Indian Motorcycle FTR 2019 Service Manual
  1. Manuals
  2. Brands
  3. Indian Motorcycle Manuals
  4. Motorcycle
  5. FTR 2019
  6. Service manual
Indian Motorcycle FTR 2019 Service Manual

Indian Motorcycle FTR 2019 Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
Table of Contents

Advertisement

Quick Links

Download this manual
2019-2020, 2022-2023 FTR
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most
recent version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer
®
technicians in a properly equipped shop and should be kept available for reference. All references to left and
right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with the service procedures before starting any repair. Certain procedures require the use of special tools. Use
only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures
outlined in this Service Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more
useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit
feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature
Question'.
Publication Printed November 2022 (PN 9941004 R01)
© Copyright 2022 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due
to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the
information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for
omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the FTR 2019 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Indian Motorcycle FTR 2019

Summary of Contents for Indian Motorcycle FTR 2019

  • Page 1 The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer ®...

  • Page 2: Safety Warnings

    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

    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 2019-2020, 2022-2023 FTR Service Manual Chapter Summary CHAPTER 1 : GENERAL / SPECIFICATIONS CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING / EXHAUST CHAPTER 4 : FUEL DELIVERY / EFI CHAPTER 5 : CLUTCH / PRIMARY / SHIFT CHAPTER 6 : TRANSMISSION / CRANKSHAFT CHAPTER 7 :...

  • Page 7: Chapter 1 General / Specifications

    GENERAL / SPECIFICATIONS CHAPTER 1 GENERAL / SPECIFICATIONS VEHICLE INFORMATION................1.2 .
  • Page 8 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E I I N N F F O O R R M M A A T T I I O O N N M M O O D D E E L L N N U U M M B B E E R R D D E E S S I I G G N N A A T T I I O O N N Example: N19RTA22AA TYPE MODEL...
  • Page 9 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E I I D D E E N N T T I I F F I I C C A A T T I I O O N N N N U U M M B B E E R R ( ( V V I I N N ) ) D D E E S S I I G G N N A A T T I I O O N N Example: 56KTCAAA0E3000024 Vehicle Descriptors...

  • Page 10: Model Numbers

    GENERAL / SPECIFICATIONS G G E E N N E E R R A A L L S S P P E E C C I I F F I I C C A A T T I I O O N N S S 2 2 0 0 1 1 9 9 - - 2 2 0 0 2 2 0 0 F F T T R R YEAR / MODEL PAINT COLOR / CODE...
  • Page 11 GENERAL / SPECIFICATIONS YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2019 Indian Red / Black Pearl N19RTS22AA N19RTS22CR N19RTS22BA N19RTS22ER FTR S P-639 / P-666 N19RTS22CA N19RTS22XR N19RTS22EA N19RTS22AC Gloss Black / Black Pearl N19RTS22XA N19RTS22BC P-266 / P666 N19RTS22AR N19RTS22CC N19RTS22BR...
  • Page 12 GENERAL / SPECIFICATIONS MODEL YEAR 49 State with ABS 50 State with ABS International / China 2019-2020 DIMENSIONS Overall Length 90 in. (2287 mm) 33.9 in. (862 mm) Overall Width Overall Height 2019–20 FTR Base / S / 45.9 in. (1167 mm) Carbon 46.9 in.
  • Page 13 GENERAL / SPECIFICATIONS 19 in. x 3.00 in. Spoked 2019 Limited Edition Rear Wheel Size/Type 2019–20 FTR Base / S / S 18 in. x 4.25 in. Spoked Rally / Carbon 18 in x 4.25 in. Spoked 2019 Limited Edition Front Tire Type/Size 120/70R19 60V Rear Tire Type/Size...

  • Page 14: Model Year

    GENERAL / SPECIFICATIONS 1 Down / 5 Up Gear Shift Pattern Final Drive Type Chain / 525HV3X Overall Gear Ratio 1st Gear 13.361 : 1 2nd Gear 9.082 : 1 3rd Gear 7.237 : 1 4th Gear 6.141 : 1 5th Gear 5.428 : 1 6th Gear...
  • Page 15 GENERAL / SPECIFICATIONS 2 2 0 0 2 2 2 2 F F T T R R YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2022 Black Smoke N22RZA22A4 N22RZA22E4 P-2034 / P-463 N22RZA22B4 N22RZA22X4 N22RZA22C4 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual ©...
  • Page 16 GENERAL / SPECIFICATIONS YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2022 Maroon Metallic N22RZS25AM N22RZS25AF FTR S P-1931 / P-711 N22RZS25BM N22RZS25BF N22RZS25CM N22RZS25CF White Smoke N22RZS25EM N22RZS25EF P-1717 / P–675 N22RZS25XM N22RZS25XF N22RZR25E8 N22RZR25A8 2022 Carbon / Silver N22RZR25X8 N22RZR25B8 FTR S Carbon...
  • Page 17 GENERAL / SPECIFICATIONS YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2022 Carbon / Indian Red N22RTE25AV N22RTE25EV P-1911 / P-639 N22RTE25BV N22RTE25XV Championship N22RTE25CV Edition YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2022 Stealth Gray N22RZS25EG FTR Stealth Gray P-804 Special Edition...
  • Page 18 GENERAL / SPECIFICATIONS MODEL YEAR 49 State with ABS 50 State with ABS International / China 2022 DIMENSIONS Overall Length 90 in. (2287 mm) 33.9 in. (862 mm) Overall Width Overall Height 45.9 in. (1167 mm) FTR, FTR S, FTR R Carbon FTR Championship Edition 52.6”...
  • Page 19 GENERAL / SPECIFICATIONS FTR Championship Edition 19 in. x 3.00 in. Cast Front Tire Type/Size FTR, FTR S, FTR R Carbon 120/70ZR17 58W FTR Rally, FTR 120/70R19M/C 60V Championship Edition Rear Wheel Size/Type FTR Rally, FTR 18 in x 4.25 in. Spoked Championship Edition FTR, FTR S, FTR R Carbon 17 in.

  • Page 20: Drive Train

    GENERAL / SPECIFICATIONS DRIVETRAIN Primary Drive Gear Drive Wet Clutch Crank Gear 46–Tooth Clutch Gear 77–Tooth Clutch Type Wet, Assist & Slip, Multi-Plate Primary Reduction Ratio 1.674 : 1 Transmission Type 6 Speed / Constant-Mesh / Foot Shift 1st Gear Ratio 2.769 : 1 2nd Gear Ratio 1.882 : 1...
  • Page 21 GENERAL / SPECIFICATIONS MODEL YEAR ALL MODELS 2022 ELECTRICAL 460W @ 3000 RPM Alternator 12 Volt, 12AH, 240CCA Battery Maintenance Free AGM Voltage Regulator 14.5 Volts / 32 Amp Headlight Non-Serviceable LED Tail/Brake Light Non-Serviceable LED Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Speedometer...
  • Page 22 GENERAL / SPECIFICATIONS 2 2 0 0 2 2 3 3 F F T T R R YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2023 Stealth Gray: N23RZA22A1 N23RZA22AG P-804 N23RZA22B1 N23RZA22BG Onyx Black Metallic: N23RZA22C1 N23RZA22CG P-800 N23RZA22E1 N23RZA22EG N233VA24E1...
  • Page 23 GENERAL / SPECIFICATIONS YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS N23RZR22XC N23RZR22AC N23RZR221C N23RZR22BC N23RZR22PC 2023 Carbon Fiber: N23RZR22CC FTR Carbon R P-557 N23RZR22EC N23RZR22JC N23FZR22J9 N23RZR22E9 N23FZR22Z9 N23FZR22P9 YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2023 Onyx Black Metallic: N23RZM22A3...
  • Page 24 GENERAL / SPECIFICATIONS YEAR / MODEL PAINT COLOR / CODE MODEL NUMBERS 2023 Black Smoke: N23RTT22JS N23RTT22PS P-866 FTR Rally 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 1.18 © Copyright Polaris Industries Inc.
  • Page 25 GENERAL / SPECIFICATIONS MODEL YEAR 49 State with ABS 50 State with ABS International / China 2023 DIMENSIONS Overall Length 90 in. (2287 mm) Overall Width 33.9 in. (862 mm) Overall Height FTR, FTR S, FTR R Carbon 45.9 in. (1167 mm) Limited Edition 46.9 in.
  • Page 26 GENERAL / SPECIFICATIONS Rear Wheel Size/Type FTR Rally 18 in x 4.25 in. Spoked FTR, FTR S, FTR R Carbon 17 in. x 5.50 in. Cast Rear Tire Type/Size FTR, FTR S, FTR R Carbon 180/55ZR17 73W FTR Rally 150/70R18M/C 70V Tire Pressure Front: 36 psi (248 kPa) All wheel and tire...
  • Page 27 GENERAL / SPECIFICATIONS Transmission Type 6 Speed / Constant-Mesh / Foot Shift 1st Gear Ratio 2.769 : 1 2nd Gear Ratio 1.882 : 1 3rd Gear Ratio 1.500 : 1 4th Gear Ratio 1.273 : 1 5th Gear Ratio 1.125 : 1 6th Gear Ratio 0.966 : 1 Gear Shift Pattern...
  • Page 28 GENERAL / SPECIFICATIONS MODEL YEAR ALL MODELS 2022 ELECTRICAL Alternator 460W @ 3000 RPM Battery 12 Volt, 12AH, 240CCA, Maintenance Free AGM Voltage Regulator 14.5 Volts / 32 Amp Headlight Non-Serviceable LED Tail/Brake Light Non-Serviceable LED Turn Signal Non-Serviceable LED License Plate Non-Serviceable LED Speedometer...
  • Page 29 GENERAL / SPECIFICATIONS V V E E H H I I C C L L E E L L O O A A D D I I N N G G G G R R O O S S S S V V E E H H I I C C L L E E W W E E I I G G H H T T R R A A T T I I N N G G ( ( G G V V W W R R ) ) WARNING Exceeding the gross vehicle weight rating of your motorcycle can reduce stability and handling and...
  • Page 30 P P U U B B L L I I C C A A T T I I O O N N P P A A R R T T N N U U M M B B E E R R S S Some Indian Motorcycle publications, such as Owner’s Manuals and Parts Books may be available on-line at the Indian Motorcycle website;...
  • Page 31 GENERAL / SPECIFICATIONS E E M M I I S S S S I I O O N N I I N N F F O O R R M M A A T T I I O O N N E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L S S Y Y S S T T E E M M S S N N O O I I S S E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L Tampering with Noise Control Systems is Prohibited.
  • Page 32 GENERAL / SPECIFICATIONS C C R R A A N N K K C C A A S S E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L E E V V A A P P O O R R A A T T I I V V E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L The crankcase emission control system is comprised California and International models are equipped with...
  • Page 33 GENERAL / SPECIFICATIONS S S P P E E C C I I A A L L T T O O O O L L S S U U S S I I N N G G S S P P E E C C I I A A L L T T O O O O L L S S How To Use This Book Special tools have been designed exclusively for The Special Tools Index located in this chapter...
  • Page 34 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 35 GENERAL / SPECIFICATIONS D D I I G G I I T T A A L L W W R R E E N N C C H H I I I I U U S S E E R R M M A A N N U U A A L L Review the Digital Wrench II user manual for information and details regarding the following: •...
  • Page 36 GENERAL / SPECIFICATIONS S S P P E E C C I I A A L L T T O O O O L L S S I I N N D D E E X X MultiLink XP Battery Tester Relay Bypass Tool PU-52792 PU-50296...
  • Page 37 GENERAL / SPECIFICATIONS Brake Lever Reserve Tool Steering Head Adjustment Socket Front Axle Adapter PV-50104 (Commercially available)(See PV-43508 example below) Chain Breaker Tool Shock Preload Spanner Wrench Swingarm Bushing Tool (Commercially available) 2884176 PF-51237 (KM500R) Swingarm Lock Ring Tool Swingarm Adjuster Tool Fork Spring Compressor PF-52737 PF-52738...
  • Page 38 GENERAL / SPECIFICATIONS Fork Cap Wrench Fork Seal Guide Inverted Fork Seal Installer PF-52744 PV–47037 PV-47035 Cartridge Holder Crankshaft Locking Pin Oil Filter Wrench PF-52745 PF-51235-A PU-50105 Engine Transmission Lock Tool Flywheel Puller Output Shaft Seal Tool PA-49316–A PF-51612 PF-51243 Water Pump Seal Installation Tool Bearing Removal Kit Engine Stand Adapter Plate...
  • Page 39 GENERAL / SPECIFICATIONS Engine Stand Adapter Crankcase Separator Tool Cup Adapter PF-51609 PF-51234-A PF-51665 Engine Case Assembly Cup Mainshaft / Crankcase Installer Crankcase Installation Adapter (5/16) PF-51663 PV-45030 PV-47429 Fork spring compressor adapter Main Bearing Tool Main Bearing Tool PV–49464 PF-52726 1 PF-52726 2 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 40 GENERAL / SPECIFICATIONS Fork Pull-up Tool (Ohlins) Fork Top Nut Tool (Ohlins) Fork Spanner (Ohlins) PF-53159 PF-53158 PF-53160 Wireless Vehicle Link Electrical Tester Kit PU-51435 PV-43526 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 1.34 © Copyright Polaris Industries Inc.
  • Page 41 GENERAL / SPECIFICATIONS R R E E F F E E R R E E N N C C E E M M A A S S T T E E R R T T O O R R Q Q U U E E T T A A B B L L E E - - F F T T R R TORQUE 36 in-lbs (4 N·m) ITEM...
  • Page 42 GENERAL / SPECIFICATIONS Exhaust Clamp (Muffler Coolant Recovery Bottle 36 in-lbs (4 N·m) 144 in-lbs (16 N·m) Fasteners to Resonator) Coolant Temperature Exhaust Clamp (Front 17 ft-lbs (23 N·m) Sensor Headpipe to Rear 144 in-lbs (16 N·m) Headpipe) – 2019 /2020 Cooling Fan Fastener 36 in-lbs (4 N·m) models...
  • Page 43 GENERAL / SPECIFICATIONS Fuel Pump Fastener 80 in-lbs (9 N·m) Oil Pickup Fastener 88 in-lbs (10 N·m) Fuse Box Mounting Oil Separator Fasteners 14 in-lbs (2 N·m) 36 in-lbs (4 N·m) Fasteners Oxygen Sensor 14 ft-lbs (19 N·m) Gear Position Sensor 53 in-lbs (6 N·m) Fastener Piston Cooling Jet...
  • Page 44 GENERAL / SPECIFICATIONS 14 ft-lbs (19 N·m) Oil Plug Transmission Knock Sensor Fastener 159 in-lbs (18 N·m) Input Shaft 10 ft-lbs (14 N·m) Oil Pressure Switch Throttle Body Hose 17 in-lbs (2 N·m) Oxygen Sensor 14 ft-lbs (19 N·m) Clamp Regulator / Rectifier Nut 30 in-lbs (3 N·m) 53 in-lbs (6 N·m)
  • Page 45 GENERAL / SPECIFICATIONS Bearing Retainer Plate Horn to Frame Bracket 88 in-lbs (10 N·m) 96 in-lbs (11 N·m) Fastener Fastener Balance Shaft Gear Instrument Panel 83 ft-lbs (112 N·m) 84 in-lbs (9 N·m) Fasteners Fastener 72 in-lbs (8 N·m) 22 ft-lbs (30 N·m) Crankcase Fasteners License Plate Fasteners Step 1: Torque both...
  • Page 46 GENERAL / SPECIFICATIONS Sub-Frame Fasteners Fork Cap 12 ft-lbs (16 N·m) 47 ft-lbs (64 N·m) (M10) Fork Triple Clamp 18 ft-lbs (24 N·m) Sub-Frame Fasteners Fasteners (Upper) 96 in-lbs (11 N·m) (M6) Fork Triple Clamp 18 ft-lbs (24 N·m) Swingarm Pivot Bolt 52 ft-lbs (70 N·m) Fasteners (Lower) Tail Light Fasteners...
  • Page 47 GENERAL / SPECIFICATIONS Tone Ring Fasteners 84 in-lbs (9 N·m) Master Cylinder Pushrod 54 in-lbs (6 N·m) Nut: 44 in-lbs (5 N·m) Valve Stem Nut P-Clamp Fastener 84 in-lbs (9 N·m) BRAKES Brake Pedal Pivot Inner 18 ft-lbs (24 N·m) Wheel Speed Sensor Fastener 97 in-lbs (11 N·m)
  • Page 48 GENERAL / SPECIFICATIONS License Plate Mount 96 in-lbs (11 N·m) Fasteners Oil Cooler Mount 72 in-lbs (8 N·m) Fastener Regulator / Rectifier Nut 30 in-lbs (3 N·m) Speedometer Fastener, 10 in-lbs (1 N·m) speedometer to case Speedometer Fastener, speedometer to riser 55 in-lbs (6 N·m) Speedometer (touch 54 in-lbs (6 N·m)
  • Page 49 GENERAL / SPECIFICATIONS S S A A E E T T A A P P D D R R I I L L L L S S I I Z Z E E S S M M E E T T R R I I C C T T A A P P D D R R I I L L L L S S I I Z Z E E S S NEAREST THREAD SIZE / DRILL THREAD SIZE / DRILL...
  • Page 50 GENERAL / SPECIFICATIONS D D E E C C I I M M A A L L E E Q Q U U I I V V A A L L E E N N T T S S 1/64 in = .0156 in 39/64 in = .6094 in 1/32 in = .0312 in [1 mm = .0394 in] 5/8 in = .625 in [16mm=.
  • Page 51 GENERAL / SPECIFICATIONS F F A A H H R R E E N N H H E E I I T T T T O O C C E E L L S S I I U U S S M M E E A A S S U U R R E E M M E E N N T T C C O O N N V V E E R R S S I I O O N N C C H H A A R R T T UNIT OF MULTIPLIED...
  • Page 52 GENERAL / SPECIFICATIONS UNIT OF MULTIPLIED COVERTS TO MEASURE Kilograms force = Kilo pascals x 98.1 per cm (kPa) = Cylinder p (3.14159) x R x H (height) Volume 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 1.46 © Copyright Polaris Industries Inc.

  • Page 53: Chapter 2 Maintenance

    ........2.3 INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS .
  • Page 54 — DOT 4 Engine / Transmission Oil 15W60 Full Synthetic 4.5 qts. (4.25 L) Dry Engine Indian Motorcycle Fork Oil FTR / FTR S: 508 cc Fuchs SAF 5113, Öhlins Motorcycle Fork Oil FTR Rally: 519 cc Front Fork Fluid R&T, or approved...
  • Page 55 2880016 Carbon Cleaner, Fuel 12 oz 2881911 Commercially Crankcase Sealant (Loctite Ultra Black 598) Available Indian Motorcycle Fork Oil (PN: 2208093) FTR / FTR S / FTR Rally Fuchs SAF 5113, Ohlins Fork Oil Type quart fork oil, or approved...
  • Page 56 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Indian Motorcycle dealer perform these services. E - Emission Control System Service (California / International) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 57 MAINTENANCE 500 MILE (800 KM) SERVICE ITEM REMARKS Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Mount Fasteners Inspect; tighten, adjust Engine Coolant Inspect fluid level, add coolant if necessary Engine Oil &...
  • Page 58 MAINTENANCE 2,500 MILE (4,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Evaporative Emission Control System Inspect;...
  • Page 59 MAINTENANCE 5,000 MILE (8,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Evaporative Emission Control System Inspect;...
  • Page 60 MAINTENANCE 10,000 MILE (16,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Compression Inspect; correct if necessary Engine Coolant Inspect fluid level, add coolant if necessary Engine Oil &...
  • Page 61 MAINTENANCE 15,000 MILE (24,000 KM) SERVICE ITEM REMARKS Replace Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Replace Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Evaporative Emission Control System Inspect;...
  • Page 62 MAINTENANCE 20,000 MILE (32,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Engine Compression Inspect;...
  • Page 63 MAINTENANCE 25,000 MILE (40,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Evaporative Emission Control System Inspect;...
  • Page 64 MAINTENANCE 30,000 MILE (48,000 KM) SERVICE ITEM REMARKS Replace Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Replace Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Engine Compression Inspect;...
  • Page 65 MAINTENANCE 35,000 MILE (52,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Evaporative Emission Control System Inspect;...
  • Page 66 MAINTENANCE 40,000 MILE (64,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Engine Compression Inspect;...
  • Page 67 MAINTENANCE 45,000 MILE (72,000 KM) SERVICE ITEM REMARKS Replace Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Replace Drive Chain Engine Coolant Inspect fluid level, add coolant if necessary Evaporative Emission Control System Inspect;...
  • Page 68 MAINTENANCE 50,000 MILE (80,000 KM) SERVICE ITEM REMARKS Inspect; clean Air Filter Inspect, clean, replace if necessary Chain Sliders Cooling System / Radiator Inspect Crankcase Ventilation System Inspect; tighten, clean, adjust Inspect; clean, lubricate Drive Chain Engine Coolant Replace Engine Compression Inspect;...
  • Page 69 MAINTENANCE G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S - - O O I I L L I I N N G G S S Y Y S S T T E E M M S S P P E E C C I I A A L L T T O O O O L L S S - - M M A A I I N N T T E E N N A A N N C C E E The FTR engine uses a semi-dry sump lubrication TOOL DESCRIPTION...

  • Page 70: Break-In Procedure

    MAINTENANCE B B R R E E A A K K - - I I N N P P R R O O C C E E D D U U R R E E W W A A S S H H I I N N G G P P R R E E C C A A U U T T I I O O N N S S Engine break-in for Indian Motorcycles occurs in the The FTR models have air ducts located on the front...
  • Page 71 MAINTENANCE R R O O U U T T I I N N E E M M A A I I N N T T E E N N A A N N C C E E P P R R O O C C E E D D U U R R E E S S 5.
  • Page 72 MAINTENANCE 8. Remove the air filter from the airbox. • Make sure air filter is fully seated in air filter cover during installation. 9. Inspect filter element and replace if dirty, wet, or oil fouled. 11. Install air filter access cover and secure with seven 10.
  • Page 73 Due to the semi-dry sump lubrication system, the add Indian Motorcycle 15W–60 Full Synthetic engine oil level shown in the sight glass will fluctuate engine oil. Repeat steps 1- 4 until the reading is with movement of the motorcycle from a vertical within the safe operation range.
  • Page 74 MAINTENANCE E E N N G G I I N N E E O O I I L L & & F F I I L L T T E E R R C C H H A A N N G G E E 9.
  • Page 75 MAINTENANCE T T I I R R E E P P R R E E S S S S U U R R E E / / S S P P E E C C I I F F I I C C A A T T I I O O N N S S WARNING Indian motorcycles are produced using the designated tires listed below as original equipment.
  • Page 76 MAINTENANCE FTR S = 3.5 x Metzeler 36 PSI (248 2023: FRONT Sportec M9 120/70ZR17 FTR / FTR kPa) FTR / Carbon = 5.5 1/16 in (1.6 FTR S / x 17 FTR R Metzeler Carbon 40 PSI (276 REAR Sportec M9 180/55ZR17 5.5 x 17...
  • Page 77 MAINTENANCE 9. View fluid level through the fluid reservoir. The fluid should be clear and between the MIN markings. 10. Wipe area around reservoir cover with a clean cloth. 11. Wipe brake fluid container with a clean cloth. 12. Remove reservoir cover 13.
  • Page 78 MAINTENANCE F F U U S S E E R R E E P P L L A A C C E E M M E E N N T T 3. If any fuse is blown, turn off main switch. Install new fuse of specified amperage.
  • Page 79 MAINTENANCE H H E E A A D D L L I I G G H H T T A A I I M M I I N N S S P P E E C C T T I I O O N N - - F F T T R R M M O O D D E E L L S S On LOW beam, the top of the horizontal cut-off of the light beam should be 7 in (17.8 cm) lower than the center of the headlight bulb and centered straight ahead at 32 ft 10 in (10 m).
  • Page 80 1. To adjust the headlamp vertically, loosen the two housing mount fasteners (one on each side) and Indian Motorcycle recommends using the pivot the housing upward or downward. Tighten BatteryMINDer® 2012 AGM - 2 AMP battery charger the fasteners to specification.
  • Page 81 B B A A T T T T E E R R Y Y T T E E S S T T I I N N G G P P R R O O C C E E D D U U R R E E : : – – L L O O W W C C H H A A R R G G E E The nominal voltage for an Indian Motorcycle battery 1. Test battery using the battery tester PU-50296.

  • Page 82: Battery Charging

    MAINTENANCE A A G G M M B B A A T T T T E E R R Y Y C C H H A A R R G G I I N N G G R R E E C C O O M M M M E E N N D D A A T T I I O O N N S S A A G G M M B B A A T T T T E E R R Y Y M M A A I I N N T T E E N N A A N N C C E E T T I I P P S S –...
  • Page 83 MAINTENANCE C C O O O O L L A A N N T T L L E E V V E E L L I I N N S S P P E E C C T T I I O O N N 5.
  • Page 84 Clean the chain using a chain brush or clean rag to remove any dirt or grit. The chain must be lubricated using Indian Motorcycle chain lube (2884172). See Maintenance Intervals page 2.4 CAUTION Always have the motorcycle off and the transmission in neutral when performing this procedure.
  • Page 85 MAINTENANCE S S U U S S P P E E N N S S I I O O N N A A D D J J U U S S T T M M E E N N T T G G U U I I D D E E IMPORTANT Make sure rear shock preload is set correctly before changing compression and rebound settings below.
  • Page 86 MAINTENANCE RIDING TYPE: SHOCK COMPRESSION SHOCK REBOUND (S MODEL ONLY) Aggressive Riding (Track) 0.75 turns (out from full in) 5 clicks (out from full in) FTR R Carbon Recommended Damping Settings RIDING TYPE: SHOCK COMPRESSION SHOCK REBOUND Low Speed Riding (Urban) 20 clicks (out from full in) 17 clicks (out from full in) General Riding (Town/Highway)
  • Page 87 MAINTENANCE Front Fork Factory Setting FTR S Fork Rebound, right side screw slot 7 clicks (out from full in) (20 click range) Fork Compression, left side screw 10 clicks (out from full in) slot (20 click range) Fork Preload, 19 mm hex (10 turn 5 turns (in from full out) range) FTR S Recommended Damping Settings...
  • Page 88 MAINTENANCE FTR S Recommended Pre-Load Settings Adjustments can be make to the fork to increase or decrease pre-load for a personal rider preference. IMPORTANT Make sure both forks are adjusted evenly. F F T T R R R R C C A A R R B B O O N N R R E E C C O O M M M M E E N N D D E E D D D D A A M M P P I I N N G G S S E E T T T T I I N N G G S S RIDING TYPE: COMPRESSION REBOUND...
  • Page 89 MAINTENANCE F F T T R R R R C C A A R R B B O O N N R R E E C C O O M M M M E E N N D D E E D D P P R R E E - - L L O O A A D D S S E E T T T T I I N N G G S S Adjustments can be make to the fork to increase or decrease pre-load for a personal rider preference.
  • Page 90 MAINTENANCE S S I I D D E E - - S S T T A A N N D D I I N N S S P P E E C C T T I I O O N N B B R R A A K K E E P P E E D D A A L L I I N N S S P P E E C C T T I I O O N N 1.
  • Page 91 MAINTENANCE M M A A J J O O R R M M A A I I N N T T E E N N A A N N C C E E P P R R O O C C E E D D U U R R E E S S IMPORTANT Reference the Maintenance Intervals page 2.4 for details on how often to perform each procedure.

  • Page 92: Maintenance Procedure

    MAINTENANCE MAINTENANCE PROCEDURE LOCATION Front Brake Lever Lubrication page 9.4 Front Brake Lever Lubrication Brake Pedal Inspection Brake Pedal Inspection page 2.38 Brake Pedal Lubrication page 9.6 Brake Pedal Lubrication Rear Brake Pedal Adjustment Rear Brake Pedal Adjustment page 9.12 Front Brake Pad Inspection Front Brake Pad Inspection page 9.43 Rear Brake Pad Inspection...

  • Page 93: Chapter 3 Engine / Cooling / Exhaust

    ENGINE / COOLING / EXHAUST CHAPTER 3 ENGINE / COOLING / EXHAUST GENERAL INFORMATION ................3.5 .
  • Page 94 ENGINE / COOLING / EXHAUST ................3.37 OIL COOLER INSPECTION .
  • Page 95 ENGINE / COOLING / EXHAUST ............3.87 CAM CHAIN TENSIONER INSTALLATION .
  • Page 96 ENGINE / COOLING / EXHAUST ........3.129 FRONT HEAD PIPE REMOVAL / INSTALLATION, 2022+ MODELS .
  • Page 97 ENGINE / COOLING / EXHAUST G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S - - E E N N G G I I N N E E A floor jack or commercially available motorcycle engine lift or hoist is required for engine removal.

  • Page 98: Tool Description

    ENGINE / COOLING / EXHAUST S S P P E E C C I I A A L L T T O O O O L L S S - - E E N N G G I I N N E E TOOL DESCRIPTION PART NUMBER Engine Stand Adapter...
  • Page 99 ENGINE / COOLING / EXHAUST S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - E E N N G G I I N N E E ITEM SPECIFICATIONS Engine Dry Weight...

  • Page 100: Hot Components

    ENGINE / COOLING / EXHAUST M M A A I I N N T T E E N N A A N N C C E E - - E E N N G G I I N N E E S S P P A A R R K K P P L L U U G G R R E E M M O O V V A A L L I I D D L L E E S S P P E E E E D D / / F F A A S S T T I I D D L L E E S S P P E E E E D D CAUTION...
  • Page 101 ENGINE / COOLING / EXHAUST S S P P A A R R K K P P L L U U G G I I N N S S P P E E C C T T I I O O N N / / G G A A P P 2.
  • Page 102 ENGINE / COOLING / EXHAUST 6. Remove ignition coils. See Ignition Coil Replacement page 10.42. 7. Remove spark plug from cylinder to be tested. See Spark Plug Removal page 3.8. 8. Install compression tester in the spark plug hole following manufacturers instructions. 9.
  • Page 103 ENGINE / COOLING / EXHAUST A A I I R R C C L L E E A A N N E E R R S S E E R R V V I I C C E E A A I I R R B B O O X X A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
  • Page 104 ENGINE / COOLING / EXHAUST A A I I R R F F I I L L T T E E R R R R E E P P L L A A C C E E M M E E N N T T 5.
  • Page 105 ENGINE / COOLING / EXHAUST 8. Remove the air filter from the airbox. • Make sure air filter is fully seated in air filter cover during installation. 9. Inspect filter element and replace if dirty, wet, or oil fouled. 11. Install air filter access cover and secure with seven 10.
  • Page 106 ENGINE / COOLING / EXHAUST A A I I R R B B O O X X R R E E M M O O V V A A L L 6. Remove fastener securing the air box cover 1. Remove the seat. See Seat Removal / Installation page 7.19.
  • Page 107 ENGINE / COOLING / EXHAUST 9. Remove two fasteners securing ECM mount. 15. Remove air filter access panel and air filter. 16. Remove three fasteners securing air box to the air box adapter. 10. Remove three fasteners securing oil separator to air box 17.
  • Page 108 ENGINE / COOLING / EXHAUST A A I I R R B B O O X X I I N N S S T T A A L L L L A A T T I I O O N N 2.
  • Page 109 ENGINE / COOLING / EXHAUST 3. Install three fasteners securing air box to the air 6. Install oil separator and secure with three fasteners box adapter. TORQUE TORQUE Air Box Adapter Fasteners: Oil Separator Fasteners: 36 in-lbs (4 N·m) 14 in-lbs (2 N·m) 4.
  • Page 110 ENGINE / COOLING / EXHAUST 11. Install alignment bracket and secure with three 14. Install four fasteners securing air box bezel. fasteners TORQUE TORQUE Air Box Bezel Fastener Bodywork Alignment Bracket Fasteners: 36 in-lbs (4 N·m) 36 in-lbs (4 N·m) 15.
  • Page 111 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A S S S S E E M M B B L L Y Y V V I I E E W W S S E E N N G G I I N N E E B B R R A A C C K K E E T T / / F F A A S S T T E E N N E E R R C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE)
  • Page 112 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E R R E E M M O O V V A A L L 14. Disconnect jumper harness connector P P R R E E P P A A R R A A T T I I O O N N F F O O R R E E N N G G I I N N E E R R E E M M O O V V A A L L NOTICE Different methods can be used to remove the engine depending on the equipment available to...
  • Page 113 ENGINE / COOLING / EXHAUST E E N N G G I I N N E E T T O O F F R R A A M M E E , , R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 6.

  • Page 114: Installation

    ENGINE / COOLING / EXHAUST INSTALLATION 6. Connect gear position sensor 1. Installation is performed by reversing the removal procedure. TORQUE Headmount Bracket To Cylinder Head Fastener: 26 ft-lbs (35 N·m) TORQUE Mid Frame Through Bolt: 51 ft-lbs (69 N·m) TORQUE Headmount To Main Frame Fastener: 7.

  • Page 115: Low Oil Pressure

    ENGINE / COOLING / EXHAUST L L U U B B R R I I C C A A T T I I O O N N / / C C O O O O L L I I N N G G T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G - - L L U U B B R R I I C C A A T T I I O O N N S S Y Y S S T T E E M M G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N LOW OIL PRESSURE...
  • Page 116 ENGINE / COOLING / EXHAUST S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - L L U U B B R R I I C C A A T T I I O O N N OIL PUMP CLEARANCES (SCAVENGE) S S Y Y S S T T E E M M Pump Gerotor...

  • Page 117: Cooling System Specifications

    ENGINE / COOLING / EXHAUST COOLING SYSTEM SPECIFICATIONS Cooling Fan Off 215Ω 203 Degrees F (95 Degrees C) Room 2500Ω 68 Degrees F Temperature (20 Degrees C) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 118 ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S R R A A D D I I A A T T O O R R I I N N S S P P E E C C T T I I O O N N / / C C L L E E A A N N I I N N G G CAUTION Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness.
  • Page 119 ENGINE / COOLING / EXHAUST C C O O O O L L I I N N G G S S Y Y S S T T E E M M H H O O S S E E S S NUMBER DESCRIPTION Recovery Bottle Drain Hose...
  • Page 120 ENGINE / COOLING / EXHAUST C C O O O O L L I I N N G G S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W 2019–2020 MODELS TORQUE (IF APPLICABLE) NUMBER...
  • Page 121 ENGINE / COOLING / EXHAUST C C O O O O L L I I N N G G S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W 2022+ MODELS TORQUE (IF APPLICABLE) NUMBER...

  • Page 122: Part Description

    ENGINE / COOLING / EXHAUST T T H H E E R R M M O O S S T T A A T T A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE / NOTE NUMBER PART DESCRIPTION...
  • Page 123 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T F F L L O O W W D D I I A A G G R R A A M M Cooling System Flow Thermostat Closed (Bypass) Cooling System Flow...
  • Page 124 ENGINE / COOLING / EXHAUST W W A A T T E E R R P P U U M M P P A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 125 ENGINE / COOLING / EXHAUST L L U U B B R R I I C C A A T T I I O O N N S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W Pressure Lubrication System Assembly View NUMBER DESCRIPTION...
  • Page 126 ENGINE / COOLING / EXHAUST Scavenge Lubrication System Assembly View TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Engine Oil Scavenge Pump Oil Scavenge Pump Fasteners (QTY: 5) 88 in-lbs (10 N·m) Scavenge Inlet Tube Fastener 88 in-lbs (10 N·m) Oil Drain Plug 15 ft-lbs (20 N·m) Oil Drain Plug Sealing Washer Scavenge Pickup...
  • Page 127 ENGINE / COOLING / EXHAUST O O I I L L F F L L O O W W D D I I A A G G R R A A M M 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 3.35 ©...
  • Page 128 ENGINE / COOLING / EXHAUST O O I I L L C C O O O O L L E E R R 5. Remove three fasteners securing oil cooler O O I I L L C C O O O O L L E E R R R R E E P P L L A A C C E E M M E E N N T T WARNING Engine components get hot and remain hot for a period of time after the engine is stopped.
  • Page 129 ENGINE / COOLING / EXHAUST O O I I L L C C O O O O L L E E R R A A D D A A P P T T E E R R R R E E P P L L A A C C E E M M E E N N T T 5.
  • Page 130 ENGINE / COOLING / EXHAUST O O I I L L P P R R E E S S S S U U R R E E T T E E S S T T O O I I L L P P U U M M P P S S E E R R V V I I C C E E S S C C A A V V E E N N G G E E O O I I L L P P U U M M P P R R E E M M O O V V A A L L CAUTION 1.
  • Page 131 ENGINE / COOLING / EXHAUST S S C C A A V V E E N N G G E E O O I I L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 6.
  • Page 132 ENGINE / COOLING / EXHAUST P P R R E E S S S S U U R R E E O O I I L L P P U U M M P P R R E E M M O O V V A A L L 5.
  • Page 133 ENGINE / COOLING / EXHAUST P P R R E E S S S S U U R R E E O O I I L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 134 C C O O O O L L I I N N G G S S Y Y S S T T E E M M O O V V E E R R V V I I E E W W IMPORTANT Use Indian Motorcycle 50/50 Extended Life Coolant only. Do not mix coolant types.
  • Page 135 ENGINE / COOLING / EXHAUST C C O O O O L L I I N N G G S S Y Y S S T T E E M M P P R R E E S S S S U U R R E E T T E E S S T T C C O O O O L L I I N N G G S S Y Y S S T T E E M M P P R R E E S S S S U U R R E E C C A A P P T T E E S S T T WARNING WARNING...
  • Page 136 7. Remove the pinch pliers from the coolant line between the reservoir and thermostat housing. 8. Add Indian Motorcycle Extended Life 50/50 Engine Coolant to the reservoir fill opening until the coolant reservoir it is between markings.
  • Page 137 ENGINE / COOLING / EXHAUST 9. Run the engine until the cooling fan cycles ON and 3. Remove fastener securing the left-side air box OFF. cover. Remove left-side air box cover. 10. Recheck the coolant level in the reservoir and add until the level is between the markings.
  • Page 138 ENGINE / COOLING / EXHAUST 50 state and INTL models need to have the EVAP f. Remove the purge valve from its bracket. and purge valve lines removed: a. Clip the cable tie securing the EVAP drain line. NOTICE Soapy water may be used to aid in removal of purge b.
  • Page 139 ENGINE / COOLING / EXHAUST 7. Drain Cooling System: 8. Pull the harness aside and remove TMAP sensor fastener . Pull the TMAP sensor straight out to remove. WARNING Never remove pressure cap when engine is warm or hot. The cooling system is under pressure and serious burns may result.
  • Page 140 ENGINE / COOLING / EXHAUST COOLANT JUNCTION REMOVAL b. Install a remote clamp tool on the FRONT and leave it attached to the clamp. 1. Release the clamp and then remove coolant bleed fitting from the coolant junction. c. Using a 90 degree needle nose pliers, insert through the left-hand frame, squeeze the bottom clamp to release, and lift the coolant junction up 2.
  • Page 141 ENGINE / COOLING / EXHAUST COOLANT JUNCTION INSTALLATION 3. Preset the FRONT and BOTTOM clamps open on the fittings as shown. 1. To keep the clamp in the open position, squeeze the front and bottom clamps and place the on a 22– 25mm deep-well socket.
  • Page 142 ENGINE / COOLING / EXHAUST 5. Place non-marring support between the engine 7. Make sure you align the NEW coolant junction block and the thermostat to support the coolant notch with the thermostat alignment tab. junction installation. 8. With the clamps positioned over the fittings, install 6.
  • Page 143 ENGINE / COOLING / EXHAUST • Verify the FRONT of coolant junction is fully 10. Install the front and bottom clamps into position seated. over the ribbed area of the coolant junction arms. Remove the sockets once orientated in the correct position.
  • Page 144 ENGINE / COOLING / EXHAUST 15. 49 state motorcycles proceed to step 16 (step 16 page 3.54). IMPORTANT 50 state and INTL models need to have the EVAP Inspect the TMAP sensor for damage before and purge valve lines installed: installation.
  • Page 145 ENGINE / COOLING / EXHAUST c. Conect the purge valve input line. g. Install a NEW cable tie securing the EVAP drain line. d. Connect the purge valve electrical connector. IMPORTANT Listen for audible “click” when pressing into place. Pull gently on connector once seated to ensure a proper connection has been made.
  • Page 146 ENGINE / COOLING / EXHAUST 16. Unwrap the tape from the motorcycle frame and clean the frame to remove any residue. 17. Install lower radiator hose. Secure clamp over hose with clamp 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 3.54 ©...
  • Page 147 ENGINE / COOLING / EXHAUST COOLANT FILL AND BLEEDING 6. Add Indian Motorcycle Extended Life 50/50 Engine Coolant to the reservoir fill opening until the 1. Remove the safety set screw from the pressure cap coolant is between markings. and remove the pressure cap.
  • Page 148 ENGINE / COOLING / EXHAUST MOTORCYCLE ASSEMBLY 3. Install four fasteners securing air box bezel. 1. Lubricate air box cover grommets. Install air box cover and secure with fastener TORQUE Air Box Bezel Fastener: NOTICE 36 in-lbs (4 N·m) Use Soapy Water to help with installation. DO NOT USE BRAKE CLEANER OR OIL BASED 4.
  • Page 149 ENGINE / COOLING / EXHAUST R R A A D D I I A A T T O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 8.
  • Page 150 ENGINE / COOLING / EXHAUST A A L L U U M M I I N N U U M M R R A A D D I I A A T T O O R R C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 11.
  • Page 151 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T R R E E C C O O V V E E R R Y Y B B O O T T T T L L E E R R E E M M O O V V A A L L / / 5.
  • Page 152 ENGINE / COOLING / EXHAUST W W A A T T E E R R P P U U M M P P R R E E P P L L A A C C E E M M E E N N T T 6.
  • Page 153 ENGINE / COOLING / EXHAUST 9. Install new water pump seal in engine case by 2. Remove water pump shaft oil seal with a hooked hand. Thread water pump seal installation tool PF- tool or equivalent taking care to not damage water 51608 on the water pump shaft.
  • Page 154 ENGINE / COOLING / EXHAUST 5. Use a suitable driver to install the seal so the outer face is flush with the step on the engine case. 6. Install new water pump seal. Refer to Water Pump Seal Removal and Installation. 7.
  • Page 155 ENGINE / COOLING / EXHAUST T T H H E E R R M M O O S S T T A A T T R R E E P P L L A A C C E E M M E E N N T T 6.
  • Page 156 ENGINE / COOLING / EXHAUST 10. Remove two fasteners securing fuel rail. 12. Remove the springband clamps securing the coolant junction and thermostat housing. Disconnect fuel rail from routing clip remove from unit. Cover the fuel injector holes to IMPORTANT prevent debris from entering the engine.
  • Page 157 ENGINE / COOLING / EXHAUST C C O O O O L L A A N N T T T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R 16.
  • Page 158 ENGINE / COOLING / EXHAUST T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G 7. Reinstall throttle bodies. See Throttle Body Assembly Removal / Installation page 4.18.
  • Page 159 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D / / V V A A L L V V E E S S S S E E R R V V I I C C E E N N O O T T E E S S - - C C A A M M C C H H A A I I N N G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N Read the following tips to ease the removal,...

  • Page 160: Specification

    ENGINE / COOLING / EXHAUST S S P P E E C C I I A A L L T T O O O O L L S S - - C C Y Y L L I I N N D D E E R R H H E E A A D D TOOL DESCRIPTION PART NUMBER Valve Spring Compressor...
  • Page 161 ENGINE / COOLING / EXHAUST CYLINDER HEAD & VALVE TRAIN DATA ITEM STANDARD SERVICE LIMIT Cam Chain Tensioner Hydraulic / Self-Adjusting MIN: .9844" (25.003 mm) .9745” (24.753 mm) INTAKE MAX: .9920" (25.197 mm) Lobe Height MIN: .9844" (25.003 mm) .9745” (24.753 mm) EXHAUST MAX: .9920"...
  • Page 162 ENGINE / COOLING / EXHAUST V V A A L L V V E E C C L L E E A A R R A A N N C C E E I I N N S S P P E E C C T T I I O O N N 11.
  • Page 163 ENGINE / COOLING / EXHAUST V V A A L L V V E E C C L L E E A A R R A A N N C C E E A A D D J J U U S S T T M M E E N N T T 6.

  • Page 164: Part Description

    ENGINE / COOLING / EXHAUST A A S S S S E E M M B B L L Y Y V V I I E E W W S S C C A A M M C C H H A A I I N N C C O O M M P P O O N N E E N N T T S S A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
  • Page 165 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Water Pump Driven Gear Shaft Assembly Cam Driven Sprocket Fastener 11 ft-lbs (15 N·m) Cam Chain Guide Fastener (QTY.2) 88 in-lbs (10 N·m) Cam Chain Fixed Cover Guide (Rear) Cam Driven Sprocket Cam Chain Fixed Cover Guide (Front) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 166 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D / / C C A A M M S S H H A A F F T T A A S S S S E E M M B B L L Y Y V V I I E E W W NUM- QUANTITY TORQUE...
  • Page 167 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 168 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T T T I I M M I I N N G G M M A A R R K K S S Camshaft Timing Front Cylinder 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 3.76...
  • Page 169 ENGINE / COOLING / EXHAUST Camshaft Timing Rear Cylinder 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 170 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N S S E E R R V V I I C C E E C C A A M M C C H H A A I I N N T T E E N N S S I I O O N N E E R R R R E E M M O O V V A A L L C C A A M M C C H H A A I I N N G G U U I I D D E E ( ( U U P P P P E E R R ) ) , , R R E E M M O O V V A A L L CAUTION 1.
  • Page 171 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N T T E E N N S S I I O O N N E E R R I I N N S S P P E E C C T T I I O O N N C C A A M M S S H H A A F F T T S S P P R R O O C C K K E E T T R R E E M M O O V V A A L L 1.
  • Page 172 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S P P R R O O C C K K E E T T R R E E M M O O V V A A L L 11.
  • Page 173 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S H H A A F F T T R R E E M M O O V V A A L L 5.
  • Page 174 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N I I N N S S T T A A L L L L A A T T I I O O N N C C A A M M C C H H A A I I N N G G U U I I D D E E ( ( L L O O W W E E R R ) ) , , R R E E M M O O V V A A L L 1.
  • Page 175 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N 3.
  • Page 176 ENGINE / COOLING / EXHAUST C C A A M M D D R R I I V V E E S S P P R R O O C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N C C A A M M C C H H A A I I N N G G U U I I D D E E ( ( L L O O W W E E R R ) ) , , I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 177 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T S S P P R R O O C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N / / T T I I M M I I N N G G 5.
  • Page 178 ENGINE / COOLING / EXHAUST 5. Verify that the timing marks line up with the top 11. The single dot timing mark on the primary drive of the head with the chain installed and drive gear gear will be at approximately 10 o’clock. to intake cam sprocket slack removed.
  • Page 179 ENGINE / COOLING / EXHAUST C C A A M M C C H H A A I I N N T T E E N N S S I I O O N N E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 180 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D S S E E R R V V I I C C E E V V A A L L V V E E C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N V V A A L L V V E E C C O O V V E E R R R R E E M M O O V V A A L L 1.
  • Page 181 ENGINE / COOLING / EXHAUST V V A A L L V V E E C C L L E E A A R R A A N N C C E E A A S S S S E E M M B B L L Y Y 6.
  • Page 182 ENGINE / COOLING / EXHAUST 10. If any of the valve clearance measurements are out 17. Reinstall the camshafts and camshaft carriers and of specification, remove the camshaft carriers and tighten the bolts evenly to specification. camshafts and proceed with this procedure. TORQUE NOTICE Camshaft Carrier Fasteners (short &...
  • Page 183 ENGINE / COOLING / EXHAUST C C A A M M S S H H A A F F T T I I N N S S P P E E C C T T I I O O N N For the following camshaft inspection procedure, refer to the camshaft service specifications section.
  • Page 184 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D R R E E M M O O V V A A L L 8.
  • Page 185 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D D D I I S S A A S S S S E E M M B B L L Y Y 11.
  • Page 186 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R H H E E A A D D I I N N S S P P E E C C T T I I O O N N 4.
  • Page 187 ENGINE / COOLING / EXHAUST V V A A L L V V E E S S P P R R I I N N G G F F R R E E E E L L E E N N G G T T H H I I N N S S P P E E C C T T I I O O N N •...
  • Page 188 ENGINE / COOLING / EXHAUST V V A A L L V V E E I I N N S S P P E E C C T T I I O O N N NOTICE Valve service specifications can be found at the beginning of this chapter.
  • Page 189 ENGINE / COOLING / EXHAUST V V A A L L V V E E I I N N S S P P E E C C T T I I O O N N - - Q Q U U I I C C K K R R E E F F E E R R E E N N C C E E CONDITION ILLUSTRATION POSSIBLE CAUSE...
  • Page 190 3. Apply a light coating of machinist’s layout fluid or 3. Apply Indian Motorcycle engine oil to valve guide paste to valve face. seal and install seal on valve, rotating the seal as you install it.
  • Page 191 Cylinder Installation page 3.115. 1. Verify that locating dowels are in position on the cylinder deck. 5. Apply a thin coat of Indian Motorcycle engine oil to the cylinder head bolt threads and underneath bolt heads and install fasteners finger-tight.
  • Page 192 ENGINE / COOLING / EXHAUST 6. Torque cylinder head fasteners in an “X” pattern 8. Apply a thin coat of Indian Motorcycle engine oil to following the specified sequence: each of the tappets and install them in the same position from which they were removed.
  • Page 193 ENGINE / COOLING / EXHAUST 11. Temporarily install the upper cam chain guide and torque the carrier fasteners per the specified sequence. TORQUE Camshaft Carrier Fasteners (short & long): 88 in-lbs (10 N·m) 12. Check valve lash and adjust if necessary. See Valve Clearance Assembly page 3.89.
  • Page 194 ENGINE / COOLING / EXHAUST V V A A L L V V E E L L A A S S H H - - T T A A P P P P E E T T S S E E L L E E C C T T I I O O N N A 440 tappet means the thickness of the tappet is 4.40 mm.
  • Page 195 ENGINE / COOLING / EXHAUST T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G C C Y Y L L I I N N D D E E R R H H E E A A D D A A N N D D V V A A L L V V E E T T R R A A I I N N NOTICE Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test.
  • Page 196 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Piston Rings or Piston Ring Replace Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Chain Tensioner and / or Guide Replace Worn Bottom End Area Main Bearings...
  • Page 197 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S NOTE Clean the machine thoroughly before removing...

  • Page 198: Service Limit

    ENGINE / COOLING / EXHAUST S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N ITEM STANDARD...
  • Page 199 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 200 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N S S E E R R V V I I C C E E P P I I S S T T O O N N R R I I N N G G P P R R O O F F I I L L E E A A N N D D O O R R I I E E N N T T A A T T I I O O N N Lower Oil Ring Rail End Gap Arrows on piston crown indicate installation...
  • Page 201 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R R R E E M M O O V V A A L L C C Y Y L L I I N N D D E E R R B B O O R R E E M M E E A A S S U U R R E E M M E E N N T T 1.

  • Page 202: Specification

    ENGINE / COOLING / EXHAUST P P I I S S T T O O N N T T O O C C Y Y L L I I N N D D E E R R C C L L E E A A R R A A N N C C E E W W O O R R K K S S H H E E E E T T FRONT CYLINDER RECORDED MEASUREMENT SPECIFICATION...
  • Page 203 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R W W A A R R P P A A G G E E M M E E A A S S U U R R E E M M E E N N T T P P I I S S T T O O N N &...
  • Page 204 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N & & P P I I S S T T O O N N R R I I N N G G I I N N S S P P E E C C T T I I O O N N 7.
  • Page 205 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N P P I I N N / / P P I I N N B B O O R R E E I I N N S S P P E E C C T T I I O O N N 4.
  • Page 206 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N R R I I N N G G I I N N S S T T A A L L L L A A T T I I O O N N 6.
  • Page 207 ENGINE / COOLING / EXHAUST P P I I S S T T O O N N I I N N S S T T A A L L L L A A T T I I O O N N C C Y Y L L I I N N D D E E R R I I N N S S T T A A L L L L A A T T I I O O N N The pistons are marked with an arrow on the crown IMPORTANT...
  • Page 208 ENGINE / COOLING / EXHAUST 7. Install piston ring compressor over rings and compress rings into ring grooves. CAUTION Be sure compressor band end gap does not align with any ring end gap when compressing the rings. IMPORTANT Install cylinders in their original locations. Cylinder with cam chain tensioner is the front cylinder.
  • Page 209 ENGINE / COOLING / EXHAUST C C Y Y L L I I N N D D E E R R / / P P I I S S T T O O N N T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
  • Page 210 ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Worn Wrist Pin, Wrist Pin Replace Bore and / or Connecting Worn Piston Rings or Replace Piston Ring Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Chain Tensioner and / or...
  • Page 211 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T E E X X H H A A U U S S T T S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W ( ( 2 2 0 0 1 1 9 9 - - 2 2 0 0 2 2 0 0 ) ) TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
  • Page 212 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Heat Shield Fastener, Front 88 in-lbs (10 N·m) Front Headpipe Assembly 88 in-lbs (10 N·m) Heat Shield Base Fastener, Central Central Heat Shield Base Central Heat Shield 88 in-lbs (10 N·m) Heat Shield Fastener, Central 2&...
  • Page 213 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W ( ( 2 2 0 0 2 2 2 2 ) ) TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
  • Page 214 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Heat Shield Fastener, Front 88 in-lbs (10 N·m) Headpipe Assembly, Front 88 in-lbs (10 N·m) Heat Shield Base Fastener, Central Central Heat Shield Base Central Heat Shield 88 in-lbs (10 N·m) Heat Shield Fastener, Central 2&...
  • Page 215 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W ( ( 2 2 0 0 2 2 3 3 ) ) TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION...
  • Page 216 ENGINE / COOLING / EXHAUST TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Heat Shield Fastener, Front 88 in-lbs (10 N·m) Headpipe Assembly, Front 88 in-lbs (10 N·m) Heat Shield Base Fastener, Central Central Heat Shield Base Central Heat Shield 88 in-lbs (10 N·m) Heat Shield Fastener, Central 2&...
  • Page 217 ENGINE / COOLING / EXHAUST H H I I G G H H M M O O U U N N T T E E X X H H A A U U S S T T A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE ITEM DESCRIPTION...
  • Page 218 ENGINE / COOLING / EXHAUST E E X X H H A A U U S S T T S S E E R R V V I I C C E E 5. Installation is performed by reversing the removal procedure.
  • Page 219 ENGINE / COOLING / EXHAUST R R E E S S O O N N A A T T O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 220 ENGINE / COOLING / EXHAUST F F R R O O N N T T H H E E A A D D P P I I P P E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N , , 6.
  • Page 221 ENGINE / COOLING / EXHAUST F F R R O O N N T T H H E E A A D D P P I I P P E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N , , 9.
  • Page 222 ENGINE / COOLING / EXHAUST 7. Remove two fasteners securing front exhaust 10. Remove two right-hand resonator mount fasteners heat shield and remove hanger from frame. 8. Remove head pipe fasteners securing head pipe 11. Slide the exhaust assembly forward to disengage to cylinder head.
  • Page 223 ENGINE / COOLING / EXHAUST FRONT HEAD PIPE INSTALLATION 2. Clock the Exhaust Clamp (Front Headpipe to Rear Headpipe) to the correct angle for 2022 models. 1. Installation is performed by reversing the Break off end of stud at break point. removal procedure.
  • Page 224 ENGINE / COOLING / EXHAUST R R E E A A R R H H E E A A D D P P I I P P E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N , , 6.
  • Page 225 ENGINE / COOLING / EXHAUST 10. Install Front head pipe. See Front Head Pipe 3. Install exhaust mount to mufflers with two Removal / Installation, 2019–2020 models page exhaust mount fasteners and two washers , as 3.128. shown. 11. Install Fuel Tank. See Fuel Tank Installation page Do not torque exhaust mount fasteners at this 4.30.
  • Page 226 ENGINE / COOLING / EXHAUST EXHAUST INSTALLATION 5. Pass two heat shield clamps through slots of installed gussets. 1. Slide exhaust pipe clamp onto base of exhaust pipe and place exhaust pipe onto exhaust resonator. Align exhaust mount with accessory mounts and install with two mounting fasteners and two washers Do not torque two mounting fasteners...
  • Page 227 ENGINE / COOLING / EXHAUST 4. Torque exhaust mount fasteners , installed in 7. Pass heat shield fasteners through three step 3 of Exhaust Assembly section. washers , heat shield , and three spacers TORQUE Exhaust Mount Fasteners (mount to muffler) 19 ft-lbs (26 N·m) 5.
  • Page 228 ENGINE / COOLING / EXHAUST 9. Adjust heat shield so that it does not contact passenger foot peg when opened or closed. 10. Tighten heat shield clamps to specification. TORQUE Upper Heat Shield Clamps 18 in-lbs (2 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 3.136 ©...

  • Page 229: Chapter 4 Fuel Delivery / Efi

    FUEL DELIVERY / EFI CHAPTER 4 FUEL DELIVERY / EFI GENERAL INFORMATION ................4.3 .
  • Page 230 FUEL DELIVERY / EFI ............. .4.50 FUEL INJECTOR REMOVAL / INSTALLATION .
  • Page 231 FUEL DELIVERY / EFI G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S WARNING Many hazards are present when working on or around...

  • Page 232: Tool Description

    FUEL DELIVERY / EFI S S P P E E C C I I A A L L T T O O O O L L S S - - F F U U E E L L S S Y Y S S T T E E M M / / E E F F I I TOOL DESCRIPTION PART NUMBER Fuel Pressure Adapter...
  • Page 233 FUEL DELIVERY / EFI E E F F I I S S Y Y S S T T E E M M P P R R E E C C A A U U T T I I O O N N S S Static electricity can damage the electronic controllers beyond repair.
  • Page 234 FUEL DELIVERY / EFI A A S S S S E E M M B B L L Y Y V V I I E E W W S S F F U U E E L L S S Y Y S S T T E E M M A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION Fuel Tank Mounting Fastener...
  • Page 235 FUEL DELIVERY / EFI TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Fuel Pump Fasteners 80 in-lbs (9 N·m) Fuel Pump Lock Ring Fuel Pump Assembly Fuel Pump Seal Fuel Line 43 in-lbs (5 N·m) Fuel Line Retainer Fastener Fuel Line Retainer 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual ©...
  • Page 236 FUEL DELIVERY / EFI F F U U E E L L L L I I N N E E R R O O U U T T I I N N G G / / R R E E T T E E N N T T I I O O N N Fuel Vent Line Routing / Retention NUMBER DESCRIPTION...
  • Page 237 FUEL DELIVERY / EFI Purge Hose Routing / Retention NUMBER DESCRIPTION Throttle Body Assembly Purge Valve Carbon Canister 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual © Copyright Polaris Industries Inc.
  • Page 238 FUEL DELIVERY / EFI Vapor Canister Vent Line Routing / Retention NUMBER DESCRIPTION Carbon Canister Routing Clip 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 4.10 © Copyright Polaris Industries Inc.
  • Page 239 FUEL DELIVERY / EFI S S E E N N S S O O R R S S - - P P O O W W E E R R T T R R A A I I N N M M A A N N A A G G E E M M E E N N T T C C O O M M P P O O N N E E N N T T S S TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 240 FUEL DELIVERY / EFI TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Fuse Box Ignition Coil Fastener 88 in-lbs (10 N·m) Fuel Injector / Fuel Rail Fastener 88 in-lbs (10 N·m) Coolant Temperature Sensor 17 ft-lbs (23 N·m) Oxygen Sensor 14 ft-lbs (19 N·m) Angle Sensor Wheel Speed Sensor Fastener 88 in-lbs (10 N·m)
  • Page 241 Fuel Vent Valve: The fuel vent valves direct fuel vapors down into the canister. Fuel Cap: It is important to note that Indian Motorcycle does not use an enhanced EVAP control system. This means the system does not detect a gross leak, or restrictions in the EVAP system such as a missing or loose fuel cap.
  • Page 242 FUEL DELIVERY / EFI E E V V A A P P O O R R A A T T I I V V E E E E M M I I S S S S I I O O N N C C O O N N T T R R O O L L S S Y Y S S T T E E M M IMPORTANT The fuel tank vent line is routed to a carbon canister where the fuel vapors are stored until specific operating parameters are met and the ECM opens the purge valve.
  • Page 243 FUEL DELIVERY / EFI E E V V A A P P C C O O N N D D I I T T I I O O N N S S A A N N D D S S Y Y M M P P T T O O M M S S The following conditions and symptoms should be taken into consideration when working on a vehicle with an EVAP System: •...
  • Page 244 FUEL DELIVERY / EFI C C A A R R B B O O N N C C A A N N I I S S T T E E R R R R E E P P L L A A C C E E M M E E N N T T C C A A R R B B O O N N C C A A N N I I S S T T E E R R B B R R A A C C K K E E T T R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 245 FUEL DELIVERY / EFI P P U U R R G G E E V V A A L L V V E E R R E E P P L L A A C C E E M M E E N N T T 5.
  • Page 246 FUEL DELIVERY / EFI F F U U E E L L D D E E L L I I V V E E R R Y Y S S E E R R V V I I C C E E T T H H R R O O T T T T L L E E B B O O D D Y Y A A S S S S E E M M B B L L Y Y R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N NOTICE...
  • Page 247 FUEL DELIVERY / EFI 5. Remove the throttle body assembly from the Installation throttle adapters. 1. If removed, install throttle adapters orientated correctly. 6. If throttle adapters are to be removed, loosen lower clamps remove. TORQUE NOTICE Throttle Body Clamp: Throttle adapters have text referring to orientation as 17 in-lbs (2 N·m) well as an arrow pointing toward its respective...
  • Page 248 FUEL DELIVERY / EFI 2. Install throttle body assembly into throttle 3. Torque upper clamps securing the throttle body adapters. assembly to the throttle adapters. NOTICE 2022+ Models: Align the band clamps in the adapter as shown. TORQUE Throttle Body Clamp: 17 in-lbs (2 N·m) 4.
  • Page 249 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P P P R R E E S S S S U U R R E E I I N N S S P P E E C C T T I I O O N N 5.
  • Page 250 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M D D E E P P R R E E S S S S U U R R I I Z Z A A T T I I O O N N 4.
  • Page 251 FUEL DELIVERY / EFI 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. 6.
  • Page 252 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K R R E E M M O O V V A A L L 6. Remove fastener securing the air box cover remove air box cover by pulling up and out.
  • Page 253 FUEL DELIVERY / EFI 10. Remove passenger foot peg mount by removing its 13. Remove tail light by removing two fasteners disconnecting electrical connection. fasteners . Repeat step for remaining side. 14. Remove front seat support bracket by removing its 11.
  • Page 254 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P R R E E M M O O V V A A L L 21. Remove left hand sub-frame by removing two fasteners WARNING Replace all mounting screws and pump seal O-ring...
  • Page 255 Indian Motorcycle replacement parts. WARNING The fuel line exiting fuel pump is subjected to high pressure. Replace with genuine Indian Motorcycle replacement parts to reduce the possibility of fuel line failure. Be sure the fuel line is routed properly and does not come in contact with sharp or hot 9.
  • Page 256 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P I I N N S S T T A A L L L L A A T T I I O O N N 2.
  • Page 257 FUEL DELIVERY / EFI 2. Install Fuel Pump Lock Ring and secure with 3. Connect the fuel line fasteners IMPORTANT IMPORTANT Verify fuel line is properly seated and locked in place by listening for audible "click" when pressing Ensure fuel pump is indexed with the lock ring as into place.
  • Page 258 FUEL DELIVERY / EFI F F U U E E L L T T A A N N K K I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 259 FUEL DELIVERY / EFI 10. Install the front and rear seat support brackets and 13. Torque fasteners to specification. hand tighten their fasteners TORQUE Sub-frame Fasteners M10: 47 ft-lbs (64 N·m) TORQUE Sub-frame Fasteners M6: 96 in-lbs (11 N·m) TORQUE Fuel Tank Support Fasteners (Bottom): 96 in-lbs (11 N·m) TORQUE...
  • Page 260 FUEL DELIVERY / EFI 14. Install passenger foot peg bracket and fasteners 19. Install four fasteners securing air box bezel. TORQUE TORQUE Air Box Bezel Fastener: Footpeg Bracket Fasteners (Passenger): 36 in-lbs (4 N·m) 17 ft-lbs (23 N·m) 20. Reconnect battery connections and install battery cover.
  • Page 261 FUEL DELIVERY / EFI F F U U E E L L L L E E V V E E L L S S E E N N S S O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T F F U U E E L L P P U U M M P P S S U U P P P P L L Y Y V V O O L L T T A A G G E E T T E E S S T T Before performing this test, verify that battery is fully 1.
  • Page 262 FUEL DELIVERY / EFI F F U U E E L L P P U U M M P P C C U U R R R R E E N N T T D D R R A A W W T T E E S S T T 8.
  • Page 263 FUEL DELIVERY / EFI P P R R I I M M I I N N G G T T H H E E F F U U E E L L S S Y Y S S T T E E M M 3.
  • Page 264 FUEL DELIVERY / EFI E E F F I I S S E E R R V V I I C C E E F F U U E E L L I I N N J J E E C C T T I I O O N N S S Y Y S S T T E E M M - - O O V V E E R R V V I I E E W W O O F F The locations of sensors and other EFI system related O O P P E E R R A A T T I I O O N N components are outlined in this chapter.
  • Page 265 FUEL DELIVERY / EFI E E C C M M C C O O N N N N E E C C T T O O R R M M A A P P NOTICE Unused pins are not included in the list below IMPORTANT Last 2 digits of 100 series number correspond to connector cavity number.
  • Page 266 FUEL DELIVERY / EFI CRANKSHAFT POSITION ECM SWITCHED POWER SENSOR POSITIVE SIGNAL ENGINE COOLANT WH/GN PEDAL POSITION SENSOR 1 SIGNAL OG/DB TEMPERATURE SENSOR SIGNAL AMBIENT AIR TEMP SENSOR OG/BD SIGNAL RUN/STOP SWITCH OUTPUT REAR BRAKE PRESSURE RD/BK BK/YE GROUND SWITCH OUTPUT GROUND PEDAL POSITION SENSOR 2 +5V TIP-OVER SENSOR (TOS) YE/RD...
  • Page 267 FUEL DELIVERY / EFI D D I I A A G G N N O O S S T T I I C C T T R R O O U U B B L L E E C C O O D D E E S S COMPONENT CONDITION CODE...
  • Page 268 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Driver Circuit Open P0201 Driver Circuit Short to B+ P0265 Injector 2 (Rear) Driver Circuit Grounded P0264 Driver Circuit Open P0202 Driver Circuit Open/Grounded P0615 Starter Solenoid Driver Circuit Driver Circuit Short to B+ P0617 Driver Circuit Grounded P0616...
  • Page 269 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Voltage Too High P0223 520198 Throttle Position Sensor 2 Voltage Too Low P0222 Signal Fault P1501 Voltage High P1503 Voltage Low P1502 Tipover Sensor 520200 Condition Exists (tip over condition P1504 detected) Open Circuit P1512 Driver Circuit Open/Grounded P0444...
  • Page 270 FUEL DELIVERY / EFI COMPONENT CONDITION CODE Throttle Body Control - requested throttle 520305 Condition Exists P1530 angle not plausible 520306 ECU ADC Fault No Load Condition Exists P1531 ECU ADC Fault Voltage Condition Exists 520307 P1532 Accelerator Sensor Synchronicity Fault 520308 Sensor Difference Exceeds Limit P1533...
  • Page 271 FUEL DELIVERY / EFI ABS Trouble Codes TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Bad Intelligent Device Replace Module 520140 ABS ECU C2437 ABS Valve Relay Replace Module 520131 Condition Exists C2420 ABS Solenoid (Front In) Replace Module...
  • Page 272 FUEL DELIVERY / EFI TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Check Supply/ Voltage Below Normal Signal Line C123D Voltage Check Tone Wheel Speed Sensor Wheel Speed Sensor Wheel Alignment 520135 C2430 Signal Error...
  • Page 273 FUEL DELIVERY / EFI TRACTION ABS LAMP CONTROL SERVICE ON (YES / COMPONENT CONDITION CODE LAMP ON ACTION (YES / NO) Check wiring and PGN 61441 Missing connection to 516136 Condition Exists U1112 EBC1–Lamp Info Gauge and ABS Check wiring and connections for PGN 65265 Missing Abnormal Update Rate...
  • Page 274 FUEL DELIVERY / EFI S S E E N N S S O O R R D D I I A A G G N N O O S S T T I I C C S S E E C C M M P P I I N N O O U U T T T T E E S S T T I I N N G G If a sensor fails or reads outside a “normal”...
  • Page 275 FUEL DELIVERY / EFI E E C C M M C C O O N N N N E E C C T T O O R R D D I I S S C C O O N N N N E E C C T T / / E E C C M M R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 276 FUEL DELIVERY / EFI T T E E M M P P E E R R A A T T U U R R E E M M A A N N I I F F O O L L D D A A B B S S O O L L U U T T E E 2.
  • Page 277 FUEL DELIVERY / EFI C C O O O O L L A A N N T T T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R , , T T E E S S T T Testing CHT TEST OVERVIEW INDICATES...
  • Page 278 FUEL DELIVERY / EFI F F U U E E L L I I N N J J E E C C T T O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N •...
  • Page 279 FUEL DELIVERY / EFI 8. Disconnect fuel injector electrical connections 11. To aid in installation of injectors, use non-silicone motor oil to lubricate the circumference of the o- 2019–2020 ring and grommet prior to assembly. 2022+ TORQUE Fuel Rail Fastener: 88 in-lbs (10 N·m) 12.
  • Page 280 FUEL DELIVERY / EFI F F U U E E L L I I N N J J E E C C T T O O R R O O - - R R I I N N G G S S F F U U E E L L I I N N J J E E C C T T O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T IMPORTANT 1.
  • Page 281 FUEL DELIVERY / EFI C C R R A A N N K K S S H H A A F F T T P P O O S S I I T T I I O O N N S S E E N N S S O O R R , , T T E E S S T T / / Crankshaft Position Sensor (CPS) Replacement R R E E P P L L A A C C E E 1.
  • Page 282 FUEL DELIVERY / EFI L L E E A A N N A A N N G G L L E E S S E E N N S S O O R R I I M M U U ( ( I I N N T T E E R R N N A A L L M M E E A A S S U U R R I I N N G G U U N N I I T T ) ) O O V V E E R R V V I I E E W W The Lean Angle Sensor is located on the back side of the battery tray.
  • Page 283 FUEL DELIVERY / EFI R R E E A A R R C C Y Y L L I I N N D D E E R R D D E E A A C C T T I I V V A A T T I I O O N N NOTICE Rear Cylinder Deactivation is only available on 2022 + models.

  • Page 284: Troubleshooting

    FUEL DELIVERY / EFI C C Y Y L L I I N N D D E E R R M M I I S S F F I I R R E E D D E E T T E E C C T T I I O O N N The ECU monitors crankshaft speed via the crankshaft position sensor.
  • Page 285 FUEL DELIVERY / EFI 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. 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 4.57 ©...
  • Page 286 FUEL DELIVERY / EFI D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I G G I I T T A A L L W W R R E E N N C C H H I I I I U U S S E E R R M M A A N N U U A A L L D D I I A A G G N N O O S S T T I I C C S S O O F F T T W W A A R R E E V V E E R R S S I I O O N N Review the Digital Wrench II user manual for Always use the most current version of the Digital...
  • Page 287 FUEL DELIVERY / EFI G G U U I I D D E E D D D D I I A A G G N N O O S S T T I I C C A A V V A A I I L L A A B B L L E E Guided diagnostics are available within Digital Wrench for most supported Diagnostic Trouble Codes (DTCs).
  • Page 288 FUEL DELIVERY / EFI D D I I G G I I T T A A L L W W R R E E N N C C H H D D I I A A G G N N O O S S T T I I C C C C O O N N N N E E C C T T O O R R The diagnostic connector is located behind the ECU on the right side of the unit.
  • Page 289 Internet at: http://polaris.diagsys.com. The Digital Wrench website can also be accessed through the dealer website at: www.polarisdealers.com. IMPORTANT Only authorized Indian Motorcycle dealers and distributors can access the dealer website. 1. Log on to www.polarisdealers.com. 2. Locate the Service and Warranty drop-down menu.
  • Page 290 FUEL DELIVERY / EFI E E N N G G I I N N E E C C O O N N T T R R O O L L L L E E R R R R E E P P R R O O G G R R A A M M M M I I N N G G •...
  • Page 291 FUEL DELIVERY / EFI 8. Copy (CTRL+C) the Request Code that will be required on the dealer website in the next step. DO NOT CLOSE Digital Wrench or the Request Code will be invalid. NOTICE All characters are letters; there are no numbers in a request code.
  • Page 292 FUEL DELIVERY / EFI 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 4.64 © Copyright Polaris Industries Inc.
  • Page 293 FUEL DELIVERY / EFI T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 1 1 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
  • Page 294 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 2 2 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
  • Page 295 FUEL DELIVERY / EFI F F U U E E L L S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G P P A A R R T T 3 3 PROBLEM POSSIBLE CAUSE AFFECTED PART(S)
  • Page 296 Won’t Accept Non-Current Go to Dealer website and New Calibration Calibration File Set download the most current Low Battery Voltage Indian Motorcycle Calibration Attempting Re-Flash File Set Without Proper VIN, Calibration I.D. Attach Battery Charger number, or calibration During Re-Flash, and Re-...

  • Page 297: Chapter 5 Clutch / Primary / Shift

    CLUTCH / PRIMARY / SHIFT CHAPTER 5 CLUTCH / PRIMARY / SHIFT GENERAL INFORMATION ................5.3 .
  • Page 298 CLUTCH / PRIMARY / SHIFT ................. .5.33 CLUTCH ASSEMBLY .

  • Page 299: Specifications

    Engine Stand Adapter PF-51609 • Oil additives of any kind are not recommended by Indian Motorcycle. Using oil additives or oil of the Flywheel Puller PA-49316–A wrong viscosity can have a detrimental affect on clutch performance, operation, and service life.
  • Page 300 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H - - M M A A I I N N T T E E N N A A N N C C E E S S H H I I F F T T P P E E D D A A L L A A D D J J U U S S T T M M E E N N T T S S H H I I F F T T P P E E D D A A L L I I N N S S P P E E C C T T I I O O N N / / L L U U B B R R I I C C A A T T I I O O N N 1.
  • Page 301 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H C C A A B B L L E E I I N N S S P P E E C C T T I I O O N N / / IMPORTANT L L U U B B R R I I C C A A T T I I O O N N Make sure Dots...
  • Page 302 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H L L E E V V E E R R F F R R E E E E P P L L A A Y Y 3.
  • Page 303 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H L L E E V V E E R R L L U U B B R R I I C C A A T T I I O O N N 1.
  • Page 304 CLUTCH / PRIMARY / SHIFT A A S S S S E E M M B B L L Y Y V V I I E E W W S S P P R R I I M M A A R R Y Y C C O O V V E E R R A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 305 CLUTCH / PRIMARY / SHIFT Primary Cover Torque Sequence 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual © Copyright Polaris Industries Inc.
  • Page 306 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T A A S S S S E E M M B B L L Y Y V V I I E E W W Internal View NUMBER DESCRIPTION...
  • Page 307 CLUTCH / PRIMARY / SHIFT External View NUMBER DESCRIPTION Shaft Bearing (Clutch Pinion Shaft) Shaft Seal Clutch Pinion Shaft Primary Cover 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 5.11 © Copyright Polaris Industries Inc.
  • Page 308 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION NUMBER...
  • Page 309 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H ( ( 2 2 0 0 2 2 3 3 ) ) TORQUE TORQUE DESCRIPTION DESCRIPTION — — Lift Rack Pressure Plate Internal —...
  • Page 310 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P L L A A T T E E A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION Friction Plate B...
  • Page 311 CLUTCH / PRIMARY / SHIFT Judder Spring Orientation 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 5.15 © Copyright Polaris Industries Inc.
  • Page 312 CLUTCH / PRIMARY / SHIFT S S E E R R V V I I C C E E P P R R O O C C E E D D U U R R E E S S P P R R I I M M A A R R Y Y C C O O V V E E R R R R E E M M O O V V A A L L P P R R I I M M A A R R Y Y D D R R I I V V E E / / C C L L U U T T C C H H C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 313 CLUTCH / PRIMARY / SHIFT P P R R I I M M A A R R Y Y C C O O V V E E R R L L I I P P S S E E A A L L R R E E P P L L A A C C E E M M E E N N T T 3.
  • Page 314 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T R R E E M M O O V V A A L L 6.
  • Page 315 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T S S E E A A L L C C L L U U T T C C H H P P I I N N I I O O N N S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 316 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T R R A A T T C C H H E E T T R R E E M M O O V V A A L L / / I I N N S S P P E E C C T T I I O O N N 10.
  • Page 317 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T R R A A T T C C H H E E T T I I N N S S T T A A L L L L A A T T I I O O N N 15.
  • Page 318 CLUTCH / PRIMARY / SHIFT 2. Install thrust washer external ring retaining 7. Remove locking pin to release the detent roller arm. and press new oil seal into position until flush with crankcase. Reference Shift Shaft Seal Replacement page 5.23 8.
  • Page 319 CLUTCH / PRIMARY / SHIFT S S H H I I F F T T L L E E V V E E R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N S S H H I I F F T T S S H H A A F F T T S S E E A A L L R R E E P P L L A A C C E E M M E E N N T T Removal 1.
  • Page 320 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H S S E E R R V V I I C C E E C C L L U U T T C C H H S S E E R R V V I I C C E E ( ( 2 2 0 0 1 1 9 9 - - 2 2 0 0 2 2 0 0 , , 2 2 0 0 2 2 2 2 ) ) C C L L U U T T C C H H R R E E M M O O V V A A L L C C L L U U T T C C H H R R A A C C K K R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 321 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H D D I I S S A A S S S S E E M M B B L L Y Y 10. Lift the clutch assembly out of the basket and set aside.
  • Page 322 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H I I N N S S P P E E C C T T I I O O N N 7. Inspect surface of steel plate guides on outer edge of hub for wear, grooves, or damage.
  • Page 323 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y 14. Inspect lifter bearing visually for any signs or wear or discoloration.
  • Page 324 CLUTCH / PRIMARY / SHIFT 5. Refer to the Clutch Plate Assembly View outlined in this chapter for clutch plate orientation. See Clutch Plate Assembly View page 5.14 IMPORTANT The first friction plate to be installed has a larger inner diameter, allowing it to fit around the judder spring.
  • Page 325 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H I I N N S S T T A A L L L L A A T T I I O O N N 7.
  • Page 326 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H S S E E R R V V I I C C E E ( ( 2 2 0 0 2 2 3 3 ) ) INSTALLATION C C L L U U T T C C H H R R A A C C K K , , R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 327 CLUTCH / PRIMARY / SHIFT 1. Remove the clutch. See Clutch Removal page 7. Remove inner hub and clutch assembly 5.30. 2. Remove the sleeve and needle bearing from the back side of the clutch assembly. 8. Remove thrust washer C C L L U U T T C C H H I I N N S S P P E E C C T T I I O O N N 3.
  • Page 328 CLUTCH / PRIMARY / SHIFT 6. Lubricate bearing with engine oil. 11. Replace steel plates if grooved, distorted or discolored. Inspect plates for distortion by placing each plate on a precision flat surface. Insert a feeler gauge between plate and flat surface in several places.
  • Page 329 CLUTCH / PRIMARY / SHIFT C C L L U U T T C C H H A A S S S S E E M M B B L L Y Y 4. Install the hub bearing and sleeve into the clutch assembly.
  • Page 330 CLUTCH / PRIMARY / SHIFT 1. Slide the clutch assembly onto the transmission in- put shaft until fully seated. 2. Install washer and NEW stake nut TORQUE Clutch Stake Nut 125 ft-lbs (170 N·m) 3. Stake the nut. 4. Install clutch rack. See Clutch Rack, Removal / Installation (2023) page 5.30.
  • Page 331 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L S S E E R R V V I I C C E E S S T T A A T T O O R R C C O O V V E E R R R R E E M M O O V V A A L L S S T T A A T T O O R R C C O O V V E E R R I I N N S S T T A A L L L L A A T T I I O O N N NOTICE 1.
  • Page 332 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L R R E E M M O O V V A A L L 4. Install flywheel remove tool PA-49316-A on the flywheel and tighten puller to remove flywheel...
  • Page 333 CLUTCH / PRIMARY / SHIFT F F L L Y Y W W H H E E E E L L I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 334 CLUTCH / PRIMARY / SHIFT T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G C C L L U U T T C C H H / / P P R R I I M M A A R R Y Y / / S S H H I I F F T T PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
  • Page 335 CLUTCH / PRIMARY / SHIFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Will Not Shift Broken shift drum Shift drum Replace shift drum Bent shift forks Shift fork Replace shift forks Worn shift drum Shift drum Replace shift drum Broken gears Transmission gears Replace broken gear(s)
  • Page 336 CLUTCH / PRIMARY / SHIFT NOTES 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 5.40 © Copyright Polaris Industries Inc.

  • Page 337: Chapter 6 Transmission / Crankshaft

    TRANSMISSION / CRANKSHAFT CHAPTER 6 TRANSMISSION / CRANKSHAFT GENERAL INFORMATION ................6.3 .
  • Page 338 TRANSMISSION / CRANKSHAFT ................6.49 TRANSMISSION INSTALLATION .
  • Page 339 TRANSMISSION / CRANKSHAFT G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S •...

  • Page 340: Service Limit

    TRANSMISSION / CRANKSHAFT S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - T T R R A A N N S S M M I I S S S S I I O O N N / / C C R R A A N N K K S S H H A A F F T T CONNECTING ROD / CRANKSHAFT SPECIFICATIONS ITEM...

  • Page 341: Specifications

    TRANSMISSION / CRANKSHAFT TRANSMISSION SPECIFICATIONS ITEM PART SPECIFIC STANDARD SERVICE LIMIT Shift Fork 10.00 - 10.022 mm 10.082 mm (0.3969") Shift Fork I.D. (Rail) (.3937 - .3945") 6.95–7.00 mm 6.50 mm (0.2559 ") Shift Fork Pin O.D. (.273 - .275") Shift Fork Rail 9.972–9.987 mm 9.902 mm ( 0.3898")
  • Page 342 TRANSMISSION / CRANKSHAFT L L O O C C K K I I N N G G T T H H E E C C R R A A N N K K S S H H A A F F T T F F O O R R S S E E R R V V I I C C E E 5.
  • Page 343 TRANSMISSION / CRANKSHAFT A A S S S S E E M M B B L L Y Y V V I I E E W W S S C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 344 TRANSMISSION / CRANKSHAFT 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual © Copyright Polaris Industries Inc.
  • Page 345 TRANSMISSION / CRANKSHAFT Crankcase Torque Pattern IMPORTANT Left crankcase bolts , and are M8 x 1.25 x 40. The rest of the fasteners are M8 x 1.25 x 75. Torque case bolts to specification following the torque sequence. TORQUE Crankcase Fasteners: 22 ft-lbs (30 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual ©...
  • Page 346 TRANSMISSION / CRANKSHAFT IMPORTANT Right crankcase bolt is M8 x 1.25 x 60. Torque case bolts to specification following the torque sequence. TORQUE Crankcase Fasteners: 22 ft-lbs (30 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 6.10 © Copyright Polaris Industries Inc.
  • Page 347 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 348 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N A A S S S S E E M M B B L L Y Y V V I I E E W W 2 2 0 0 1 1 9 9 –...
  • Page 349 TRANSMISSION / CRANKSHAFT 2 2 0 0 1 1 9 9 - - 2 2 0 0 2 2 0 0 O O U U T T P P U U T T S S H H A A F F T T NUMBER DESCRIPTION O-Ring...
  • Page 350 TRANSMISSION / CRANKSHAFT 2 2 0 0 2 2 2 2 I I N N P P U U T T S S H H A A F F T T ( ( I I N N A A S S A A K K A A ) ) NUMBER DESCRIPTION Input Shaft Plug...
  • Page 351 TRANSMISSION / CRANKSHAFT 2 2 0 0 2 2 2 2 + + I I N N P P U U T T S S H H A A F F T T ( ( M M U U S S A A S S H H I I ) ) NUMBER DESCRIPTION Input Shaft Plug...
  • Page 352 TRANSMISSION / CRANKSHAFT 2 2 0 0 2 2 2 2 O O U U T T P P U U T T S S H H A A F F T T ( ( I I N N A A S S A A K K A A ) ) NUMBER NUMBER DESCRIPTION...
  • Page 353 TRANSMISSION / CRANKSHAFT 2 2 0 0 2 2 2 2 + + O O U U T T P P U U T T S S H H A A F F T T ( ( M M U U S S A A S S H H I I ) ) NUMBER DESCRIPTION NUMBER...
  • Page 354 TRANSMISSION / CRANKSHAFT S S H H I I F F T T D D R R U U M M / / S S H H I I F F T T F F O O R R K K A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION Bearing, Shift Drum - Drive Sprocket Side...
  • Page 355 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION Balance Shaft Gear Fasteners (QTY.1)
  • Page 356 TRANSMISSION / CRANKSHAFT G G E E A A R R T T R R A A I I N N P P O O W W E E R R F F L L O O W W 4th Gear 1st Gear 5th Gear 2nd Gear...
  • Page 357 TRANSMISSION / CRANKSHAFT B B A A L L A A N N C C E E S S H H A A F F T T S S E E R R V V I I C C E E B B A A L L A A N N C C E E S S H H A A F F T T R R E E M M O O V V A A L L B B A A L L A A N N C C E E S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 358 TRANSMISSION / CRANKSHAFT 4. Fit the crankshaft assembly into the engine case 6. Assemble the crankcase. See Crankcase Assembly page 6.50. and align the timing marks on the crank and balance shaft gears as shown. 7. Rotate the engine to verify smooth operation and install in motorcycle chassis.
  • Page 359 TRANSMISSION / CRANKSHAFT S S T T A A R R T T E E R R D D R R I I V V E E S S E E R R V V I I C C E E S S T T A A R R T T E E R R D D R R I I V V E E R R E E M M O O V V A A L L S S T T A A R R T T E E R R D D R R I I V V E E I I N N S S P P E E C C T T I I O O N N 1.
  • Page 360 TRANSMISSION / CRANKSHAFT S S T T A A R R T T E E R R D D R R I I V V E E I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 361 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T S S E E R R V V I I C C E E C C R R A A N N K K S S H H A A F F T T G G E E A A R R R R E E M M O O V V A A L L / / 4.
  • Page 362 TRANSMISSION / CRANKSHAFT C C R R A A N N K K C C A A S S E E S S E E P P A A R R A A T T I I O O N N 19.
  • Page 363 TRANSMISSION / CRANKSHAFT 24. Insert two M6 threaded spacers with fasteners 27. While holding the nut with a wrench, tighten the into the two lower “B” threaded holes and two M12 center splitting tool to separate the case. threaded spacers with fasteners into the upper “B” threaded holes as shown.
  • Page 364 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N R R E E M M O O V V A A L L 5.
  • Page 365 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N I I N N S S P P E E C C T T I I O O N N Input Shaft NUMBER MEASUREMENT LOCATION...
  • Page 366 TRANSMISSION / CRANKSHAFT Output Shaft NUMBER MEASUREMENT LOCATION SPECIFICATION O-Ring 17.5 x 1.5 mm Flat Washer 20.4 x 35 x 0.08 mm Gear, 1st, Output OD: 96.75 – 97.25 mm ID: 27.00 – 27.021 mm Plain Bushing OD: 26.96 – 26.98 mm ID: 24.02 –...
  • Page 367 TRANSMISSION / CRANKSHAFT NUMBER MEASUREMENT LOCATION SPECIFICATION Flat tooth washer 30 x 38 mm Plain Bushing 34 mm Gear, 2nd, Output OD: 87.30 – 87.50 mm ID: 34.000 – 34.025 mm Shaft, Output 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 6.31 ©...
  • Page 368 TRANSMISSION / CRANKSHAFT NOTICE Refer to the Assembly View section in this chapter for component locations and exploded diagrams. See Transmission Assembly View page 6.12 . Refer to the Service Specifications section in this chapter for complete transmission specifications. See Service Specifications - Transmission / Crankshaft page 6.4.
  • Page 369 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T R R E E M M O O V V A A L L C C O O N N N N E E C C T T I I N N G G R R O O D D S S I I D D E E C C L L E E A A R R A A N N C C E E I I N N S S P P E E C C T T I I O O N N 1.
  • Page 370 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D R R E E M M O O V V A A L L / / C C O O N N N N E E C C T T I I N N G G R R O O D D I I N N S S P P E E C C T T I I O O N N ( ( B B I I G G E E N N D D ) ) I I D D E E N N T T I I F F I I C C A A T T I I O O N N CAUTION...
  • Page 371 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G I I N N S S P P E E C C T T I I O O N N 3.
  • Page 372 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G C C L L E E A A R R A A N N C C E E I I N N S S P P E E C C T T I I O O N N 1.
  • Page 373 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D B B E E A A R R I I N N G G S S E E L L E E C C T T I I O O N N 1.
  • Page 374 TRANSMISSION / CRANKSHAFT 4. The color code on the connecting rod is laser etched onto the big end side of the connecting rod. There will be an “R” for Red or “W” for White. reads: Last Digit “W” = WHITE “R”...
  • Page 375 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T I I N N S S P P E E C C T T I I O O N N Record all measurements and compare to 4.
  • Page 376 TRANSMISSION / CRANKSHAFT C C O O N N N N E E C C T T I I N N G G R R O O D D I I N N S S T T A A L L L L A A T T I I O O N N 7.
  • Page 377 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T C C L L E E A A N N I I N N G G M M A A I I N N B B E E A A R R I I N N G G O O I I L L C C L L E E A A R R A A N N C C E E I I N N S S P P E E C C T T I I O O N N 1.
  • Page 378 TRANSMISSION / CRANKSHAFT M M A A I I N N B B E E A A R R I I N N G G S S E E L L E E C C T T I I O O N N The FTR models utilize serviceable graded crankshaft main bearings.
  • Page 379 TRANSMISSION / CRANKSHAFT 3. Record both marking colors reference the table. BEARING INSERT Crankcase Crankshaft Reference Marking Marking Clearance Size Color PN Top PN Bottom White (1) Red (2) Blue 3515065–001 3515066–001 0.00138 – White (1) White (1) Yellow 3515065–002 3515066–002 0.0027 Inches Red (2)

  • Page 380: Installation

    TRANSMISSION / CRANKSHAFT M M A A I I N N B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T 3.
  • Page 381 TRANSMISSION / CRANKSHAFT 3. Use the bearing driver to push the bearings out 6. Use the bearing driver tool to start the bearing into approximately 1/16” (1.6 mm). the case. 4. Ensure the main bearing bore is free of debris. 5.
  • Page 382 TRANSMISSION / CRANKSHAFT L L E E F F T T C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 8.
  • Page 383 TRANSMISSION / CRANKSHAFT R R I I G G H H T T C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 5.
  • Page 384 TRANSMISSION / CRANKSHAFT C C R R A A N N K K S S H H A A F F T T I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 385 TRANSMISSION / CRANKSHAFT T T R R A A N N S S M M I I S S S S I I O O N N I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 386 TRANSMISSION / CRANKSHAFT 10. Assemble crankcase. See Crankcase Assembly 7. Lower the left-hand case onto the right-hand case page 6.50. and install mainshaft / crankcase installer PV-45030 and engine case assembly cup PF-51663 onto the transmission output shaft. C C R R A A N N K K C C A A S S E E A A S S S S E E M M B B L L Y Y 1.
  • Page 387 TRANSMISSION / CRANKSHAFT S S T T A A K K E E N N U U T T I I N N S S T T A A L L L L A A T T I I O O N N 12.
  • Page 388 TRANSMISSION / CRANKSHAFT T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G T T R R A A N N S S M M I I S S S S I I O O N N / / C C R R A A N N K K S S H H A A F F T T PROBLEM POSSIBLE CAUSE PART(S) AFFECTED...
  • Page 389 TRANSMISSION / CRANKSHAFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Hard to Shift Improper Clutch Clutch Refer to Clutch / Primary Operation / Shift Chapter Incorrect Oil Viscosity Engine oil and filter Refer to Maintenance Chapter Incorrect Clutch Clutch Adjustment Refer to Clutch / Primary Adjustment / Shift Chapter...
  • Page 390 TRANSMISSION / CRANKSHAFT NOTES 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 6.54 © Copyright Polaris Industries Inc.

  • Page 391: Chapter 7 Frame / Body

    FRAME / BODY CHAPTER 7 FRAME / BODY GENERAL INFORMATION ................7.2 .
  • Page 392 FRAME / BODY G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S This section covers the removal and installation of frame and body components, assemblies and systems.
  • Page 393 FRAME / BODY A A S S S S E E M M B B L L Y Y V V I I E E W W S S F F E E N N D D E E R R S S A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE...
  • Page 394 FRAME / BODY M M U U D D G G U U A A R R D D A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE...
  • Page 395 FRAME / BODY F F R R A A M M E E A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE NUMBER DESCRIPTION Shock Fastener (Lower) 44 ft-lbs (60 N·m) Engine Mount Fastener (Rear Upper)
  • Page 396 FRAME / BODY F F O O O O T T P P E E 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 2019–2020 Models: NUMBER DESCRIPTION...
  • Page 397 FRAME / BODY 2022+ Models: NUMBER DESCRIPTION TORQUE Footpeg Fasteners (driver) 17 ft-lbs (23 N·m) Footpeg Fasteners (passenger) 17 ft-lbs (23 N·m) Feeler Peg 96 in-lbs (11 N·m) 50 ft-lbs (68 N·m) Footpeg Shoulder Fasteners Apply grease to shaft portion 15 ft-lbs (20 N·m) Shift / Brake Pedal Peg Apply LOCTITE 263...
  • Page 398 FRAME / BODY H H I I G G H H L L I I C C E E N N S S E E P P L L A A T T E E M M O O U U N N T T 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual ©...
  • Page 399 FRAME / BODY TORQUE ITEM DESCRIPTION Weld–Arm, License Plate, High — Spacer, Fender, Right Rear, High — License Plate 72 in-lbs (8 N·m) Front License Plate Mount Fasteners 15 ft-lbs (20 N·m) Rear License Plate Mount Fasteners Upper License Plate Bracket 72 in-lbs (8 N·m) Fasteners —...
  • Page 400 FRAME / BODY H H E E A A D D L L I I G G H H T T C C O O V V E E R R A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 401 FRAME / BODY W W I I N N D D S S H H I I E E L L D D M M O O U U N N 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 L L O O W W W W I I N N D D D D E E F F L L E E C C T T O O R R W W I I T T H H O O U U T T H H E E A A D D L L I I G G H H T T C C O O W W L L ITEM DESCRIPTION...
  • Page 402 FRAME / BODY W W I I N N D D S S C C R R E E E E N N M M O O U U N N T T TORQUE ITEM DESCRIPTION Weld–Windscreen Mount, FTR ™ , Right-Hand —...
  • Page 403 FRAME / BODY N N U U M M B B E E R R P P L L A A T T E E A A S S S S E E M M B B L L Y Y TORQUE ITEM DESCRIPTION...
  • Page 404 FRAME / BODY W W I I N N D D S S C C R R E E E E N N A A S S S S E E M M B B L L Y Y TORQUE ITEM DESCRIPTION —...
  • Page 405 FRAME / BODY B B O O D D Y Y / / F F R R A A M M E E S S E E R R V V I I C C E E A A I I R R B B O O X X C C O O V V E E R R R R E E M M O O V V A A L L 5.
  • Page 406 FRAME / BODY F F O O O O T T P P E E G G ( ( D D R R I I V V E E R R ) ) R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N Left Foot Peg Right Foot Peg 1.
  • Page 407 FRAME / BODY F F O O O O T T P P E E G G ( ( P P A A S S S S E E N N G G E E R R ) ) R R E E M M O O V V A A L L / / 5.
  • Page 408 FRAME / BODY S S E E A A T T C C O O W W L L R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 2.
  • Page 409 FRAME / BODY S S E E A A T T R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 410 FRAME / BODY F F R R O O N N T T F F E E N N D D E E R R R R E E M M O O V V A A L L F F R R O O N N T T F F E E N N D D E E R R I I N N S S T T A A L L L L A A T T I I O O N N CAUTION CAUTION Use care not to scratch or damage painted surfaces...
  • Page 411 FRAME / BODY F F R R O O N N T T M M U U D D G G U U A A R R D D I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 412 FRAME / BODY R R E E A A R R B B O O D D Y Y A A C C C C E E S S S S O O R R Y Y M M O O U U N N T T 3.
  • Page 413 FRAME / BODY R R E E A A R R M M U U D D G G U U A A R R D D I I N N S S T T A A L L L L A A T T I I O O N N IMPORTANT The rear body accessory mount needs to be installed before the procedure below can be performed.
  • Page 414 FRAME / BODY R R E E A A R R F F E E N N D D E E R R R R E E M M O O V V A A L L R R E E A A R R F F E E N N D D E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 415 FRAME / BODY 5. Torque fasteners to specification. 5. Remove the tail light jumper harness as shown. TORQUE License Plate Mount Fasteners: 96 in-lbs (11 N·m) R R E E A A R R F F E E N N D D E E R R A A R R M M R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 416 FRAME / BODY I I N N S S T T R R U U M M E E N N T T P P A A N N E E L L R R E E M M O O V V A A L L / / 6.
  • Page 417 FRAME / BODY R R I I D D E E C C O O M M M M A A N N D D ™ D D I I S S P P L L A A Y Y R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 1.

  • Page 418: Installation

    FRAME / BODY F F R R A A M M E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 16.
  • Page 419 FRAME / BODY 2. Install wiring harness to frame. Reference Harness Routing page 10.65 3. Install triple clamp. See Triple Clamp Installation / Steering Head Bearing Adjustment page 8.54 4. Install front forks. See Front Fork Installation page 8.51 5. Install headlight. See Headlight Replacement page 10.74 6.
  • Page 420 FRAME / BODY H H I I G G H H L L I I C C E E N N S S E E P P L L A A T T E E I I N N S S T T A A L L L L A A T T I I O O N N 3.
  • Page 421 FRAME / BODY 6. Route license plate light cable through right-hand 8. Secure license plate to bracket with four fasteners tube and connect to license plate light and pull and four nuts slack from license plate light into tube so that TORQUE connection is not exposed.
  • Page 422 FRAME / BODY L L I I C C E E N N S S E E P P L L A A T T E E M M O O U U N N T T I I N N S S T T A A L L L L A A T T I I O O N N 2.
  • Page 423 FRAME / BODY 4. Install each passenger handle onto sub-frame 6. Join chassis harness connector to license plate light connector. Join turn signal connectors to license with two retained screws per handle. plate harness, installed in License Plate Assembly IMPORTANT section.
  • Page 424 FRAME / BODY W W I I N N D D S S H H I I E E L L D D I I N N S S T T A A L L L L A A T T I I O O N N H H E E A A D D L L I I G G H H T T R R E E M M O O V V A A L L 1.
  • Page 425 W W I I N N D D S S H H I I E E L L D D M M O O U U N N T T I I N N S S T T A A L L L L A A T T I I O O N N 3. With headlight assembly unmounted, tilt assembly forward and slide electronic throttle control (ETC) NOTE connection off push-pin clip. It is not necessary to All Indian Motorcycle ® ™ models require disconnect harnesses.
  • Page 426 FRAME / BODY 4. Install right-hand mount and left-hand mount 6. Reinstall bottom of headlight assembly with two to back of headlight bracket with Windshield fasteners Mount Fasteners and four washers NOTICE TORQUE Turn handlebars lock-to-lock to access two fasteners from rear-side.
  • Page 427 FRAME / BODY H H E E A A D D L L I I G G H H T T C C O O W W L L I I N N S S T T A A L L L L A A T T I I O O N N 7.
  • Page 428 FRAME / BODY S S I I D D E E - - S S T T A A N N D D R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N Installation: 6.
  • Page 429 FRAME / BODY B B R R A A C C K K E E T T R R E E M M O O V V A A L L 2. Remove two (one per side) lower chin fairing side fasteners 1.
  • Page 430 FRAME / BODY B B R R A A C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N C C H H I I N N F F A A I I R R I I N N G G I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 431 FRAME / BODY F F R R O O N N T T N N U U M M B B E E R R P P L L A A T T E E R R E E P P L L A A C C E E M M E E N N T T 3.
  • Page 432 FRAME / BODY 5. Reinstall top of headlight assembly with two retained headlight bracket fasteners TORQUE Headlight Bracket Fasteners 84 in-lbs (9.5 N·m) 6. Mount front number plate onto two brackets with the following hardware: • Four bracket fasteners • Four washers •...

  • Page 433: Chapter 8 Steering / Suspension

    STEERING / SUSPENSION CHAPTER 8 STEERING / SUSPENSION FRONT WHEEL & SUSPENSION ............... . . 8.4 .
  • Page 434 STEERING / SUSPENSION ......... .8.59 SERVICE SPECIFICATIONS - REAR WHEEL &...
  • Page 435 STEERING / SUSPENSION TIRES ......................8.102 .

  • Page 436: Tool Description

    Bearing Kit PU-51324 the tire information label. Tubeless tires are used on certain Indian Motorcycle Fork Spring Compressor PV-49464 models. Operating the motorcycle with damaged Adapter...
  • Page 437 Not Applicable Inner Fork Tube Diameter .20 mm (.008 in.) Inner and Outer Fork Tube Runout Indian Motorcycle Fork Oil (PN: 2208093) FTR / FTR S / FTR Rally Fuchs SAF 5113, Ohlins fork oil, or approved equivalent Fork Oil Type...
  • Page 438 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K A A D D J J U U S S T T M M E E N N T T G G U U I I D D E E NOTICE FTR Rally features a preload and rebound adjustments on the rear shock but no fork adjustments.
  • Page 439 STEERING / SUSPENSION RIDING TYPE: COMPRESSION REBOUND (LEFT-HAND FORK) (RIGHT-HAND FORK) General Riding (2-up) 10 clicks out 5 clicks out Aggressive Riding (Track) 5 clicks out 4 clicks out FTR / FTR S RECOMMENDED PRE-LOAD SETTINGS Adjustments can be make to the fork to increase or decrease pre-load for a personal rider preference. IMPORTANT Make sure both forks are adjusted evenly.
  • Page 440 STEERING / SUSPENSION FTR R CARBON RECOMMENDED DAMPING SETTINGS RIDING TYPE: COMPRESSION REBOUND (LEFT-HAND FORK) (RIGHT-HAND FORK) Low Speed Riding (Urban) 22 clicks out 18 clicks out General Riding (Town/Highway) 18 clicks out 16 clicks out General Riding (2-up) 15 clicks out 14 clicks out Aggressive Riding (Track) 14 clicks out...
  • Page 441 STEERING / SUSPENSION Adjustments can be make to the fork to increase or decrease pre-load for a personal rider preference. IMPORTANT Make sure both forks are adjusted evenly. D D R R I I V V E E C C H H A A I I N N T T E E N N S S I I O O N N - - S S P P E E C C I I F F I I C C A A T T I I O O N N S S 1.
  • Page 442 STEERING / SUSPENSION 2. Turn handlebars from full left to full right and inspect for smooth, free movement. Point front wheel straight ahead, grasp fork tubes and pull/ push fork tubes back and forth. If steering binds, feels rough or uneven, or if movement is detected at steering stem, adjust or replace steering head bearings as necessary.
  • Page 443 STEERING / SUSPENSION A A S S S S E E M M B B L L Y Y V V I I E E W W S S H H A A N N D D C C O O N N T T R R O O L L S S - - A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 444 STEERING / SUSPENSION TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Throttle Assembly Throttle assembly Fastener 27 in-lbs (3 N·m) Right Hand Switch Cube Retention Clip 88 in-lbs (10 N·m) IMPORTANT Master Cylinder Clamp Fastener (Front) Torque the Master Cylinder Clamp upper fastener first and the bottom fastener second.
  • Page 445 STEERING / SUSPENSION 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 2019,2020,2022 TORQUE (IF APPLICABLE) NUMBER...
  • Page 446 STEERING / SUSPENSION 2023+ TORQUE (IF APPLICABLE) NUMBER DESCRIPTION 18 ft-lbs (24 N·m) Cap Riser Fasteners Tighten Front Bolts First, then Rear Riser Caps Handlebar Risers Handlebar Isolator Riser Bracket Handlebar Riser Nut (2023) 24 ft-lbs (33 N·m) Handlebar End Weight Handlebar Cap Fastener 18 ft-lbs (24 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 447 STEERING / SUSPENSION T T R R I I P P L L E E C C L L A A M M P P - - A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 448 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K - - A A S S S S E E M M B B L L Y Y V V I I E E W W NON-ADJUSTABLE FORKS IMPORTANT The fork cartridges...
  • Page 449 STEERING / SUSPENSION NUMBER DESCRIPTION TORQUE (IF APPLICABLE) Cartridge Fastener 17 ft-lbs (23 N·m) Cartridge Washer Inner Tube Assembly Seal Kit Outer Fork Tube Cartridge, Non-Adjustable Spring Assembly Spring Spacer Fork Cap, Non-Adjustable 12 ft-lbs (16 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.17 ©...

  • Page 450: Adjustable Forks

    STEERING / SUSPENSION ADJUSTABLE FORKS IMPORTANT The fork cartridges are non-serviceable and can not be rebuilt. In the event of replacement, a cartridge assembly must be installed. 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.18 © Copyright Polaris Industries Inc.
  • Page 451 STEERING / SUSPENSION NUMBER DESCRIPTION TORQUE (IF APPLICABLE) Cartridge Fastener 17 ft-lbs (23 N·m) Cartridge Washer Inner Tube Assembly Seal Kit Outer Fork Tube Cartridge, Adjustable Spring Assembly Spring Spacer Fork Cap, Adjustable 11 ft-lbs (15 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.19 ©...
  • Page 452 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K - - A A S S S S E E M M B B L L Y Y V V I I E E W W 2022+ FTR R Carbon adjustable Ohlins NUMBER DESCRIPTION...
  • Page 453 STEERING / SUSPENSION 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 2019–2020 / 2023+ MODELS NUMBER DESCRIPTION...
  • Page 454 STEERING / SUSPENSION 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 2022 MODELS NUMBER DESCRIPTION...
  • Page 455 STEERING / SUSPENSION S S E E R R V V I I C C E E P P R R O O C C E E D D U U R R E E S S 6. Carefully insert a 2mm allen wrench into the switchcube relief to release the retention feature H H A A N N D D L L E E B B A A R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N Removal...
  • Page 456 STEERING / SUSPENSION 18. Remove the four fasteners securing the handlebars. • 2019-2022: Remove the instrument by removing • 2019-2022: its fasteners • 2023+: • 2023+: Remove rear display fasteners • Remove rear middle display fastener and cover. 17. Disconnect the instrument cluster electrical connections.
  • Page 457 STEERING / SUSPENSION Installation 2. Line up the handlebar index mark and torque instrument cluster, starting with the front bolts, to 1. Installation is performed by reversing the specification. removal procedure. TORQUE Handlebar Riser Nut: 18 ft-lbs (24 N·m) TORQUE Handlebar Riser Nut (2023) 24 ft-lbs (33 N·m) TORQUE...
  • Page 458 STEERING / SUSPENSION 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 459 STEERING / SUSPENSION M M I I R R R R O O R R R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N REMOVAL 1.
  • Page 460 STEERING / SUSPENSION C C L L U U T T C C H H C C A A B B L L E E R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 461 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 3.
  • Page 462 STEERING / SUSPENSION F F R R O O N N T T A A X X L L E E I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T W W H H E E E E L L I I N N S S P P E E C C T T I I O O N N 1.
  • Page 463 STEERING / SUSPENSION B B R R A A K K E E D D I I S S C C R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 464 STEERING / SUSPENSION 1. Visually inspect bearing seals on each side for wear or damage. 2. Check bearings by turning inner race by hand. • Look for signs of discoloration, scoring, galling, or contamination from moisture or dirt. Replace bearings if any of the above are present. •...
  • Page 465 STEERING / SUSPENSION F F R R O O N N T T W W H H E E E E L L B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T F F R R O O N N T T F F O O R R K K R R E E M M O O V V A A L L CAUTION WARNING...
  • Page 466 STEERING / SUSPENSION 5. Remove turn signal assembly by removing bolt • 2022+ models and nut Remove wheel speed sensor line retainer fastener 6. Loosen top triple clamp pinch bolt 8. Loosen lower triple clamp pinch bolts 7. For the left-hand fork: •...
  • Page 467 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K D D I I S S A A S S S S E E M M B B L L Y Y 3.
  • Page 468 STEERING / SUSPENSION 5. Insert the base of the fork into the tool. 8. Using a 19 mm socket and special tool (PF-52744), turn counter-clockwise to remove the preload. CAUTION Ensure the two axle pinch bolts are removed from the Right-Hand fork leg to avoid damage on the post.
  • Page 469 STEERING / SUSPENSION 10. Using a 19 mm socket and a 19 mm wrench, loosen 15. Carefully lift dust seal out of outer fork tube with a cap from the cartridge. small flat screwdriver. 16. Use a pick to remove seal retaining ring. Use care IMPORTANT not to scratch the surface of the inner fork tube During cap removal, make sure the inner clicker...
  • Page 470 STEERING / SUSPENSION 18. Remove bushing , slide , washer and oil seal 19. Gently pry the bushing apart using a small flat blade screwdriver to remove. 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 471 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K D D I I S S A A S S S S E E M M B B L L Y Y ( ( O O H H L L I I N N S S ) ) 2.
  • Page 472 STEERING / SUSPENSION 5. Carefully slide the outer tube all the way down. 8. Remove the spring seat, main spring and preload tube. Use a wire with a hook to remove the preload tube. 6. Install the Spanner (PF-53160) on the top cap lock nut.
  • Page 473 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K I I N N S S P P E E C C T T I I O O N N 14.
  • Page 474 1. Install Fork Seal Installation Tool (PV-47037) on fork tube. NOTICE Clean all parts prior to assembly. NOTICE Refer to Indian Motorcycle Service Products and Lubricants page 2.3 for fork oil type and pn info. IMPORTANT New parts stackup should be ordered on the inner tube as shown.
  • Page 475 STEERING / SUSPENSION 3. Install the seal locking clip. 6. Install the lower bushing. 4. Apply a light film of fork oil to outside edge and 7. Lubricate and install a new upper bushing on inner inside seal lips of new oil seal and install by hand. fork tube.
  • Page 476 STEERING / SUSPENSION 2. To properly seat the bushing and washer, use Fork 5. Seat the Dust Seal by hand. Sealer Installer (PV-47035) with the short end of the seal installer positioned down toward the bushing as shown. IMPORTANT Fork Seal Installer must be positioned with the short end facing the bushing as shown.
  • Page 477 STEERING / SUSPENSION Cartridge Installation 3. Install Cartridge Holder (PF-52745) into the top of the fork body to prevent cartridge from turning 1. Install new cartridge. while torquing the cartridge fastener. Using a 8 mm allen, torque cartridge fastener to specification. 2.
  • Page 478 STEERING / SUSPENSION • Push the dampening rod down into the fork body. 8. Install new spring and washer. • Set the micrometer to specification height and insert the tail end of the micrometer into the fork body as shown. •...
  • Page 479 STEERING / SUSPENSION 11. Compress fork and install the fork cap onto the cartridge body handtight. 12. Place the fork body into a soft jawed vice. Tighten cap with special tool (PF-52744). Torque to specification. TORQUE Fork Cap: 12 ft-lbs (16 N·m) NOTICE To use the special tool (PF-52744) with a torque wrench, install the torque wrench at 90 degrees to...
  • Page 480 Push down the NOTICE outer tube while covering the tube until you cant Refer to Indian Motorcycle Service Products and push harder, then release the hand. Lubricants page 2.3 for fork oil type and pn info.
  • Page 481 STEERING / SUSPENSION 8. Using a fluid measuring syringe, set the depth to 12. Install the Pull-Up Tool (PF-53159) to the piston 135 mm. Install the syringe into the outer fork tube shaft. Top out the piston shaft at the same time as to determine the height of fluid in the fork body.
  • Page 482 STEERING / SUSPENSION 15. Use the Spanner (PF-53160) and tighten the fork 18. Reset clickers and preload to previous settings cap lock nut to specification. noted before disassembly. NOTICE If you want to return the fork settings back to factory, see Front Fork Adjustment Guide page 8.6 NOTICE The nut will be loosen when the top cap is in the...
  • Page 483 STEERING / SUSPENSION F F R R O O N N T T F F O O R R K K I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 484 STEERING / SUSPENSION 9. Install turn signal assembly. Torque bolt 1. Secure the motorcycle in an upright position with specification. tie-down straps and a platform jack positioned beneath the engine cases. TORQUE IMPORTANT Turn Signal Mount Fastener (Front): Do not operate the front brake lever with the calipers 36 in-lbs (4 N·m) or wheel removed.
  • Page 485 STEERING / SUSPENSION 10. Slide upper triple clamp off steering stem. 11. Remove stem adjuster nut with a spanner socket PV-43508. IMPORTANT Support lower triple clamp while removing the adjuster nut. 12. Remove lower triple clamp, with steering stem, and lower bearing (outer race will remain in head tube).
  • Page 486 STEERING / SUSPENSION T T R R I I P P L L E E C C L L A A M M P P I I N N S S T T A A L L L L A A T T I I O O N N / / S S T T E E E E R R I I N N G G 4.
  • Page 487 STEERING / SUSPENSION 9. Tighten top triple clamp pinch bolt enough to hold tubes in place. Leave lower triple clamp pinch bolts loose. 10. Torque the top steering stem nut to specification. TORQUE Steering Stem Nut (top): 92 ft-lbs (125 N·m) NOTICE CHECK STEERING STEM BEARINGS at this time.
  • Page 488 STEERING / SUSPENSION T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F R R O O N N T T W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
  • Page 489 STEERING / SUSPENSION PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Fork Tube Height Unequal Install Correctly Fork Oil Level Unequal Set Correctly Fork Spring Free Length Different Replace Between Right & Left Wheel Assembly Out-of-Balance Balance Low Tire Pressure Inflate to specification Front Suspension Too Soft Weak Fork Springs Replace...

  • Page 490: Special Tool

    PF-52737 the recommended tires inflated to the recommended Tool tire pressures. Spring Compressor Commercially Available Tubeless tires are used on certain Indian Motorcycle Platform Jack Commercially Available models. Operating the motorcycle with damaged rims Drive Chain Tool KM500R creates a safety hazard including air pressure loss, steering imbalance and/or reduced steering control.
  • Page 491 STEERING / SUSPENSION S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - R R E E A A R R W W H H E E E E L L & & S S U U S S P P E E N N S S I I O O N N ITEM STANDARD SERVICE LIMIT...
  • Page 492 STEERING / SUSPENSION 2. Determine shock preload by measuring the amount of exposed thread on the shock body behind the jam nut. See the table below for measurement based on weight. 3. Adjust preload as needed to achieve dimension specified in the table below. To adjust, See Rear Shock Preload Adjustment page 8.61.
  • Page 493 STEERING / SUSPENSION R R E E A A R R S S H H O O C C K K P P R R E E L L O O A A D D A A D D J J U U S S T T M M E E N N T T 1.
  • Page 494 STEERING / SUSPENSION S S H H O O C C K K A A N N A A L L Y Y S S I I S S Shock “misting” or “weepage” is common and should be present during normal vehicle operation. All Shock Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock.
  • Page 495 STEERING / SUSPENSION A A S S S S E E M M B B L L Y Y V V I I E E W W S S R R E E A A R R S S U U S S P P E E N N S S I I O O N N A A S S S S E E M M B B L L Y Y V V I I E E W W 2019–2020 Models TORQUE (IF APPLICABLE) NUMBER...
  • Page 496 STEERING / SUSPENSION TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Rear Axle Swingarm 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.64 © Copyright Polaris Industries Inc.
  • Page 497 STEERING / SUSPENSION 2022+ Models TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Swingarm Pivot Bolt 52 ft-lbs (70 N·m) Washer 44 ft-lbs (60 N·m) Swingarm Lock Ring See Tightening Procedure Outlined in this Chapter 11 (15 N·m) Swingarm Pivot Adjuster See Tightening Procedure Outlined in this Chapter Swingarm Bushing (Left-Hand) Swingarm Bushing (Right-Hand) Pivot Shaft...
  • Page 498 STEERING / SUSPENSION R R E E A A R R S S H H O O C C K K A A S S S S E E M M B B L L Y Y V V I I E E W W TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 499 STEERING / SUSPENSION R R E E A A R R 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 NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 500 STEERING / SUSPENSION D D R R I I V V E E C C H H A A I I N N S S E E R R V V I I C C E E D D R R I I V V E E C C H H A A I I N N T T O O O O L L KM500R NUMBER DESCRIPTION...
  • Page 501 STEERING / SUSPENSION 2. Measure the length of 20 pitches from pin center to pin center, and compare to the specification. length of 20 pitches: 317.5–319 mm 3. Replace the drive chain if the length exceeds specification. See DRIVE CHAIN SERVICE in the Steering / Suspension chapter.
  • Page 502 STEERING / SUSPENSION D D R R I I V V E E C C H H A A I I N N M M A A S S T T E E R R L L I I N N K K R R E E M M O O V V A A L L 3.
  • Page 503 STEERING / SUSPENSION 5. Thread the tool until the cutting pin contacts the pin head. CAUTION Ensure the cutting pin is lined up with the center of the pin and not angled. 6. Use a 27mm wrench to hold the tool body in place. 7.
  • Page 504 STEERING / SUSPENSION D D R R I I V V E E C C H H A A I I N N M M A A S S T T E E R R L L I I N N K K I I N N S S T T A A L L L L A A T T I I O O N N 8.
  • Page 505 STEERING / SUSPENSION 14. Ensure the outer plate is straight by placing the plate holder onto the new master link and a link to the left and right IMPORTANT Ensure the new link is not stiff and can move freely. 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.73 ©...
  • Page 506 STEERING / SUSPENSION Pin Head Flaring 9. Repeat the for the remaining pin head. 1. Install the U-shaped holder so the pin heads on the IMPORTANT master link align with the dimples. Ensure the new link is not stiff and can move freely. 2.
  • Page 507 D D R R I I V V E E C C H H A A I I N N A A D D J J U U S S T T M M E E N N T T Lubricate the drive chain with Indian Motorcycle chain...
  • Page 508 STEERING / SUSPENSION 2. Loosen both tension bolt jam nuts 4. Use the adjuster marks to ensure even axle alignment. 3. Adjust the tension bolts evenly until correct tension is achieved. Reference Drive Chain 5. Without moving the tension bolts, Tighten jam nuts. Tension page 8.9.
  • Page 509 Clean the chain using a chain brush or clean rag to remove any dirt or grit. The chain must be lubricated using Indian Motorcycle chain lube (2884172). See Maintenance Intervals page 2.4 CAUTION Always have the motorcycle off and the transmission in neutral when performing this procedure.
  • Page 510 STEERING / SUSPENSION D D R R I I V V E E C C H H A A I I N N S S L L I I D D E E R R R R E E P P L L A A C C E E M M E E N N T T 8.
  • Page 511 STEERING / SUSPENSION 1. Remove three fasteners securing sprocket cover. 4. Installation is performed by reversing the removal procedure. TORQUE Chain Guard Fastener: 88 in-lbs (10 N·m) TORQUE Drive Sprocket Cover Fasteners: 88 in-lbs (10 N·m) 2. Remove chain guard 3.
  • Page 512 STEERING / SUSPENSION D D R R I I V V E E S S P P R R O O C C K K E E T T S S E E R R V V I I C C E E C C H H A A I I N N G G U U A A R R D D R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N D D R R I I V V E E S S P P R R O O C C K K E E T T C C O O V V E E R R R R E E M M O O V V A A L L / / 1.
  • Page 513 STEERING / SUSPENSION D D R R I I V V E E S S P P R R O O C C K K E E T T R R E E M M O O V V A A L L 5.

  • Page 514: Installation

    STEERING / SUSPENSION D D R R I I V V E E S S P P R R O O C C K K E E T T I I N N S S P P E E C C T T I I O O N N 8.
  • Page 515 STEERING / SUSPENSION D D R R I I V V E E S S P P R R O O C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 516 STEERING / SUSPENSION D D R R I I V V E E N N S S P P R R O O C C K K E E T T S S E E R R V V I I C C E E 4.
  • Page 517 STEERING / SUSPENSION D D R R I I V V E E N N S S P P R R O O C C K K E E T T I I N N S S P P E E C C T T I I O O N N 3.
  • Page 518 STEERING / SUSPENSION D D R R I I V V E E N N S S P P R R O O C C K K E E T T I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 519 STEERING / SUSPENSION R R E E A A R R W W H H E E E E L L S S E E R R V V I I C C E E 5. Remove two caliper mounting bolts and remove caliper.
  • Page 520 STEERING / SUSPENSION 7. Remove chain guard by removing its fasteners 10. Move wheel rearward to gain access to remove wheel speed sensor mounting bolt and sensor NOTICE Pay attention to the number of washers between the sensor and the bracket for reinstallation. 8.
  • Page 521 STEERING / SUSPENSION R R E E A A R R A A X X L L E E I I N N S S P P E E C C T T I I O O N N 12. Remove rear wheel assembly by sliding it to the rear of the motorcycle.
  • Page 522 STEERING / SUSPENSION R R E E A A R R W W H H E E E E L L B B E E A A R R I I N N G G I I N N S S P P E E C C T T I I O O N N W W H H E E E E L L B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T IMPORTANT CAUTION...
  • Page 523 STEERING / SUSPENSION S S H H O O C C K K A A B B S S O O R R B B E E R R R R E E M M O O V V A A L L 5.
  • Page 524 STEERING / SUSPENSION S S H H O O C C K K A A B B S S O O R R B B E E R R I I N N S S P P E E C C T T I I O O N N 5.
  • Page 525 STEERING / SUSPENSION S S H H O O C C K K A A B B S S O O R R B B E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 526 STEERING / SUSPENSION S S W W I I N N G G A A R R M M S S E E R R V V I I C C E E 6. Inspect rear shock for leakage and all rear suspension components for damage or loose S S W W I I N N G G A A R R M M I I N N S S P P E E C C T T I I O O N N fasteners.
  • Page 527 STEERING / SUSPENSION 7. Position a platform jack beneath the engine cases 11. Remove pivot bolt and washer. and raise until it contacts the engine and the rear wheel is off the stand. 12. Remove lock ring with special tool PF-52737. 13.
  • Page 528 STEERING / SUSPENSION S S W W I I N N G G A A R R M M B B U U S S H H I I N N G G / / B B E E A A R R I I N N G G R R E E P P L L A A C C E E M M E E N N T T REMOVAL INSTALLATION 1.
  • Page 529 STEERING / SUSPENSION S S W W I I N N G G A A R R M M I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 530 STEERING / SUSPENSION 6. Install lock ring and torque to specification with 7. Install pivot bolt special tool PF-52737. IMPORTANT Pivot bolts have to be tightened at the same time, they can NOT be torqued separately. IMPORTANT Ensure the adjusters are not turning while torquing by holding the adjuster with special tool PF–52738 while turning special tool PF-52737 as shown.
  • Page 531 STEERING / SUSPENSION 10. Install rear wheel. See Rear Wheel Removal / Installation page 8.87. 11. Install rear brake caliper. See Rear Caliper Removal page 9.57. 12. Connect tail light / turn signal electrical connectors. 13. Install chain and adjust as needed.. See Drive Chain Adjustment page 8.75.
  • Page 532 STEERING / SUSPENSION T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G R R E E A A R R W W H H E E E E L L / / S S U U S S P P E E N N S S I I O O N N PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
  • Page 533 STEERING / SUSPENSION T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F I I N N A A L L D D R R I I V V E E PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED...
  • Page 534 STEERING / SUSPENSION T T I I R R E E S S G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S WARNING The use of tires other than original equipment may cause instability which can lead to a crash resulting in...
  • Page 535 STEERING / SUSPENSION 1. Inspect tires for weather checking, cuts, imbedded foreign objects, etc. 2. Inspect front and rear wheels for damage. 3. Measure tread depth at center of tread. 4. Measure in 3-4 places equally spaced around the tire and record the smallest measurement. WARNING It is dangerous to ride with a worn tire.
  • Page 536 STEERING / SUSPENSION Metzeler 40 PSI (276 REAR Sportec M9 180/55ZR17 5.5 x 17 kPa) Metzeler 36 PSI (248 120/70R19M/ FRONT Sportec M9 3.0 x 19 kPa) 2023: 1/16 in (1.6 FTR Rally Metzeler 40 PSI (276 150/70R18M/ REAR Sportec M9 4.25 x 18 kPa) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 537 • Manual manipulation of tire irons Ozone cracking usually shows up on the sidewalls of tires and is caused by sunlight, electric motor Indian Motorcycle permits and recommends all three emissions, smog, or other environmental factors. of the general methods, but realizes that careless or...
  • Page 538 STEERING / SUSPENSION T T I I R R E E R R E E M M O O V V A A L L 6. Carefully work around the circumference of the upper bead with the tire lever until it is IMPORTANT completely off of the rim.
  • Page 539 DANGER Balance Dots Indian Motorcycle does not recommend the use of liquid balancer/sealers. These are a form of temporary repair which may adversely affect ply material and mask secondary damage caused by the penetrating object.
  • Page 540 STEERING / SUSPENSION T T I I R R E E B B A A L L A A N N C C I I N N G G • Lock assembly on mounting machine or place in safety cage before inflating to seat beads WARNING •...
  • Page 541 STEERING / SUSPENSION W W H H E E E E L L I I N N S S P P E E C C T T I I O O N N T T I I R R E E R R E E P P A A I I R R P P R R E E C C A A U U T T I I O O N N S S V V I I S S U U A A L L I I N N S S P P E E C C T T I I O O N N / / R R U U N N O O U U T T WARNING 1.
  • Page 542 STEERING / SUSPENSION V V A A L L V V E E S S T T E E M M V V A A L L V V E E S S T T E E M M I I N N S S T T A A L L L L A A T T I I O O N N - - M M E E T T A A L L V V A A L L V V E E S S T T E E M M I I N N S S P P E E C C T T I I O O N N 1.
  • Page 543 STEERING / SUSPENSION S S P P O O K K E E D D W W H H E E E E L L S S E E R R V V I I C C E E NOTICE W W H H E E E E L L T T R R U U I I N N G G Axial runout is side to side movement (wobble) of the rim.
  • Page 544 STEERING / SUSPENSION W W H H E E E E L L L L A A C C I I N N G G 3. Using the index marks from step one, insert all inside spokes skipping one hole between each. NOTICE If an assembled wheel is available, it can be referenced for proper spoke pattern.
  • Page 545 STEERING / SUSPENSION T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G T T I I R R E E S S PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED...
  • Page 546 STEERING / SUSPENSION NOTES 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 8.114 © Copyright Polaris Industries Inc.

  • Page 547: Chapter 9 Brakes

    BRAKES CHAPTER 9 BRAKES GENERAL INFORMATION ................9.3 .
  • Page 548 BRAKES ..............9.53 FRONT BRAKE LEVER REPLACEMENT .
  • Page 549 S S E E R R V V I I C C E E N N O O T T E E S S CAUTION Use only genuine Indian Motorcycle replacement Brake fluid and some types of brake cleaners will parts when servicing the brake system.

  • Page 550: Tool Description

    BRAKES S S P P E E C C I I A A L L T T O O O O L L S S - - B B R R A A K K E E S S TOOL DESCRIPTION PART NUMBER ABS Tool (Lever Reserve) PV-50104...
  • Page 551 BRAKES 3. Remove brake lever and apply grease to pivot fastener , as shown. 4. Assemble brake lever. 5. Torque brake lever pivot fastener nut to specification. TORQUE Brake Lever Pivot Fastener: 52 in-lbs (6 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual ©...
  • Page 552 BRAKES B B R R A A K K E E P P E E D D A A L L L L U U B B R R I I C C A A T T I I O O N N 2019–2020 NUMBER TORQUE (IF APPLICABLE)
  • Page 553 BRAKES Lubricate brake pedal at intervals listed on periodic 4. Remove the brake pedal pivot c-clip and flat maintenance table. See Maintenance Intervals page washer 2.4. 1. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 2.
  • Page 554 BRAKES 9. Install pushrod pivot pin. 10. Assemble foot peg support to frame. Torque mounting bolts to specification. See Foot Peg (Driver) Removal / Installation page 7.16. 11. Depress brake pedal to verify proper operation and pedal feel. Bleed brakes if necessary. See “Brake System Bleeding”...
  • Page 555 BRAKES 2022+ NUMBER TORQUE (IF APPLICABLE) DESCRIPTION – Brake Pedal Brake Pedal Pivot Bearing – Footpeg Mount – Footpeg – Spring – Brake Return Spring – Spacer Bolt – – Brake Pedal Pivot Outer Fastener Adjuster Nut 54 in-lbs (6 N·m) –...
  • Page 556 BRAKES Lubricate brake pedal at intervals listed on periodic 4. Remove the Brake Pedal Pivot Inner Fastener maintenance table. See Maintenance Intervals page 2.4. 1. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 2.
  • Page 557 BRAKES 9. Install pushrod pivot pin. 10. Assemble foot peg support to frame. Torque mounting bolts to specification. See Foot Peg (Driver) Removal / Installation page 7.16. 11. Depress brake pedal to verify proper operation and pedal feel. Bleed brakes if necessary. See “Brake System Bleeding”...
  • Page 558 BRAKES R R E E A A R R B B R R A A K K E E P P E E D D A A L L A A D D J J U U S S T T M M E E N N T T 2.
  • Page 559 BRAKES 4. Remove the spring 8. Install the spring 5. Loosen the nut on the stop adjustment screw. 9. Install the master cylinder control assembly with mounting fasteners and footpeg mounting fasteners . Torque to specification. 6. Adjust stop screw until desired brake pedal position is achieved.
  • Page 560 BRAKES 10. Connect the master cylinder pin to the brake 13. Tighten nut on master cylinder pushrod. pedal. TORQUE Master Cylinder Pushrod Nut: 54 in-lbs (6 N·m) 11. Loosen adjuster nut on master cylinder pushrod. 12. Adjust pushrod length until the correct brake lever free travel is achieved.
  • Page 561 BRAKES 2 2 0 0 2 2 2 2 + + F F T T R R / / F F T T R R S S / / F F T T R R R R C C A A R R B B O O N N – – R R E E A A R R 3.
  • Page 562 BRAKES 7. Loosen adjuster nut on master cylinder pushrod. 8. Adjust pushrod length until the correct brake lever free travel is achieved. Free travel at brake lever peg: 3 - 7 mm 9. Tighten nut on master cylinder pushrod. TORQUE Master Cylinder Pushrod Nut: 54 in-lbs (6 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 563 BRAKES A A S S S S E E M M B B L L Y Y V V I I E E W W S S F F R R O O N N T T B B R R A A K K E E S S Y Y S S T T E E M M - - A A S S S S E E M M B B L L Y Y V V I I E E W W 2019–2020 FTR Models NUMBER DESCRIPTION...
  • Page 564 BRAKES NUMBER DESCRIPTION TORQUE (IF APPLICABLE) 52 in-lbs (6 N·m) Brake Lever Pivot Nut Banjo Bolt 18 ft-lbs (24 N·m) Master Cylinder Bleeder Screw (front) 10 ft-lbs (14 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 9.18 © Copyright Polaris Industries Inc.
  • Page 565 BRAKES 2022+ FTR Models NUMBER DESCRIPTION TORQUE (IF APPLICABLE) Brake Disc Fasteners (front) 22 ft-lbs (30 N·m) Front Wheel Speed Sensor Sensor Wire Retaining Fastener 84 in-lbs (9 N·m) Caliper Mounting Fasteners (front) 35 ft-lbs (48 N·m) Banjo Bolt (to caliper) 18 ft-lbs (24 N·m) Front Caliper Bleeder Screw (on banjo bolt) 80 in-lbs (9 N·m)
  • Page 566 BRAKES NUMBER DESCRIPTION TORQUE (IF APPLICABLE) 52 in-lbs (6 N·m) Brake Lever Pivot Nut Banjo Bolt 18 ft-lbs (24 N·m) Master Cylinder Bleeder Screw 10 ft-lbs (14 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 9.20 © Copyright Polaris Industries Inc.
  • Page 567 BRAKES R R E E A A R R B B R R A A K K E E S S Y Y S S T T E E M M - - A A S S S S E E M M B B L L Y Y V V I I E E W W 2019–2020 FTR Models NUMBER DESCRIPTION...
  • Page 568 BRAKES 2022+ FTR Models NUMBER DESCRIPTION TORQUE (IF APPLICABLE) Rear Caliper Bleeder Screw 10 ft-lbs (14 N·m) Caliper Mounting Fasteners (rear) 18 ft-lbs (24 N·m) Banjo Fastener 18 ft-lbs (24 N·m) Sealing Washer Banjo Switch Fastener 18 (24 N·m) Sealing Washers Master Cylinder Cover (rear) Rubber Diaphragm (under cover) Master Cylinder Mount Fasteners...
  • Page 569 BRAKES B B R R A A K K E E L L I I N N E E R R O O U U T T I I N N G G 2019, 2020 FTR / FTR S & 2022 FTR Rally NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 570 BRAKES 2022+ FTR / FTR S / FTR R Carbon NUMBER DESCRIPTION TORQUE (IF APPLICABLE) Brake Line (Rear Caliper to ABS Module) Brake Line (Rear Master Cylinder to ABS Module) Brake Line (Front Caliper to ABS Module) Brake Line (Handlebar to ABS Module) Brake Line Junction Fastener (front) 84 in-lbs (9 N·m) Holder, Front Brake Lines...
  • Page 571 BRAKES R R E E A A R R M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R - - A A S S S S E E M M B B L L Y Y V V I I E E W W 2019, 2020 FTR / FTR S TORQUE (IF APPLICABLE) NUMBER...
  • Page 572 BRAKES 2022+ FTR models TORQUE (IF APPLICABLE) NUMBER DESCRIPTION Brake Fluid Reservoir Hose Master Cylinder Body Dust Boot Clevis Master Cylinder Reservoir Mounting Fastener (rear) - 62 in-lbs (7 N·m) 2022+ Master Cylinder Mounting Fasteners 84 in-lbs (9 N·m) Banjo Switch Fastener 18 (24 N·m) Mounting Bracket 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual...
  • Page 573 BRAKES F F R R O O N N T T B B R R A A K K E E C C A A L L I I P P E E R R - - A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 574 BRAKES R R E E A A R R B B R R A A K K E E C C A A L L I I P P E E R R - - A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 575 • Always maintain the recommended tire pressure. • Indian Motorcycle DOT 4 Brake Fluid is recommended. Change brake fluid at least every 2 years. • The anti-lock brake system will not prevent wheel lock-up, loss of traction, or loss of control under all conditions.
  • Page 576 BRAKES A A B B S S G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N A A B B S S O O V V E E R R V V I I E E W W O O F F O O P P E E R R A A T T I I O O N N The Anti-Lock Brake System is a safety feature The ABS system is active and available when vehicle...
  • Page 577 BRAKES A A B B S S M M O O D D U U L L E E FUNCTION FUNCTION Ground for ECU Ground for Motor CAN High CAN Low Front Wheel Speed Sensor — Signal Front Wheel Speed Sensor — Voltage Ignition Rear Wheel Speed Sensor —...
  • Page 578 BRAKES A A B B S S S S Y Y S S T T E E M M S S E E R R V V I I C C E E W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R - - R R E E P P L L A A C C E E M M E E N N T T ( ( 2 2 0 0 1 1 9 9 - - 2 2 0 0 2 2 0 0 , , 2 2 0 0 2 2 3 3 M M O O D D E E L L S S ) ) R R E E M M O O V V A A L L —...
  • Page 579 BRAKES R R E E M M O O V V A A L L — — R R E E A A R R I I N N S S T T A A L L L L A A T T I I O O N N — — R R E E A A R R 1.
  • Page 580 BRAKES W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R - - R R E E P P L L A A C C E E M M E E N N T T ( ( 2 2 0 0 2 2 2 2 M M O O D D E E L L S S ) ) R R E E M M O O V V A A L L —...
  • Page 581 BRAKES R R E E M M O O V V A A L L — — R R E E A A R R I I N N S S T T A A L L L L A A T T I I O O N N — — R R E E A A R R 1.
  • Page 582 BRAKES W W H H E E E E L L S S P P E E E E D D S S E E N N S S O O R R - - A A I I R R G G A A P P A A D D J J U U S S T T M M E E N N T T 6.
  • Page 583 BRAKES A A B B S S M M O O D D U U L L E E R R E E P P L L A A C C E E M M E E N N T T 7.
  • Page 584 • Always torque banjo bolts and other brake system fluid such as silicone-based or petroleum-based. fasteners and components to specified torque. • Always install NEW genuine Indian Motorcycle replacement parts and rubber parts upon assembly. WARNING Apply special lubricant where indicated (included in service kits).
  • Page 585 BRAKES A A B B S S B B R R A A K K E E V V A A C C U U U U M M B B L L E E E E D D E E R R A vacuum bleeder is recommended for ABS system bleeding and can also be used to bleed conventional (non-ABS) brake systems.
  • Page 586 BRAKES R R E E A A R R B B R R A A K K E E B B L L E E E E D D I I N N G G 11. If pedal is not firm, repeat bleeding procedure and insect brake system.
  • Page 587 BRAKES F F R R O O N N T T B B R R A A K K E E B B L L E E E E D D I I N N G G 7. With vacuum bleeder still attached to the bleeder screw and the bleeder screw closed, pump the 1.
  • Page 588 BRAKES 13. Fill fluid reservoir and install diaphragm and cover. 4. Connect a scale (commercially available) with a Torque cover screws to specification. minimum of 25 kg / 50 lb capacity to end of tool. 5. Keep tool centered so it does not touch hand grip. TORQUE Pull on scale to specified force.
  • Page 589 BRAKES B B R R A A K K E E S S Y Y S S T T E E M M S S E E R R V V I I C C E E F F R R O O N N T T B B R R A A K K E E P P A A D D I I N N S S P P E E C C T T I I O O N N F F R R O O N N T T B B R R A A K K E E P P A A D D R R E E P P L L A A C C E E M M E E N N T T NOTICE IMPORTANT...
  • Page 590 BRAKES 5. Install shims onto brake pads as shown. 10. Inspect brake fluid in reservoir and set to proper level. NOTICE 11. Slowly pump lever to set brake pads against disc. 2019 did not have shims Lever should be firm, not spongy. If lever is spongy, inspect pad installation, bleed brake lines and inspect brake disc.
  • Page 591 BRAKES R R E E A A R R B B R R A A K K E E P P A A D D I I N N S S P P E E C C T T I I O O N N NOTICE Inspect pads by viewing from the rear of the motorcycle, directly behind the muffler.
  • Page 592 BRAKES R R E E A A R R B B R R A A K K E E P P A A D D R R E E P P L L A A C C E E M M E E N N T T 4.
  • Page 593 BRAKES B B R R A A K K E E D D I I S S C C I I N N S S P P E E C C T T I I O O N N 12. Bleed brake system if necessary. 1.
  • Page 594 BRAKES B B R R A A K K E E D D I I S S C C R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 5.
  • Page 595 BRAKES F F R R O O N N T T M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R R R E E P P L L A A C C E E M M E E N N T T INSTALLATION 1.
  • Page 596 BRAKES 2. Install two NEW sealing washers, brake line and 5. Install reservoir cover and torque to specification. Banjo Bolt to the master cylinder. TORQUE Master Cylinder Cap Screws (front): 10 in-lbs (1 N·m) 6. Operate brake lever several times until lever is firm and pressure can be felt.
  • Page 597 BRAKES F F R R O O N N T T M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R R R E E S S E E R R V V O O I I R R R R E E P P L L A A C C E E M M E E N N T T CAUTION Brake fluid and brake cleaners could damage paint,...
  • Page 598 BRAKES INSTALLATION 1. Install fastener and nut to secure master cylinder reservoir on handlebar. Torque nut to specification. TORQUE Brake Fluid Reservoir Mounting Nut (front): 44 in-lbs (5 N·m) 2. Install the lower end of the hose onto barb fitting and slide clamp into place.
  • Page 599 BRAKES F F R R O O N N T T B B R R A A K K E E L L E E V V E E R R R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 600 BRAKES F F R R O O N N T T C C A A L L I I P P E E R R R R E E M M O O V V A A L L 4. Remove brake pads. See Front Brake Pad Replacement page 9.43 CAUTION IMPORTANT...
  • Page 601 BRAKES F F R R O O N N T T C C A A L L I I P P E E R R I I N N S S T T A A L L L L A A T T I I O O N N 1.
  • Page 602 BRAKES R R E E A A R R M M A A S S T T E E R R C C Y Y L L I I N N D D E E R R S S E E R R V V I I C C E E 2.
  • Page 603 BRAKES R R E E A A R R C C A A L L I I P P E E R R R R E E M M O O V V A A L L 7. Install the master cylinder and torque reservoir fastener, mounting fasteners, and brake line banjo 1.
  • Page 604 BRAKES R R E E A A R R C C A A L L I I P P E E R R I I N N S S T T A A L L L L A A T T I I O O N N 3.
  • Page 605 BRAKES T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component Erratic Braking...
  • Page 606 / dirt on pads and / brake disc. or brake disc. Repair as Necessary. Inspect Pad Pad Not Secure in Caliper Installation Aftermarket (not genuine Indian Motorcycle) Install Genuine Indian Motorcycle Parts Parts Replace Worn or Damaged Wheel Bearing(s) Replace...

  • Page 607: Chapter 10 Electrical

    ELECTRICAL CHAPTER 10 ELECTRICAL STARTING / CHARGING................10.4 .
  • Page 608 ELECTRICAL ........... . 10.35 STATOR WINDINGS TO GROUND INSPECTION .
  • Page 609 ELECTRICAL ..........10.75 AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT .
  • Page 610 ELECTRICAL S S T T A A R R T T I I N N G G / / C C H H A A R R G G I I N N G G Battery Label G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S All electrical system and component service can be performed with the engine in the frame.

  • Page 611: Wire Routing

    ELECTRICAL WARNING CAUTION Battery electrolyte is poisonous. It contains sulfuric WIRE ROUTING acid. Serious burns can result from contact with skin, Make sure that all wires are routed correctly away eyes or clothing. Antidote: from moving parts, hot exhaust, or sharp edges. •...
  • Page 612 ELECTRICAL S S P P E E C C I I A A L L T T O O O O L L S S - - E E L L E E C C T T R R I I C C A A L L ( ( S S T T A A R R T T I I N N G G / / C C H H A A R R G G I I N N G G ) ) PART NUMBER TOOL DESCRIPTION Battery Tester...
  • Page 613 ELECTRICAL S S E E R R V V I I C C E E S S P P E E C C I I F F I I C C A A T T I I O O N N S S - - E E L L E E C C T T R R I I C C A A L L ( ( S S T T A A R R T T I I N N G G / / C C H H A A R R G G I I N N G G ) ) ELECTRICAL SPECIFICATIONS STARTING SYSTEM SPECIFICATIONS ITEM...
  • Page 614 ELECTRICAL A A S S S S E E M M B B L L Y Y V V I I E E W W S S S S T T A A R R T T E E R R M M O O T T O O R R / / S S O O L L E E N N O O I I D D - - A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 615 ELECTRICAL 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 NUMBER DESCRIPTION TORQUE (IF APPLICABLE) —...
  • Page 616 ELECTRICAL R R E E G G U U L L A A T T O O R R / / R R E E C C T T I I F F I I E E R R - - A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 617 ELECTRICAL B B A A T T T T E E R R Y Y T T R R A A Y Y - - A A S S S S E E M M B B L L Y Y V V I I E E W W NUMBER DESCRIPTION TORQUE (IF APPLICABLE)
  • Page 618 ELECTRICAL B B A A T T T T E E R R Y Y S S E E R R V V I I C C E E B B A A T T T T E E R R Y Y D D I I S S C C O O N N N N E E C C T T B B A A T T T T E E R R Y Y CAUTION This motorcycle is equipped with a maintenance free...
  • Page 619 ELECTRICAL B B A A T T T T E E R R Y Y R R E E M M O O V V A A L L 3. Remove battery from battery tray. CAUTION Do not allow battery cables to touch opposing terminals.
  • Page 620 ELECTRICAL B B A A T T T T E E R R Y Y I I N N S S T T A A L L L L A A T T I I O O N N B B A A T T T T E E R R Y Y T T R R A A Y Y R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N CAUTION CAUTION Do not allow battery cables to touch opposing...
  • Page 621 ELECTRICAL 6. Remove the two nuts securing the stater 11. Installation is performed by reversing the solenoid from the battery tray. removal procedure. TORQUE Battery Tray Through Bolt: 96 in-lbs (11 N·m) TORQUE Battery Tray Base Fasteners: 96 in-lbs (11 N·m) TORQUE Starter Solenoid Bracket Nuts: 12 in-lbs (1 N·m)
  • Page 622 B B A A T T T T E E R R Y Y C C H H A A R R G G I I N N G G A A N N D D M M A A I I N N T T E E N N A A N N C C E E INDIAN MOTORCYCLE RECOMMENDED AGM BATTERY...
  • Page 623 AGM BATTERY CHARGING RECOMMENDATIONS – CHARGE DEEPLY DISCHARGED (BELOW 3 VOLTS) The nominal voltage for an Indian Motorcycle battery AGM batteries discharged to a voltage of 3 volts or is 12.8 Volts when fully charged. The battery will self- less may not be recognized by the recommended discharge when disconnected from a vehicle, and will automatic battery charger.
  • Page 624 ELECTRICAL AGM BATTERY MAINTENANCE TIPS 5. FTR motorcycles equipped with a SAE bullet style connector for quick access to charging the battery. 1. If the motorcycle will not be driven for more than 2 The recommended BatteryMINDer® 2012 charger weeks, maintaining the battery with the comes with the mating connector for easy plug and BatteryMINDer®...
  • Page 625 ELECTRICAL B B A A T T T T E E R R Y Y I I N N S S P P E E C C T T I I O O N N 1. Remove battery. See Battery Removal page 10.13.
  • Page 626 ELECTRICAL S S T T A A R R T T I I N N G G S S Y Y S S T T E E M M T T E E S S T T S S B B A A T T T T E E R R Y Y L L O O A A D D T T E E S S T T 1.
  • Page 627 ELECTRICAL 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 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.21 ©...
  • Page 628 ELECTRICAL S S T T A A R R T T I I N N G G S S Y Y S S T T E E M M D D I I A A G G N N O O S S T T I I C C T T A A B B L L E E SYMPTOM POSSIBLE CAUSE RECOMMENDATION...
  • Page 629 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T 1 1 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.23 ©...
  • Page 630 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T 2 2 NOTE These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive ammeter clamp and a DMM.
  • Page 631 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T 3 3 SYMPTOM POSSIBLE CAUSE Starter clutch malfunction.
  • Page 632 ELECTRICAL G G E E A A R R P P O O S S I I T T I I O O N N S S W W I I T T C C H H N N E E U U T T R R A A L L I I N N D D I I C C A A T T O O R R •...
  • Page 633 ELECTRICAL C C L L U U T T C C H H S S W W I I T T C C H H C C I I R R C C U U I I T T T T E E S S T T S S T T A A R R T T E E R R S S O O L L E E N N O O I I D D P P O O S S I I T T I I V V E E C C I I R R C C U U I I T T T T E E S S T T IMPORTANT WARNING...
  • Page 634 ELECTRICAL S S T T A A R R T T E E R R C C U U R R R R E E N N T T D D R R A A W W T T E E S S T T 9.
  • Page 635 ELECTRICAL S S T T A A R R T T E E R R M M O O T T O O R R S S E E R R V V I I C C E E 3. Disconnect the electrical connectors at the switch cube.
  • Page 636 ELECTRICAL S S T T A A R R T T E E R R M M O O T T O O R R , , R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N S S T T A A R R T T E E R R C C L L U U T T C C H H R R E E M M O O V V A A L L •...
  • Page 637 ELECTRICAL C C H H A A R R G G I I N N G G S S Y Y S S T T E E M M S S E E R R V V I I C C E E T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G , , C C H H A A R R G G I I N N G G S S Y Y S S T T E E M M NOTE The battery must be fully charged and in good condition to obtain accurate readings.
  • Page 638 ELECTRICAL C C U U R R R R E E N N T T D D R R A A I I N N I I N N S S P P E E C C T T I I O O N N R R E E G G U U L L A A T T E E D D V V O O L L T T A A G G E E / / A A M M P P E E R R A A G G E E O O U U T T P P U U T T I I N N S S P P E E C C T T I I O O N N IMPORTANT...
  • Page 639 ELECTRICAL S S T T A A T T O O R R A A C C V V O O L L T T A A G G E E O O U U T T P P U U T T T T E E S S T T 8.
  • Page 640 ELECTRICAL 4. Connect one lead of the multi meter to pin A one lead to pin B on the 3-pin stator connector. CAUTION VOLTAGE / ARCING Use caution not to touch any of the connections or allow the exposed terminals to come close to any other part of the vehicle or other objects, as an arc may occur.
  • Page 641 ELECTRICAL S S T T A A T T O O R R R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S T T A A T T O O R R W W I I N N D D I I N N G G S S T T O O G G R R O O U U N N D D I I N N S S P P E E C C T T I I O O N N CAUTION CAUTION...
  • Page 642 ELECTRICAL 4. There should be no connection from stator 5. Remove fasteners from stator wire guide windings to ground. S S T T A A T T O O R R R R E E M M O O V V A A L L 1.
  • Page 643 ELECTRICAL S S T T A A T T O O R R I I N N S S T T A A L L L L A A T T I I O O N N 5. Insert wire terminals into stator connector housing. The electrical connector must be removed from the IMPORTANT stator assembly before it can be installed in the...
  • Page 644 ELECTRICAL F F L L Y Y W W H H E E E E L L R R E E M M O O V V A A L L 4. Install flywheel remove tool PA-49316-A on the flywheel and tighten puller to remove flywheel WARNING assembly.
  • Page 645 ELECTRICAL R R E E C C T T I I F F I I E E R R / / R R E E G G U U L L A A T T O O R R C C O O N N N N E E C C T T O O R R D D I I O O D D E E L L E E A A K K A A G G E E T T E E S S T T I I N N S S P P E E C C T T I I O O N N IMPORTANT...
  • Page 646 ELECTRICAL R R E E G G U U L L A A T T O O R R / / R R E E C C T T I I F F I I E E R R R R E E P P L L A A C C E E M M E E N N T T 1.

  • Page 647: General Precautions

    ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M GENERAL PRECAUTIONS G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N •...
  • Page 648 ELECTRICAL I I G G N N I I T T I I O O N N R R E E P P L L A A C C E E M M E E N N T T I I G G N N I I T T I I O O N N C C O O I I L L R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 649 ELECTRICAL T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G B B A A S S I I C C S S T T E E S S T T L L E E A A D D A A D D A A P P T T E E R R K K I I T T Before troubleshooting the ignition system, ensure that the engine STOP/RUN switch is in the RUN position,...
  • Page 650 ELECTRICAL E E C C M M C C O O N N N N E E C C T T O O R R M M A A P P NOTICE Unused pins are not included in the list below IMPORTANT Last 2 digits of 100 series number correspond to connector cavity number.
  • Page 651 ELECTRICAL CRANKSHAFT POSITION ECM SWITCHED POWER SENSOR POSITIVE SIGNAL ENGINE COOLANT WH/GN PEDAL POSITION SENSOR 1 SIGNAL OG/DB TEMPERATURE SENSOR SIGNAL AMBIENT AIR TEMP SENSOR OG/BD SIGNAL RUN/STOP SWITCH OUTPUT REAR BRAKE PRESSURE RD/BK BK/YE GROUND SWITCH OUTPUT GROUND PEDAL POSITION SENSOR 2 +5V TIP-OVER SENSOR (TOS) YE/RD OG/WH...
  • Page 652 ELECTRICAL I I G G N N I I T T I I O O N N S S Y Y S S T T E E M M T T E E S S T T F F L L O O W W C C H H A A R R T T 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.46 ©...
  • Page 653 ELECTRICAL B B A A T T T T E E R R Y Y I I N N S S P P E E C C T T I I O O N N ( ( T T E E S S T T 1 1 ) ) S S P P A A R R K K I I N N S S P P E E C C T T I I O O N N ( ( T T E E S S T T 2 2 ) ) Battery terminals and connections should be kept free 1.
  • Page 654 ELECTRICAL I I G G N N I I T T I I O O N N C C O O I I L L P P O O W W E E R R / / G G R R O O U U N N D D S S I I G G N N A A L L ( ( T T E E S S T T •...
  • Page 655 ELECTRICAL I I G G N N I I T T I I O O N N C C O O I I L L R R E E S S I I S S T T A A N N C C E E ( ( T T E E S S T T 4 4 ) ) Ignition Coil Primary Winding 1.
  • Page 656 ELECTRICAL C C R R A A N N K K S S H H A A F F T T P P O O S S I I T T I I O O N N S S E E N N S S O O R R , , T T E E S S T T / / Crankshaft Position Sensor (CPS) Replacement R R E E P P L L A A C C E E 1.
  • Page 657 ELECTRICAL N N O O C C R R A A N N K K S S I I T T U U A A T T I I O O N N Check that the side-stand is up, the unit must be in neutral OR have the clutch lever pulled in.
  • Page 658 ELECTRICAL N N O O S S T T A A R R T T S S I I T T U U A A T T I I O O N N Check that the battery voltage is 12.8 or greater, charge or replace battery if necessary ↓...
  • Page 659 ELECTRICAL C C H H A A S S S S I I S S E E L L E E C C T T R R I I C C A A L L G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N S S E E R R V V I I C C E E N N O O T T E E S S Keep the following notes in mind when diagnosing an electrical problem:...

  • Page 660: Input Signals

    ELECTRICAL C C O O N N T T R R O O L L L L E E R R O O V V E E R R V V I I E E W W O O V V E E R R V V I I E E W W Listed below are all the electronic controllers found on the FTR 1200 chassis.

  • Page 661: Replaceable Components

    ELECTRICAL REPLACEABLE COMPONENTS • Ambient Air Temp. Sensor • Crankshaft Position Sensor • Rear Coil • Knock Sensor • Front Coil • Throttle Body • Throttle Body – Throttle Position Sensor – ETC (Electronic Throttle Control) Motor • Gear Selector Switch •...
  • Page 662 ELECTRICAL RIGHT-HAND CONTROL Must replace as an assembly INPUT SIGNALS OUTPUT SIGNALS • Run/Stop Switch Signal • CANbus • CANbus – Start Switch Signal – Digital and Analog Display Toggle Switch Command ABS Module (Antilock Brake System) INPUT SIGNALS OUTPUT SIGNALS •...
  • Page 663 ELECTRICAL IMU (Inertia Measurement Unit INPUT SIGNALS OUTPUT SIGNALS • CANbus • CANbus • Accelerometer Data • Mode Control 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.57 © Copyright Polaris Industries Inc.
  • Page 664 ELECTRICAL A A S S S S E E M M B B L L Y Y V V I I E E W W S S H H E E A A D D L L I I G G H H T T - - A A S S S S E E M M B B L L Y Y V V I I E E W W 2019–2020 NUMBER DESCRIPTION...
  • Page 665 ELECTRICAL 2019–2020 HEAD LIGHT TORQUE SEQUENCE 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.59 © Copyright Polaris Industries Inc.
  • Page 666 ELECTRICAL 2022+ NUMBER DESCRIPTION TORQUE (IF APPLICABLE) Headlight Carrier Bolts 84 in-lbs (9 N·m) Headlight Mount Bracket — Headlight Adjustment Fasteners 25 ft-lbs (34 N·m) Headlight Mount Nuts 84 in-lbs (9 N·m) Headlight Carrier — Headlight Mount Fasteners (Upper) 84 in-lbs (9 N·m) Headlight —...
  • Page 667 ELECTRICAL 2022+ HEAD LIGHT TORQUE SEQUENCE 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.61 © Copyright Polaris Industries Inc.
  • Page 668 ELECTRICAL T T A A I I L L 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 TORQUE (IF APPLICABLE) NUMBER DESCRIPTION...
  • Page 669 ELECTRICAL F F U U S S E E B B O O X X - - A A S S S S E E M M B B L L Y Y V V I I E E W W MAIN FUSE BOX TORQUE (IF APPLICABLE) NUMBER...
  • Page 670 ELECTRICAL ADDITIONAL FUSES NUMBER DESCRIPTION Main Fuse ABS Pump Fuse ABS Valve Fuse 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.64 © Copyright Polaris Industries Inc.
  • Page 671 ELECTRICAL H H A A R R N N E E S S S S R R O O U U T T I I N N G G NOTICE If replacing the harness, noting routing during removal will aid in proper installation. NUMBER DESCRIPTION Routing Clip...
  • Page 672 ELECTRICAL 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.66 © Copyright Polaris Industries Inc.
  • Page 673 ELECTRICAL W W I I R R I I N N G G H H A A R R N N E E S S S S R R E E P P L L A A C C E E M M E E N N T T F F U U S S E E B B O O X X E E L L E E C C T T R R I I C C A A L L H H A A R R N N E E S S S S R R E E P P L L A A C C E E M M E E N N T T 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...
  • Page 674 ELECTRICAL F F U U S S E E A A P P P P L L I I C C A A T T I I O O N N C C H H A A R R T T RELAY HORN WIRE FROM...
  • Page 675 ELECTRICAL RELAY COOLING FAN WIRE FROM FUNCTION COLOR Cooling Fan Circuit Breaker Splice MFUSE Fuse Box Port: 1 Power Feed Splice ENGPWR Fan Relay Coil Power VT/PK Fuse Box Port: 2 Cooling Fan Relay Control BK/OG Fuse Box Port: 7 ECM 1 Port: 131 Ground Cooling Fan Relay Power...
  • Page 676 ELECTRICAL RELAY ENGINE WIRE FROM FUNCTION COLOR Splice MFUSE Engine Relay Power Feed Fuse Box Port: 29 Splice IGNBRK Engine Relay Coil Power Fuse Box Port: 30 Engine Relay Control Ground GY/BK Fuse Box Port: 35 ECM 1 Port: 115 Splice ENGR Engine Relay Output RD/BK...
  • Page 677 ELECTRICAL RELAY LOW BEAM WIRE FROM FUNCTION COLOR Splice IGNSW Low Beam Relay Power Feed Fuse Box Port: 39 Splice IGNSW Low Beam Relay Coil Power Fuse Box Port: 40 Low Beam Relay Control DG/BK Fuse Box Port: 45 ECM 1 Port: 140 Ground Headlight Headlight Low Beam Power...
  • Page 678 ELECTRICAL L L E E A A N N A A N N G G L L E E S S E E N N S S O O R R S S E E R R V V I I C C E E INSTALLATION L L E E A A N N A A N N G G L L E E S S E E N N S S O O R R R R E E P P L L A A C C E E M M E E N N T T 1.
  • Page 679 ELECTRICAL H H E E A A D D L L I I G G H H T T S S E E R R V V I I C C E E H H E E A A D D L L I I G G H H T T B B U U L L B B R R E E P P L L A A C C E E M M E E N N T T The headlight is comprised of LED lights that cannot be replaced individually.
  • Page 680 ELECTRICAL H H E E A A D D L L I I G G H H T T R R E E P P L L A A C C E E M M E E N N T T 6.
  • Page 681 ELECTRICAL A A M M B B I I E E N N T T A A I I R R T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R H H O O R R N N S S E E R R V V I I C C E E A A M M B B I I E E N N T T A A I I R R T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R H H O O R R N N R R E E P P L L A A C C E E M M E E N N T T...
  • Page 682 ELECTRICAL T T A A I I L L L L A A M M P P S S E E R R V V I I C C E E L L I I C C E E N N S S E E P P L L A A T T E E L L I I G G H H T T R R E E P P L L A A C C E E M M E E N N T T L L E E D D T T A A I I L L L L I I G G H H T T O O P P E E R R A A T T I I O O N N IMPORTANT The tail and brake lights are LEDs and cannot be...
  • Page 683 ELECTRICAL T T A A I I L L L L I I G G H H T T R R E E M M O O V V A A L L / / I I N N S S T T A A L L L L A A T T I I O O N N 4.
  • Page 684 ELECTRICAL T T U U R R N N S S I I G G N N A A L L / / H H A A Z Z A A R R D D S S Y Y S S T T E E M M S S E E R R V V I I C C E E T T U U R R N N S S I I G G N N A A L L R R E E P P L L A A C C E E M M E E N N T T ( ( F F R R O O N N T T ) ) T T U U R R N N S S I I G G N N A A L L O O P P E E R R A A T T I I O O N N 1.
  • Page 685 ELECTRICAL T T U U R R N N S S I I G G N N A A L L R R E E P P L L A A C C E E M M E E N N T T ( ( R R E E A A R R ) ) 1.
  • Page 686 ELECTRICAL I I N N S S T T R R U U M M E E N N T T A A T T I I O O N N I I N N 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 The instrument cluster includes the speedometer, indicator lamps and Multi-Function Display (MFD).
  • Page 687 ELECTRICAL 2022 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.81 © Copyright Polaris Industries Inc.
  • Page 688 ELECTRICAL 2023 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.82 © Copyright Polaris Industries Inc.
  • Page 689 ELECTRICAL DESCRIPTION Speedometer Indicator Lamps Multi-Function Display (MFD) The speedometer displays forward vehicle speed in either miles per hour or kilometers per hour. NOTICE For detailed information regarding MODE selection and Multi-Function Display operation refer to the Owner’s Manual. 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.83 ©...
  • Page 690 ELECTRICAL INDICATOR LIGHTS LAMP INDICATES CONDITION Chassis Fault The alert symbol illuminates if a chassis fault occurs. Low Fuel This lamp illuminates when 2.0 Liters (0.53 US gallons) of fuel remains in the tank. Neutral This lamp illuminates when the transmission is in neutral. High Beam The lamp illuminates when the headlight switch is set to high beam.
  • Page 691 ELECTRICAL Multi-Function Display (MFD) The power switch must be ON to access the MFD. Use the mode switches to toggle through the modes of the MFD and to change settings in the display. The Right-Hand mode switch located on the backside of the Right-Hand switch cube. MFD INDICATORS LAMP INDICATES...

  • Page 692: Modes Available

    ELECTRICAL MODES AVAILABLE Odometer Engine Speed Trip Odometer 1 Clock Battery Voltage Trip Odometer 2 Gear Indicator Average Fuel Economy Engine Coolant Temperature Instantaneous Fuel Economy (2019–2020) Cylinder Deactivation Diagnostic Functionality (2022+) Ambient Temperature Engine Error Codes (2022+) Misfire Detection Display Units (Standard / Metric) Over Temperature Display and Warning Indicator Odometer...
  • Page 693 ELECTRICAL Battery voltage displays real-time, regulated charge voltage supplied to the battery. The voltage level may fluctuate depending on electrical load and engine RPM. 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.87 © Copyright Polaris Industries Inc.

  • Page 694: Action Required

    After the 3 misfire, P0314 misfire fault is determined & set, the check engine light will remain on and fuel will be cut to the affected cylinder(s). If this occurs, your authorized Indian Motorcycle dealer can assist. 2022 models will have the engine shut down after 5 minutes of run time or 5 minutes of no user input after misfire detection.
  • Page 695 ELECTRICAL I I N N S S T T R R U U M M E E N N T T C C L L U U S S T T E E R R R R E E M M O O V V A A L L / / 5.
  • Page 696 ELECTRICAL 2023 FTR Sport 5. Lift the cluster assembly upward and disconnect cell USB connector. 1. Disconnect battery. See Battery Disconnect page 10.12 2. Remove fasteners and number plate. 6. Remove Antenna GPS , and chassis harness connectors. 3. Remove rear display fasteners 7.
  • Page 697 ELECTRICAL 9. Installation is performed by reversing the removal procedure. TORQUE Instrument Cluster Fasteners (2023): 9 in-lbs (1 N·m) TORQUE Center Cluster Fastener: 53 in-lbs (6 N·m) TORQUE Cluster Mount Fasteners: 53 in-lbs (6 N·m) TORQUE Number Plate Fasteners: 80 in-lbs (9 N·m) 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.91 ©...
  • Page 698 ELECTRICAL 2019–22 6. Installation is performed by reversing the removal procedure. 1. Disconnect battery. See Battery Disconnect page TORQUE 10.12 Instrument Cluster Housing Fastener: 2. Remove two instrument cluster housing fasteners 84 in-lbs (9 N·m) and washers. TORQUE Speedometer (touch screen) Fastener: 54 in-lbs (6 N·m) U U S S B B C C H H A A R R G G E E P P O O R R T T R R E E P P L L A A C C E E M M E E N N T T If equipped, the USB charge port is located on the...
  • Page 699 ELECTRICAL G G P P S S P P U U C C K K S S E E R R V V I I C C E E d. Remove fastener securing the air box cover REMOVAL 1. Remove air box bezel: a.
  • Page 700 ELECTRICAL 4. Remove rear center display fastener. 8. If GPS and or cell data is still not present, replace GPS / Cell antenna with new unit. 5. Disconnect cell USB connector. 6. Unplug the GSP puck from the display. 7. Plug the GPS / Cell Antenna back into the cell modem and display, making sure connectors are securely seated, and check fro functionality.
  • Page 701 ELECTRICAL INSTALLATION 4. Install cluster mount fasteners . Torque fasteners to specification. 1. Plug the GSP puck into the display. TORQUE 2. Connect cell USB connector. Cluster Mount Fasteners: 53 in-lbs (6 N·m) 5. Install number plate and secure with fasteners. Torque fasteners to specification.
  • Page 702 ELECTRICAL 6. Install air box bezel: c. Install four fasteners securing air box bezel. a. Lubricate air box cover grommets. Install air box cover and secure with fastener TORQUE Air Box Bezel Fastener: NOTICE 36 in-lbs (4 N·m) Use Soapy Water to help with installation. DO NOT USE BRAKE CLEANER OR OIL BASED LUBRICANTS TORQUE...
  • Page 703 ELECTRICAL R R I I D D E E C C O O M M M M A A N N D D S S Y Y S S T T E E M M B B L L U U E E T T O O O O T T H H P P A A I I R R I I N N G G The Ride Command touchscreen display can be connected to a smart-phone and a headset simultaneously.
  • Page 704 LCD display to your Bluetooth® headset. On models equipped with a INDIAN MOTORCYCLE Ride Command display, the USB port is also used to update the display software. For the latest software, go to https://ridecommand.
  • Page 705 ELECTRICAL STEP ACTION Update display with newest software available. Confirm display Refer to Update Software page 10.97 for instructions on how to Go to Step 6 operation update/reflash software. and continue Is display working properly? use. 1. Test circuit for continuity and/or shorts in wiring. 2.
  • Page 706 ELECTRICAL S S W W I I T T C C H H T T E E S S T T I I N N G G C C L L U U T T C C H H S S W W I I T T C C H H T T E E S S T T 1.
  • Page 707 ELECTRICAL S S I I D D E E - - S S T T A A N N D D S S W W I I T T C C H H T T E E S S T T The side-stand switch is located on the left side of the unit.
  • Page 708 ELECTRICAL G G E E A A R R P P O O S S I I T T I I O O N N S S E E N N S S O O R R T T E E S S T T •...
  • Page 709 ELECTRICAL A A M M B B I I E E N N T T A A I I R R T T E E M M P P E E R R A A T T U U R R E E S S E E N N S S O O R R T T E E S S T T Test the resistance of two pins and compare with the table.
  • Page 710 ELECTRICAL B B R R E E A A K K O O U U T T W W I I R R I I N N G G D D I I A A G G R R A A M M S S 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 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.104...
  • Page 711 ELECTRICAL T T H H R R O O T T T T L L E E C C O O N N T T R R O O L L 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 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.105 ©...
  • Page 712 ELECTRICAL E E L L E E C C T T R R I I C C A A L L D D I I A A G G N N O O S S T T I I C C S S E E L L E E C C T T R R I I C C A A L L S S E E R R V V I I C C E E N N O O T T E E S S S S T T A A T T I I C C A A N N D D D D Y Y N N A A M M I I C C T T E E S S T T I I N N G G Keep the following notes in mind when diagnosing an...
  • Page 713 ELECTRICAL C C O O N N N N E E C C T T O O R R P P R R O O B B I I N N G G G G U U I I D D E E L L I I N N E E S S For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.
  • Page 714 ELECTRICAL C C U U R R R R E E N N T T D D R R A A W W - - K K E E Y Y O O F F F F 6. Momentarily key the ignition switch on, then off. Parasitic draw is when there is excessive current flow IMPORTANT with the key off.
  • Page 715 ELECTRICAL T T E E S S T T I I N N G G C C O O N N T T I I N N U U I I T T Y Y / / R R E E S S I I S S T T A A N N C C E E T T E E S S T T I I N N G G F F O O R R A A S S H H O O R R T T T T O O G G R R O O U U N N D D Testing using the Ohmmeter function of your DMM is Shorts to ground happen when the current flowing in a...
  • Page 716 ELECTRICAL 9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 10.111 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.
  • Page 717 ELECTRICAL T T E E S S T T I I N N G G F F O O R R A A S S H H O O R R T T T T O O V V O O L L T T A A G G E E T T E E S S T T I I N N G G F F O O R R I I N N T T E E R R M M I I T T T T E E N N T T C C O O N N D D I I T T I I O O N N S S There are three possible short to voltage causes: Intermittent conditions are very difficult to diagnose,...
  • Page 718 ELECTRICAL T T E E S S T T I I N N G G P P A A R R A A S S I I T T I I C C D D R R A A W W T T E E S S T T I I N N G G C C U U R R R R E E N N T T F F L L O O W W ( ( A A M M P P E E R R A A G G E E ) ) Parasitic draw is when there is excessive current flow Performing a current flow test requires the meter leads...
  • Page 719 ELECTRICAL T T E E S S T T I I N N G G V V O O L L T T A A G G E E D D R R O O P P NOTICE If you disconnect the connector at the load, and measure voltage with one lead on the power supply wire, and one to ground, you will be measuring available voltage.
  • Page 720 ELECTRICAL NOTES 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual 10.114 © Copyright Polaris Industries Inc.

  • Page 721: Appendix A Wiring Diagram

    WIRING DIAGRAM APPENDIX A WIRING DIAGRAM Main wiring diagrams can be found tucked into the back of the printed manual. 2019, 2020 Chassis Harness: HERE 2022, 2023 Chassis Harness: HERE 2019, 2020, 2022, 2023 Rear Harness: HERE 2019, 2020, 2022, 2023 Engine Harness: HERE 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual ©...
  • Page 722 ELECTRICAL NOTES 9941004 R01 - 2019-2020, 2022-2023 FTR Service Manual © Copyright Polaris Industries Inc.
  • Page 723 INDEX Tail Light............10.62 Transmission, ............6.12 ABS Module Triple Clamp ............8.15 Pinout..............9.31 Voltage Regulator..........10.10 ABS Module, Replacement .........9.37 Water Pump............3.32 ABS System Wheel, Front..........8.21-8.22 Special Tools ............9.4 Windscreen............7.14 Adjustment Windshield Mount ..........7.11 Rear Brake Pedal ...........9.12 Axle Inspection Air Box Rear ..............8.89 Assembly View .............3.11...
  • Page 724 INDEX Brake Pads, Rear Replacement ............9.46 Caliper, Front Brake Pedal Assembly View .............9.27 Inspection ............2.38 Installation ............9.55 Lubrication............9.6 Removal...............9.54 Brake System Caliper, Rear ABS General Information ........9.30 Assembly View .............9.28 ABS Module Replacement ........9.37 Installation ............9.58 ABS Module, Assembly View........9.31 Removal...............9.57 ABS System Safety Precautions ........9.29 Cam Chain...
  • Page 725 INDEX Troubleshooting..........10.31 Assembly View .............8.11 Checking Oil Level ...........2.21 Conversion Chart Clutch Metric ..............1.43 Assembly.............5.27 Conversion Charts............1.44 Assembly (2023) ...........5.33 Measurement............1.45 Assembly View .............5.12 SAE ..............1.43 Assembly View (2023)..........5.13 Temperature............1.45 Coolant Disassembly ............5.25 Disassembly (2023) ..........5.30 Drain ..............3.44 Inspection ............5.26 Fill ..............3.44 Temperature sensor replacement......3.65 Inspection (2023+) ..........5.31...
  • Page 726 INDEX Special Tools ............3.105 Removal / Installation..........8.80 Warpage Measurement ........3.111 Driven Sprocket Cylinder / Piston Inspection ............8.85 Troubleshooting..........3.117 Installation ............8.86 Cylinder Deactivation ..........4.55 Removal...............8.84 Cylinder Head Dynamic Testing ............10.106 Assembly.............3.98 Assembly View .............3.75 Disassembly ............3.93 Inspection ............3.94 Installation ............3.99 Removal...............3.92 Service Specifications ..........3.68...
  • Page 727 INDEX Removing Engine from Frame .........3.21 Assembly View .............9.17 Service Notes ............3.5 Front Fork Service Specifications ..........3.7 Adjustment Guide ..........8.6 Special Tools ............3.6 Inspection ............8.41 EVAP..............1.26 Front Head Pipe ..........3.128-3.129 EVAP system ............4.14 Front Number Plate EVAP System Removal...............7.41 Front Suspension...
  • Page 728 INDEX Removal / Installation........... 10.89 Instrument Panel Gear Position Sensor Removal / Installation..........7.26 Test..............10.102 Gear Position Switch Neutral Indicator Test........... 10.26 Gear Ratios .............. 6.4 GPS puck Lean Angle Sensor..........10.72 Service .............. 10.93 Installation ............10.72 Gross Vehicle Weight Rating (GVWR) ......1.23 Module ..............4.54 Guided Diagnostics ..........4.59 Operation ............4.54...
  • Page 729 INDEX Special Tools ............5.3 Troubleshooting............5.38 Noise Emission Control ..........1.25 Primary Drive Cover Number Plate Installation ............5.16 Assembly View .............7.13 Removal...............5.16 Priming the Fuel System ..........4.35 Publication Part Numbers ..........1.24 Purge Valve Ohm Test .............4.17 Oil Change Replacement ............4.17 Checking Oil Level ..........2.21 Oil Change Procedure..........2.22 Oil Cooler Inspection ............3.37...
  • Page 730 INDEX Adjustment............8.61 Ignition System ........... 10.41 Inspection ............8.59 Lubrication System ..........3.24 Rings Piston ..............3.106 End Gap Measurement......... 3.112 Primary Drive ............5.3 Installation ............3.114 Rear Suspension............8.59 Profile & Orientation ..........3.108 Rear Wheel ............8.59 Starting System .............10.7 Removal............. 3.111 Routing Shift Arm Electrical Harness ..........
  • Page 731 INDEX Locating...............1.27 Swingarm Removal ..........8.94 Maintenance............2.17 Suspension Adjustment Ordering Information..........1.28 Front Fork ............. 8.6 Piston ..............3.105 Rear Shock ............8.59 Primary Drive ............5.3 Suspension, Front Rear Wheel and Suspension ........8.58 Fork Assembly ............8.42 Starting System .............10.6 Fork Installation ............8.51 Fork Removal............8.33 Transmission ............
  • Page 732 INDEX Overview .............4.48 Inspection ............3.98 Replacement ............4.48 Valve Spring Tools, Special ............1.30 Free Length ............3.95 Torque Specifications Valve Stem Master ..............1.35 Inspection ............8.110 Trademark Information ..........2 Valve Stem, Metal Transmission Installation ............8.110 Gear Ratios ............6.4 Valve Timing ............3.85 Gear Train............6.20 Valve Train Special Tools ............3.68...

This manual is also suitable for:

Ftr 2020Ftr 2022Ftr 2023

Table of Contents

Save PDF