserve force is not met before the lever makes contact with the hand grip, the brake system will need to be bled. See ABS Front Brake Bleeding page 9.31 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.32 © Copyright...
  • Page 653 11. Torque pad retaining pin to specification. TORQUE Pad Retaining Pin: 13 ft-lbs (17 N·m) 12. Inspect brake fluid in reservoir and set to proper level. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.33 © Copyright...
  • Page 654 NOTICE The caliper should move freely on the guide pins. 2. Slide retaining pin out until inner pad can be removed. Note orientation of spring plate. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.34 © Copyright...
  • Page 655 Runout should be measured 2-4mm in from outside edge of disc. 4. Replace brake disc if dial indicator reading displays excessive brake disc runout and other possible causes have been eliminated. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.35 © Copyright...
  • Page 656 7. Pull push rod and dust boot out of master cylinder. 4. Remove fasteners , clamp, and master cylinder. 8. Remove snap ring. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.36 © Copyright...
  • Page 657 Large diameter of beveled edge on piston cups face toward spring. Install a new retaining ring on end of piston with machined edge (sharpest of the two edges). 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.37 © Copyright...
  • Page 658 2. Remove the right-hand side mirror from the lever perch. 3. Remove banjo fastener and brake line from master cylinder. 6. Remove the pivot pin and nut . Pull lever assembly out of master cylinder. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.38 © Copyright...
  • Page 659 70 in-lbs (8 N·m) compressed air to be sure they are clean and unobstructed. 12. Apply a light film of special lubricant from piston kit to each piston seal cup. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.39 © Copyright...
  • Page 660 , sealing washers, and brake hose from caliper assembly and allow it to drain into a container. NOTICE Pads contaminated with oil or grease must be replaced as a set. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.40 © Copyright...
  • Page 661 13. Clean piston seal and dust seal bores to remove Caliper Body Fasteners: 20 ft-lbs (27 N·m) residue that could cause the pistons to stick, resulting in brake drag. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.41 © Copyright...
  • Page 662 2-3 times and release. Verify the wheel turns freely without drag. If brake drag is evident, do not operate the motorcycle. Inspect the vehicle to determine the cause and then repair as necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.42 © Copyright...
  • Page 663 11. Carefully assemble the piston and cups into the master cylinder bore. 12. Install the push rod, push rod retainer and internal snap ring. 13. Install the return spring, dust boot, washer and external snap ring. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.43 © Copyright...
  • Page 664 Brake Line Banjo Fastener: 18 ft-lbs (24 N·m) Rear Master Cylinder Jam Nut: 35 ft-lbs (48 N·m) 15. Install the push rod retaining pin, washer and cotter pin. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.44 © Copyright...
  • Page 665 11. Carefully assemble the piston and cups into the master cylinder bore. 12. Install the push rod. 13. Install the washer, external snap ring, dust boot, nut, and clevis. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.45 © Copyright...
  • Page 666 Brake Line Banjo Fastener: 18 ft-lbs (24 N·m) TORQUE Master Cylinder Mount Fasteners (Rear): 18 ft-lbs (24 N·m) 15. Install the push rod retaining pin, washer and cotter pin. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.46 © Copyright...
  • Page 667 Banjo Fastener (Rear Caliper): 18 ft-lbs (24 N·m) 4. Slide caliper bracket off pins and remove spring 21. Bleed brake system. See ABS Rear Brake Bleeding plate. page 9.30. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.47 © Copyright...
  • Page 668 2-3 times and release. Verify the wheel turns freely without drag. If brake drag is evident, do not operate the motorcycle. Inspect the vehicle to determine the cause and then repair as necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.48 © Copyright...
  • Page 669 Diaphragm (master Cylinder reservoir) Inspect / Replace Cover, Cap, Diaphragm Leaking or Reservoir as Required Fluid level too high (new brake pads installed Correct fluid level without removing added fluid) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.49 © Copyright...
  • Page 670 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 Worn Pads / Disc 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 9.50 © Copyright...
  • Page 671 ..............10.36 STATOR RESISTANCE TEST 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.1...
  • Page 672 ..............10.69 FUSE APPLICATION CHART (2017) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.2...
  • Page 673 ..............10.115 POWER WINDSHIELD OPERATION 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.3...
  • Page 674 ................10.151 TESTING VOLTAGE DROP 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.4...
  • Page 675 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.5 © Copyright...
  • Page 676 Fuel Delivery / EFI chapter and Electrical chapter, very carefully when working on electronic components. Failure to follow instructions may cause irreparable damage to the part being inspected. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.6 © Copyright...
  • Page 677 Starter Motor No Load Amp Draw (Bench 30-37 Amps after Test) initial surge CCA Rating Starter Torque Limit Clutch Break-Away 50 – 60 ft-lbs (70 - 80 Torque Nm) when new 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.7 © Copyright...
  • Page 678 88 in-lbs (10 N·m) Fastener, Starter Motor — M6 x 1.0 x 25 (QTY.2) Cable, Battery to Solenoid (B+) 88 in-lbs (10 N·m) Cable, Solenoid to Starter Motor (B+) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.8 © Copyright...
  • Page 679 S S T T A A T T O O R R A A S S S S E E M M B B L L Y Y V V I I E E W W Fastener, Stator — M6 x 1.0 x 35 (QTY.3) Stator 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.9 © Copyright...
  • Page 680 Regulator / Rectifier Fastener, Regulator Bracket — M6 x 1.0 x 12 Fastener, Regulator — M6 x 1.0 x 15 (QTY.2) (QTY.3) 88 in-lbs (10 N·m) 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.10 © Copyright...
  • Page 681 Fastener, Battery Box — M6 x 1.0 x 12 (QTY.2) 80 in-lbs (9 N·m) Fastener, VCM Mounting Plate — M6 x 1.0 x 25 (QTY.1) 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.11 © Copyright...
  • Page 682 Vehicle Control Module (VCM), Removal / Installation page 10.73. 4. Remove negative (-) battery terminal fastener and cable first 5. Remove positive (+) battery terminal fastener and cable last 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.12 © Copyright...
  • Page 683 6. Install Vehicle Control Module (VCM). Vehicle Control Module (VCM), Removal / Installation page 10.73. 7. Install seat. Seat Removal / Installation - All (except Roadmaster) page 7.26. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.13 © Copyright...
  • Page 684 3. Remove battery. See Battery Removal page 10.12. 4. Remove rear battery box fasteners 8. Remove the battery box / ECM assembly 5. Remove front battery box fasteners 6. Disconnect the multi-plugs from the ECM. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.14 © Copyright...
  • Page 685 3. Connect the ECM multi-plugs Battery Box Fasteners, Rear: 80 in-lbs (9 N·m) 6. Install battery. See Battery Installation page 10.13. 7. Install rear fender. See Rear Fender Installation page 7.43. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.15 © Copyright...
  • Page 686 Recommendations – Deeply Discharged (below 3 volts) to attempt to restore the deeply discharged battery. If charging sequence will not finish as intended, the battery needs to be replaced. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.16 © Copyright...
  • Page 687 4. Wait for the charger to complete the charge cycle before disconnecting it. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.17 © Copyright...
  • Page 688 Carefully remove the tape to Dash Column expose the connector and length of wire. Be sure to properly secure the wire and connector before operating the vehicle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.18 © Copyright...
  • Page 689 9. Install seat. See Seat Removal / Installation - All (except Roadmaster) page 7.26. 10. Install upper side covers. See Side Cover (Upper), Removal / Installation page 7.22. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.19 © Copyright...
  • Page 690 Starter motor turns at normal Ignition Problem Electrical chapter speed, but engine does not start. Engine Problem Engine / Cooling / Exhaust chapter Fuel Delivery Problem Fuel Delivery / EFI chapter 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.20 © Copyright...
  • Page 691 S S T T A A R R T T E E R R C C I I R R C C U U I I T T D D I I A A G G R R A A M M ( ( 2 2 0 0 1 1 7 7 ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.21...
  • Page 692 S S T T A A R R T T E E R R C C I I R R C C U U I I T T D D I I A A G G R R A A M M ( ( 2 2 0 0 1 1 8 8 + + ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.22...
  • Page 693 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 NOTICE Make sure the Key Fob authorization has occurred before performing troubleshooting. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.23 © Copyright...
  • Page 694 POSSIBLE CAUSE Starter clutch malfunction. Starter motor turns, but engine does not turn. The Starter torque limit clutch slipping. starter motor can be heard spinning. Starter gears damage. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.24 © Copyright...
  • Page 695 4. Working on the vehicle side of the harness, test continuity between terminal 2 (black wire) and chassis ground. Resistance should be ≤ 0.5 Ω 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.25 © Copyright...
  • Page 696 • Roll the motorcycle forward and back enough to verify that it is in neutral. • Set the multi meter to test resistance and insert meter leads into the appropriate jacks. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.26 © Copyright...
  • Page 697 7. If the gear position switch is working correctly and neutral indicator did not light with the transmission in neutral; inspect neutral lamp and circuit wiring for a open/short circuit. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.27 © Copyright...
  • Page 698 4.34 4.42 IMPORTANT Voltage can also be viewed by using digital wrench. 6. If the reading is not within specified parameters, replace switch or repair wiring as necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.28 © Copyright...
  • Page 699 Use caution when removing the clutch switch so the locating pins do not break off. 4. Installation is performed by reversing the removal procedure. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.29 © Copyright...
  • Page 700 7. Press the power button to power up the electrical system and observe ammeter. It should register negative amps. If it does not, turn the ammeter probe around. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.30 © Copyright...
  • Page 701 Torque the starter motor positive terminal nut to specification. TORQUE Starter Motor Positive Terminal Nut: 63 in-lbs (7 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.31 © Copyright...
  • Page 702 (overheated). The system should be cool when testing DC charging output or when testing the regulator / rectifier to ensure accurate readings. Refer to test procedure for individual charging system components for more information. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.32 © Copyright...
  • Page 703 When current drain falls within specifications, focus efforts on the last circuit or component that was disconnected. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.33 © Copyright...
  • Page 704 Disconnect accessories and re-test. 9. Turn ignition key off. 10. Remove inductive ammeter clamp. 11. Install seat. See Seat Removal / Installation - All (except Roadmaster) page 7.26. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.34 © Copyright...
  • Page 705 No Load AC Volts @ 2000 RPM:All Models: 40 VAC ± NOTICE The test results obtained in step 10 can read more than the specified voltage, but it is important that they are all approximately equal. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.35 © Copyright...
  • Page 706 5. Repeat test for pins B & C 4. There should be no connection from stator 6. If resistance values do not match specification, windings to ground. inspect stator and replace as necessary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.36 © Copyright...
  • Page 707 9. Push the rubber harness seal through to the inside of the primary case and remove stator assembly. 7. Using a terminal tool or pick tool, remove the three electrical terminals from the stator connector. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.37 © Copyright...
  • Page 708 Clutch Installation page 5.44. 9. Install the primary cover. See Primary Cover Installation (2017-2020) page 5.27. 6. Grasp the two fasteners and lift the flywheel off of the stator. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.38 © Copyright...
  • Page 709 Also check voltage regulator connections (input from stator and output to battery). a. If any connection was loose, the battery must be fully charged, and the system re-evaluated. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.39 © Copyright...
  • Page 710 / rectifier bracket. 5. Disconnect the regulator / rectifier 2–pin connector from the vehicle harness and remove from vehicle. 6. Remove the regulator / rectifier bracket from vehicle. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.40 © Copyright...
  • Page 711 8. Torque the bracket and regulator / rectifier fasteners to specification. TORQUE Bracket Fasteners: 88 in-lbs (10 N·m) Regulator / Rectifier Fasteners: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.41 © Copyright...
  • Page 712 2016+ models have an integrated Alarm / Immobilizer feature which is armed and disarmed using the Multi-Function Key Fob. Basic (No Button) Multi-Function (Two Button) BUTTON TYPE 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.42 © Copyright...
  • Page 713 – The power switch will flash. 10 seconds until the security light and/or power – The system will not perform the lock or unlock switch turn on. procedure. Programming the Key Fob: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.43 © Copyright...
  • Page 714 Digital Wrench® II is only available for authorized dealers. Refer to the user guide and carefully follow all instructions provided. See Digital Wrench II User Manual page 1.54 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.44 © Copyright...
  • Page 715 If key fob is suspect for decreased range, learn in new key fob and repeat STEP 2. Normal Range: Up to 2-3 feet. Cannot be closer than 8 inches 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.45 © Copyright...
  • Page 716 Inspect the 125 kHz 2-wire antenna (on top of VCM) using a DVOM. Pin 7 is Antenna OUT B; Pin 18 is Antenna OUT A. SPECIFICATION Capacitance: 3.4 nF (± 2 %) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.46 © Copyright...
  • Page 717 ELECTRICAL 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.47 © Copyright...
  • Page 718 3. Verify the new battery has the required symbol. 4. Remove the circuit board from the housing. Remove and properly discard the battery. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.48 © Copyright...
  • Page 719 3. Verify the new battery has the required symbol. 8. Verify the key fob lock and unlock functions work correctly. 4. Remove the circuit board from the housing. Remove and properly discard the battery. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.49 © Copyright...
  • Page 720 Vehicle Controllers Update reflash, located under Special Tests. IMPORTANT Motorcycles that use a Basic (No Button) Key Fob must purchase the Multi-Function (Two Button) Key Fob in order to use the Alarm System. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.50 © Copyright...
  • Page 721 ON and current is present. CAUTION Using incorrect heat range spark plugs can damage the engine. Always follow the manufacturer’s recommendations for spark plug heat range. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.51 © Copyright...
  • Page 722 Digital Wrench® II is only available for authorized dealers. Refer to the user guide and carefully follow all instructions provided. See Digital Wrench II User Manual page 1.54 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.52 © Copyright...
  • Page 723 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 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.53...
  • Page 724 • With no current flowing (open secondary side of the ignition coil) the timing light will not flash. • A faulty high tension lead (plug wire) or poor connection is one example of an open secondary. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.54 © Copyright...
  • Page 725 13. Crank the engine with the electric starter and watch the display on the multi meter. The meter display should pulse evenly while engine is cranking, indicating a ground signal is present. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.55 © Copyright...
  • Page 726 8. Move black DMM lead to the other secondary terminal and record. (Reading should be the same for both secondary windings). 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.56 © Copyright...
  • Page 727 7. INSTALLATION ignition coil performed reversing removal procedure. Torque fasteners to specification. TORQUE Coil Ground to Bracket: 88 in-lbs (10 N·m) Ignition Coil to Bracket: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.57 © Copyright...
  • Page 728 S S P P E E C C I I A A L L T T O O O O L L S S PART NUMBER TOOL DESCRIPTION Battery Tester PV-50296 Electrical Tester Kit PV-43526 Smartlink Module Kit PU-47471 TPMS Activation Tool PF-51288 USB to Serial Adapter PU-50621 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.58 © Copyright...
  • Page 729 6. Press the center button to turn off cooling mode at any time. 7. From the seat OFF position - Hold down the “minus button” for 4 seconds to advance directly to high cooling mode. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.59 © Copyright...
  • Page 730 5. If a fault is observed, follow the seat button LED fault patterns troubleshooting guide. 6. If no fault patterns are observed, the seat is operating correctly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.60 © Copyright...
  • Page 731 Red & Blue LED’s Blinking Together Open Circuit or Electrical Short Verify proper voltage and ground at the seat to chassis connector Replace the seat assembly 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.61 © Copyright...
  • Page 732 • Cruise Dec/Set Power • Auxiliary Switch Command • Cruise On/Off Power • Drive Mode Command • Auxiliary Switch Power • Security Command (VCM) • Engine Relay Power 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.62 © Copyright...
  • Page 733 • RH Auxiliary Light Signal • Key Fob • Heated Grip Switch Decrease Signal • TPMS Sensors • Heated Grip Switch Increase Signal • Windshield Motor Power • K-15 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.63 © Copyright...
  • Page 734 • Rear Wheel Speed Sensor CANbus • Front Wheel Speed Sensor • Pressure Sensors on Reservoirs REPLACEABLE COMPONENTS • Front Wheel Speed Sensor • Rear Wheel Speed Sensor 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.64 © Copyright...
  • Page 735 INPUT SIGNALS OUTPUT SIGNALS • CANbus • CANbus • Ride Command Signal • Ride Command Display • Warning Faults • Cylinder Deactivation • Engine Codes • Drive Mode Command 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.65 © Copyright...
  • Page 736 H H E E A A D D L L I I G G H H T T A A S S S S E E M M B B L L Y Y V V I I E E W W Fastener, Retaining Ring (QTY.4) Fastener, Adjuster 12 in-lbs (1 N·m) Retaining Ring Spring, Adjuster Headlight Housing Headlight Carrier Fastener, Headlight Mount 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.66 © Copyright...
  • Page 737 Fastener, Turn Signal — M8 x 1.25 x 12 (QTY.2) Pad, Tail Light Bezel 18 ft-lbs (24 N·m) Fastener, Tail Light Asm — M6 x 1.0 x 10 (QTY.3) 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.67 © Copyright...
  • Page 738 F F U U S S E E B B O O X X L L O O C C A A T T I I O O N N There are two fuse boxes utilized on the full size Indian Motorcycle platform.
  • Page 739 ECM 1 Fuse Box Chassis Fuse Power Output Fuse Box Splice (CHPWR) Main Engine Relay Control Fuse Box Splice (E115) Auxiliary Engine Relay Power Output Fuse Box Splice (AUXENG) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.69 © Copyright...
  • Page 740 Accessory Constant Fuse Output Fuse Box Splice (ACCCONST1) Auxiliary Switched Fuse Output Fuse Box Fuse Box Instrumentation Fuse Output Fuse Box Speedometer Trunk Amp Power Fuse Box Trunk 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.70 © Copyright...
  • Page 741 Splice_0115 Chassis Fuse Power Output Fuse Box Splice_0191 Fuse Box Main Fuse Output Splice_MNPWR_1 Main Fuse Output ECM 1 Splice_MNPWR_2 Aux Engine Relay Power Output Fuse Box Splice_0194 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.71 © Copyright...
  • Page 742 Splice_0127 Fuse Box Engine Relay Power Output Splice (ACCCONST1) Main Fuse Output Fuse Box Splice_MNPWR_2 Engine Relay Power Output Fuse Box Splice_0085 Engine Breaker Output Fuse Box Splice_0127 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.72 © Copyright...
  • Page 743 14. Record the new Master PIN by uploading a new Service Report. 15. Chieftain / Roadmaster ONLY: Initialize / reactivate the TPMS sensors. 16. Test ride the vehicle to verify all systems are operating correctly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.73 © Copyright...
  • Page 744 CAN HIGH CAN LOW NOT USED OG/YE SWITCHED POWER CONTROL GY/RD AUX LIGHT SWITCH INDICATOR LIGHT BU/RD HEATED GRIP SWITCH OUTPUT YE/BK TRANS GEAR POSITION SENSOR OUTPUT NOT USED 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.74 © Copyright...
  • Page 745 WINDSHIELD MOTOR B OG/WH LOCK B SIGNAL RD/WH LOCK A SIGNAL VCM POWER DG/RD LH AUX LIGHT POWER DG/BN RH AUX LIGHT POWER BN/WH NOT USED VCM GROUND VCM POWER 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.75 © Copyright...
  • Page 746 HEATED GRIP SWITCH INCREASE BU/BK HEATED GRIP SWITCH DECREASE LEFT TURN SIGNAL CONTROL (2017 ONLY) YE/DG RIGHT TURN SIGNAL CONTROL (2017 ONLY) BN/DB WINDSHIELD SWITCH UP DG/DB WINDSHIELD SWITCH DOWN 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.76 © Copyright...
  • Page 747 3. Remove fasteners and headlight retaining ring . Withdraw the reflector assembly far enough to remove bulb. 3. Using a clean, oil-free cloth, replace the headlight bulb. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.77 © Copyright...
  • Page 748 . Torque to specification. TORQUE Bezel Fasteners: 35 in-lbs (4 N·m) • In the 9 o’clock position, the E4 markings indicates Europe headlight lens. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.78 © Copyright...
  • Page 749 7. Perform headlight adjustment. See “HEADLIGHT AIM INSPECTION”. 8. Install headlight bezel and retain with two fasteners . Torque to specification. TORQUE Bezel Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.79 © Copyright...
  • Page 750 6. Pull the front portion of the nacelle out far enough to access the four fasteners securing the headlight bucket to the front nacelle cover. Remove four fasteners and washers. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.80 © Copyright...
  • Page 751 12. Install the four headlamp bucket fasteners washers. Torque to specification. 9. Remove fasteners and headlight retaining ring TORQUE Headlamp Bucket Fasteners: 88 in-lbs (10 N·m) 13. Connect the headlamp connector 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.81 © Copyright...
  • Page 752 Verify the rubber grommets securing the auxiliary light / turn signal harness have been slid into place. 17. Torque the upper nacelle fasteners specification. TORQUE Upper Nacelle Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.82 © Copyright...
  • Page 753 (low or high beam) the high beam indicator light will flash on the instrument cluster. Once the bulb has been replaced and the issue corrected, the high beam indicator will return to normal operation. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.83 © Copyright...
  • Page 754 • With the VCM connected, bypass the switch by providing the the GY wire a direct path to ground. The horn should sound until the ground path is removed. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.84 © Copyright...
  • Page 755 H H O O R R N N 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 ( ( 2 2 0 0 1 1 7 7 ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.85...
  • Page 756 60 ohms. Ignition Coil Cover: 88 in-lbs (10 N·m) • For more information regarding the CAN Network, refer to: CAN (Controller Area Network) Diagnostic Overview page 4.71 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.86 © Copyright...
  • Page 757 H H O O R R N N 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 ( ( 2 2 0 0 1 1 8 8 + + ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.87...
  • Page 758 4. Installation is performed by reversing the removal procedure. 5. Torque fasteners to specification. TORQUE Horn to Bracket: 88 in-lbs (10 N·m) TORQUE Ignition Coil Cover: 88 in-lbs (10 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.88 © Copyright...
  • Page 759 3. Lift the tail light assembly off of the rear fender and disconnect the electrical connectors noting their position for reassembly. 4. Remove the tail light assembly. License Plate Light Removal 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.89 © Copyright...
  • Page 760 88 in-lbs (10 N·m) 7. Remove the license plate light from the license plate bracket. TORQUE Tail Light Asm to Fender: 88 in-lbs (10 N·m) Tail / Brake Light Removal 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.90 © Copyright...
  • Page 761 LED assembly. 6. Installation is performed by reversing the removal procedure. Torque all fasteners to specification. TORQUE LED Trunk Light Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.91 © Copyright...
  • Page 762 3. Installation is performed by reversing the removal procedure. Torque all fasteners to specification. TORQUE Turn Signal Fastener: 35 in-lbs (4 N·m) 3. Remove turn signal. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.92 © Copyright...
  • Page 763 3. Installation is performed by reversing the removal procedure. Torque all fasteners to specification. TORQUE Turn Signal Fastener: 18 ft-lbs (24 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.93 © Copyright...
  • Page 764 REMOVAL 1. Disconnect Switch Cube electrical connection. 2. Loosen and remove outer rear and front switch cube fasteners and separate front and rear switch cube covers. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.94 © Copyright...
  • Page 765 Torque fasteners to specification. . Connect cube electrical connection. TORQUE Cube Cover Fasteners: 12 in-lbs (1 N·m) 2. Align inner switch cube control half with locating hole in handlebar. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.95 © Copyright...
  • Page 766 The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel promptly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.96 © Copyright...
  • Page 767 Illuminates when the sidestand is in the down position. Indicator Vehicle Speed When metric mode is selected, speed displays in kilometers per hour. — Multi-Function — Display (MFD) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.97 © Copyright...
  • Page 768 The lamp flashes if the key fob is not detected within range or if the fob is not programmed properly. It also illuminates with the low battery voltage indicator when the key fob battery is low. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.98 © Copyright...
  • Page 769 Gear position displays at all times while the engine is running, unless a fault occurs with the gear position sensor. Temperature The temperature area displays ambient air temperature. Fuel Range 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.99 © Copyright...
  • Page 770 ELECTRICAL The fuel range displays the distance the motorcycle can travel on the remaining fuel in the fuel tank. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.100 © Copyright...
  • Page 771 Amber Lamp: Cruise control is enabled, but not set. Green Lamp: Cruise control is set to the desired speed. Cruise Control Status 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.101 © Copyright...
  • Page 772 Security System Locked range or if the fob is not programmed properly. It also illuminates with the low battery voltage indicator when the key fob battery is low. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.102 © Copyright...
  • Page 773 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 ( ( C C H H I I E E F F T T A A I I N N / / R R O O A A D D M M A A S S T T E E R R ) ) SPEEDOMETER DISPLAY 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.103...
  • Page 774 Sidestand Illuminates when the sidestand is in the down position. Indicator Vehicle Speed When metric mode is selected, speed displays in kilometers per hour. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.104 © Copyright...
  • Page 775 ELECTRICAL TACHOMETER DISPLAY 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.105 © Copyright...
  • Page 776 The lamp flashes if the key fob is not detected within range or if the fob is not programmed properly. It also illuminates with the low battery voltage indicator when the key fob battery is low. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.106 © Copyright...
  • Page 777 1. Test circuit for continuity and/or shorts in wiring. 2. Fix any shorts in the wiring and reinstall new fuse. Go to Step 8 Go to Step 4 Did you find and repair the condition? 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.107 © Copyright...
  • Page 778 4. If antenna connector shows proper voltage, check operation of GPS. If GPS still is not functioning, proceed to step 5. 5. Turn the ignition off and make the following measurements on the antenna connector: 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.108 © Copyright...
  • Page 779 Digital Wrench® II is only available for authorized dealers. Refer to the user guide and carefully follow all instructions provided. See Digital Wrench II User Manual page 1.54 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.109 © Copyright...
  • Page 780 2. If this does not resolve the issue, clear all previously paired headsets from Ride Command, and repair the headset. 3. If there is still unclear sound, pair different headset and see if sound quality improves. 4. If sound quality improves, previous headset was malfunctioning. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.110 © Copyright...
  • Page 781 • Electronic Throttle Control (ETC) • Engine Control Module (ECM) • Vehicle Control Module (VCM) • Anti-Lock Brake Control Module Cruise Related Inputs / Outputs (RH Switch Cube): 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.111 © Copyright...
  • Page 782 C C R R U U I I S S E E C C O O N N T T R R O O L L D D I I A A G G N N O O S S T T I I C C S S 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.112...
  • Page 783 A: Does the LED on the key fob blink when the bike is turned on? B: Does the LED on the key fob blink when a key fob button is pressed? 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.113 © Copyright...
  • Page 784 3. Connect to Digital Wrench and verify the correct VCM software is installed. 4. Verify that serial numbers match the key fob being used. 5. Inspect the 125 kHz antenna for broken wires. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.114 © Copyright...
  • Page 785 C) thus breaking the ground path to the VCM and stopping power supply to the adjustment motor. 2018+ For 2018+ the windshield switch is CAN to models VCM. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.115 © Copyright...
  • Page 786 ELECTRICAL 2017 Windshield Wiring Diagram 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.116 © Copyright...
  • Page 787 ELECTRICAL 2018+ Windshield Wiring Diagram 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.117 © Copyright...
  • Page 788 3. Remove the hex-head fasteners and fasteners remove cowl panel. securing the windshield lift bracket to the motor. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.118 © Copyright...
  • Page 789 ELECTRICAL 6. Remove the four nuts securing the windshield lift motor to the mounting bracket. 7. Disconnect the electrical connector(s) and remove motor assembly. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.119 © Copyright...
  • Page 790 TORQUE Windshield Motor Nuts: 35 in-lbs (4 N·m) TORQUE Windshield Cowl Panel Fasteners: 35 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.120 © Copyright...
  • Page 791 Installation - (Chieftain Dark Horse) page 7.58 • Chieftain / Roadmaster: See Outer Fairing Installation - (Chieftain / Roadmaster) page 7.64 7. Verify the windshield moves up and down through the travel range. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.121 © Copyright...
  • Page 792 C C E E L L L L M M O O D D 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 For Cell Modem Troubleshooting see Ride Command Diagnostics / Troubleshooting page 10.107 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.122 © Copyright...
  • Page 793 The gear position switch is different based off of engine build date. These switches are not interchangeable. 2017–19 (MULTIPLE RESISTANCE SWITCH) 2020+ (ROTARY SWITCH) REMOVAL 2. Remove right-hand saddlebag (if equipped). 1. Remove upper right-hand sidecover 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.123 © Copyright...
  • Page 794 5. Remove right-hand lower sidecover Use of short (stub-nose) allen wrench is necessary for bottom two bolts and front bolt. 8. From under the motorcycle, unplug gear position connector 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.124 © Copyright...
  • Page 795 CAUTION Scotch-Brite Green (600 grit is the coarsest abrasive that should be used). DO NOT use a power tool or rotary tool to polish. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.125 © Copyright...
  • Page 796 3. Using a multimeter, test the switch for proper Listen for an audible click to indicate the connection resistance. See Gear Position Switch Test page is secure. 10.129. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.126 © Copyright...
  • Page 797 88 in-lbs (10 N·m) 7. Install right-hand rear heatshield . Torque clamps to specification. TORQUE Footpeg Fastener: 35 ft-lbs (47 N·m) TORQUE Heat Shield Clamps: 31 in-lbs (4 N·m) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.127 © Copyright...
  • Page 798 Torque fasteners to specification. position is indicated on the instrument cluster. TORQUE Tip-Over Bar Fasteners: 18 ft-lbs (24 N·m) 11. Install right-hand saddlebag (if equipped). 12. Install upper right-hand sidecover 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.128 © Copyright...
  • Page 799 2. Set multi meter to measure resistance (Ohms). 3. Connect one meter lead to each of the pins on the switch connector. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.129 © Copyright...
  • Page 800 Use fine abrasive pad (400 grit or finer), apply light pressure by Paint Is found hand in a rotary motion to the chassis ground contact point. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.130 © Copyright...
  • Page 801 2. Ensure both the top and bottom of the lug is completely clean and clear. 3. Ensure the terminal is not bent. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.131 © Copyright...
  • Page 802 4. Compare resistance across these two pin in each gear to the table below. RESISTANCE GEAR NOMINAL 261.2 248.1 274.2 41.6 39.5 43.7 73.2 69.5 76.8 108.9 103.5 114.4 146.5 139.2 153.8 196.3 186.5 206.1 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.132 © Copyright...
  • Page 803 1. Connect the unit to Digital Wrench. VOLTAGE GEAR NOMINAL 0.63 0.67 0.59 1.00 1.04 0.96 1.38 1.42 1.34 2.13 2.17 2.09 2.88 2.92 2.84 3.63 3.67 3.59 4.38 4.42 4.34 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.133 © Copyright...
  • Page 804 Examine pin for excessive wear at contact point. The pin should move freely in shift drum bore and be smooth and rounded at contact point. MEASUREMENT 14.5 mm ± 0.5 mm 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.134 © Copyright...
  • Page 805 Only in the event of an actual tipover condition is the voltage output within a range that will cause the ECM to disconnect the fuel and ignition circuits as well as the internal drivers that control them. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.135 © Copyright...
  • Page 806 9. Connect Digital Wrench for further diagnosis of the tipover sensor circuit. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.136 © Copyright...
  • Page 807 A A N N T T I I - - L L O O C C K K B B R R A A K K E E S S Y Y S S T T E E M M , , 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 ( ( 2 2 0 0 1 1 7 7 ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.137...
  • Page 808 A A N N T T I I - - L L O O C C K K B B R R A A K K E E S S Y Y S S T T E E M M , , 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 ( ( 2 2 0 0 1 1 8 8 + + ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.138...
  • Page 809 C C E E N N T T R R A A L L L L O O C C K K I I N N G G S S Y Y S S T T E E M M , , 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 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.139...
  • Page 810 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 , , 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 ( ( 2 2 0 0 1 1 7 7 ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.140...
  • Page 811 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 , , 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 ( ( 2 2 0 0 1 1 8 8 + + ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.141...
  • Page 812 K K E E Y Y L L E E S S S S I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M , , 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 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.142...
  • Page 813 P P O O W W E E R R W W I I N N D D S S H H I I E E L L D D , , 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 ( ( 2 2 0 0 1 1 7 7 ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.143...
  • Page 814 P P O O W W E E R R W W I I N N D D S S H H I I E E L L D D , , 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 ( ( 2 2 0 0 1 1 8 8 + + ) ) 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.144...
  • Page 815 Testing Voltage Drop page results. The testing practices described in this chapter 10.151 are more certain and rely only on the DMM and your knowledge. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.145 © Copyright...
  • Page 816 Use electrical tape to cover the exposed conductive parts of the circuit, mainly the clamps of your test leads. If they contact each other, circuit or component damage could occur from a short. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.146 © Copyright...
  • Page 817 Ground page 10.148 and Testing For A Short To Voltage page 10.149. For a video demonstration, scan the QR code below, or right click it and select “open in new tab.” 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.147 © Copyright...
  • Page 818 Ensure you are using the correct adapter.Connector Probing Guidelines page 10.146 8. If there is continuity, the harness is damaged and should be repaired or replaced. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.148 © Copyright...
  • Page 819 Failure to do so can lead to serious injury and/or damage to the machine. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.149 © Copyright...
  • Page 820 3. Run the unit briefly and shut it off after idle stabilizes. NOTE Do not disturb or disconnect the meter leads. 4. With ignition switch off, and after 12 minutes have passed, read current drain. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.150 © Copyright...
  • Page 821 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.151 © Copyright...
  • Page 822 ELECTRICAL NOTES 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual 10.152 © Copyright...
  • Page 823 WIRING DIAGRAMS APPENDIX A WIRING DIAGRAMS 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 824 ELECTRICAL NOTES 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual © Copyright...
  • Page 825 Assembly View ........... 10.11 Fenders ............7.4-7.5 Current Drain Test ..........10.33 Floorboards............7.7 Inspection ............10.19 Foot Pegs .............. 7.7 Installation ............10.13 Fork ..............8.27 Load Test ............10.25 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.1 © Copyright...
  • Page 826 Front Master Cylinder Service ......9.36, 9.38 Installation ............9.48 Rebuilding ............9.47 Lever Reserve Inspection........9.32 Precautions ............9.29 Removal...............9.47 Rear Caliper Installation .........9.48 Cam Chain Assembly View .............3.40 Rear Caliper Service..........9.47 Rear Master Cylinder..........9.15 Installation ............3.49 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.2 © Copyright...
  • Page 827 Cooled Seats Operation Overview ..........10.59 Installation (2023)..........5.55 Pinion Shaft Bearing Inspection........5.33 Troubleshooting..........10.59 Pinion Shaft Installation (2017-2020) ......5.26 Test / Replace ............4.62 Pinion Shaft Installation (2021-2022) ......5.31 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.3 © Copyright...
  • Page 828 Special Tools ............4.4 Cylinder Head / Valves Specifications ............3.38 Specifications ............4.4 Troubleshooting............3.95 Electrical Connector Probing Guidelines ......10.146 Cylinder Head Temperature Sensor Continuity / Resistance........10.147 Replacement ............4.48 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.4 © Copyright...
  • Page 829 Front Wheel (Cast) Installation ............7.63 Assembly View ..........8.30-8.31 Removal...............7.62 Front Wheel (Spoked) Fairing (Chieftain / Roadmaster), Outer Assembly View .............8.32 Installation ............7.64 Front Wheel & Suspension Removal...............7.60 Troubleshooting............8.58 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.5 © Copyright...
  • Page 830 Overview, Chief Classic / Chief Vintage / Chief Dark Engine..............3.37 Horse / Springfield ..........10.96 Tire Changing............. 8.115 Overview, Chieftain Dark Horse......10.101 Gross Vehicle Weight Rating (GVWR) ......1.46 Instrument Panel 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.6 © Copyright...
  • Page 831 Installation (2021-2022) ..........5.31 Model Number Decoder..........1.2 Installation (2023+)..........5.34 Model Number Location ..........1.3 Removal (2017-2020) ..........5.26 Motor Mounts Removal (2021–2022) ..........5.30 Assembly View .............3.13 Removal (2023+) ...........5.33 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.7 © Copyright...
  • Page 832 Rear Brake Sensors Assembly View .............9.11 Location...............4.15 Service Intervals Rear Fender Installation ............7.43 Maintenance............2.5 Removal...............7.42 Service Notes Rear Sprocket Body ..............7.3 Inspection ............8.78 Brake System ............9.3 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.8 © Copyright...
  • Page 833 Maintenance............2.2 Side Cover (Lower) Oiling System ............3.26 Piston ..............3.99 Removal / Installation..........7.22 Side Cover (Upper) Primary Drive ............5.4 Removal / Installation..........7.22 Speedometer Display ............10.103 Side Panels 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.9 © Copyright...
  • Page 834 Troubleshooting............8.97 Installation ............8.126 Removal............. 8.118 Swing Arm Inspection ............8.12 TMAP Sensor Swingarm Overview .............4.47 Replacement ............4.47 Assembly View .............8.72 Bushing / Bearing Replacement .......8.92 Tools, Special ............1.49 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.10 © Copyright...
  • Page 835 Front, Removal / Installation (Classic / Vintage) ..10.92 Removal / Installation..........8.39 Operation Overview ..........10.92 Service Notes ............8.20 Rear, Removal / Installation (All Models) ....10.93 Service Specifications ..........8.21 Special Tools ............8.20 Wheel, Rear 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.11 © Copyright...
  • Page 836 Special Tools ............8.100 Wiring Diagram ABS System ..........10.137-10.138 Central Locking System........10.139 Keyless Ignition System ........10.142 Power Windshield ..........10.144 Power WIndshield ..........10.143 Starting System ........10.140-10.141 9941443 R04 - 2017-2024 Indian Motorcycle (Full-Size) Service Manual IX.12 © Copyright...
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