Page 1 P/N 98-173...
Page 2 Procedures for removal and installation, disassembly, motorcycles require regular maintenance in accordance cleaning and inspection of component parts and with the recommendations of Indian Motorcycle assembly are included when more extensive repairs or a Company. This manual describes all the necessary complete overhaul is required.
Page 3 GHS8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E...
Page 4 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E S45E8ÁH9Á6HGS8GSR FOREWORD ............i Organization and Content .
Page 5 S45E8ÁH9Á6HGS8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E STEERING COMPONENTS ......... . . 39 STEERING COMPONENT SERVICE .
Page 6 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E S45E8ÁH9Á6HGS8GSR Engine Guards ..........96 Saddlebags and Saddlebag Brackets .
Page 7 S45E8ÁH9Á6HGS8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Engine Installation ..........140 Installing Chassis Components and Engine Accessories .
Page 8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E S45E8ÁH9Á6HGS8GSR Starter Solenoid ..........233 Starter Relay .
Page 9 S45E8ÁH9Á6HGS8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E viii TOOLS AND EQUIPMENT ......... . . 288 SPECIAL TOOLS .
Page 10 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E @8G8Q4EÁ G9HQF4S HG 84STQ8RÁH ÁSA8Á ÁBG7B4GÁ6AB8 ÁUBGS4@8ÁFHSHQ6X6E8 The Indian Chief motorcycle is a classic design with its • Indian Chief (standard) heritage going back to the beginning of the twentieth • Indian Chief Deluxe century. Today, the motorcycle carries forth the tradition •...
Page 11 @8G8Q4EÁ G9HQF4S HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6€x€ypy…ÁfyiÁR„…pxÁ 7p„hƒt…t€y„ 6sf„„t„ Front suspension — The Chief Vintage is fitted with a conventional-style front suspension with hydraulic compression and rebound damping. Chief Vintage models are equipped with the Paioli front suspension components.
Page 12 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E @8G8Q4EÁ G9HQF4S HG The computerized system simplifies service, eliminating the need for timing adjustments. Timing is preset and electronically controlled. Emission controls — On California only models, an evaporative system is used. The system consists of an air valve at the inlet port on the back of the air cleaner housing, tank vapor valve, a carbon canister and interconnecting vent and purge lines.
Page 13 @8G8Q4EÁ G9HQF4S HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E FHSHQ6X6E8ÁB78GSB B64SBHG There are three significant identification numbers on the Within the first 11 positions, the number provides motorcycle. The numbers include the chassis Vehicle information such as vehicle type, make, model, model Identification Number (VIN) along with individual serial year, engine, etc.
Page 14 Note: A “note” (placed in italic type) indicates Note: Indian Motorcycle Corporation continuously information that may be important in understanding strives for improvements in product design, quality and the significance of a procedure or useful in performing performance.
Page 15 GHS8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E...
Page 16 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E F4 GS8G4G68 F4BGS8G4G68 Maintenance requirements for the Indian Chief Vintage specific mileage intervals. The three levels of service motorcycle include three levels of service performed at include the following: Primary Service — at 500 miles, 5,000 miles and every 10,000 miles thereafter Interval Service —...
Page 17 F4 GS8G4G68 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E QpypˆfwÁRpƒ‡thp 27. Replace the front fork oil (page 34). 28. Lubricate the steering head bearings and check the Perform the following 33 Renewal Service checks and bearing adjustment (page 39). procedures at 10,000 miles and at every 10,000 miles 29.
Page 18 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ 6A4RRBRÁSQHT5E8RAHHSBG@ 5ƒfvp„ 5ƒfvp„ÁVpfvÁ€ƒÁ7€ÁG€…ÁA€wiÁG€ƒxfww Problem Remedy Master cylinder(s) low on fluid. Refill with recommended brake fluid. Brake fade from heat build-up (excessive braking). Let brakes cool. Downshift to cause engine braking. Brake fade due to brake pad hang-up or dragging. Inspect caliper/master cylinder.
Page 19: Troubleshooting
TROUBLESHOOTING INDIAN CHIEF VINTAGE SERVICE MANUAL 8G@BG8ÁSQHT5E8RAHHSBG@ Rx…€xQpwf…piÁ7tfry€„…th„ Engine difficult to start: • Battery low on charge • Spark plugs in bad condition, have improper gap or 6fƒg†ƒp…€ƒ are partially fouled Engine floods: • Incorrect spark plugs • Excessive pumping of throttle before or while •...
Page 20 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ Starter does not operate or does not turn engine over: • Exhaust pipe — indicates a defective exhaust valve • Engine stop switch in OFF position • Head gasket — indicates defective head gasket, cylinder head surface or cylinder surface •...
Page 21 TROUBLESHOOTING INDIAN CHIEF VINTAGE SERVICE MANUAL 8FBRRBHGÁ6HGSQHEÁRXRS8FÁSQHT5E8RAHHSBG@ 8‡f€ƒf…t‡pÁR„…pxÁ6sphv„ • Check the electrical circuit supplying power to the solenoid for continuity and appropriate power. Repair the circuit as necessary. Problems with the evaporative emission system are • Check the mechanical linkage between the sole- primarily the result from the failure of the air valve to noid and the air valve door for proper setup and open or close.
Page 22 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ 8wph…ƒ€ythÁBryt…t€yÁ7tfry€„…th„ Note: Check to make sure that the location of the colored wire leads in the adapter harness connector correspond with the color indicators on the tester The Indian Chief Vintage motorcycle is equipped with module.
Page 23 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E With the transmission in neutral, move the motorcycle forward slowly and observe the SENSOR indicator while doing so. • Indicator light cycles on and off — The speed sensor is OK. • Indicator light does not cycle on and off — The speed sensor is malfunctioning or it is improperly positioned in the transmission housing and not sensing gear rotation.
Page 24 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ Turn the ignition key to the ON position and the engine stop switch to the RUN position. The tester will repeatedly cycle the ignition system up and down through a range of 0–6000 rpm. DO NOT touch the ignition coil, the spark plugs or the spark plugs.
Page 25 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 12 — Typical operation check screen...
Page 26 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ 64Q5TQ8SHQÁSQHT5E8RAHHSBG@ H‡pƒqw€ˆÁ€ƒÁ9w€€ityr Problem Remedy Loose float bowl or damaged float bowl seal ring. Tighten float bowl screws. Replace seal ring as necessary. Improper fuel level in float bowl. Adjust needle actuating tab on float to correct fuel level. Worn or dirty float needle valve or seat.
Page 27 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E I€€ƒÁ iwp Problem Remedy Damaged or restricted fuel tank vent system. Repair or unclog vent system. Loose float bowl or damaged float bowl seal ring. Tighten float bowl screws. Replace seal ring as necessary.
Page 28 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ I€€ƒÁ9†wwÁSsƒ€……wpÁIpƒq€ƒxfyhp Problem Remedy Leaks in intake between carburetor and cylinder heads. Repair leaks or replace parts as required. Damaged or restricted fuel tank vent system. Repair or unclog vent system. Dirty air cleaner element. Clean or replace as required.
Page 29 TROUBLESHOOTING INDIAN CHIEF VINTAGE SERVICE MANUAL SQ4GRFBRRBHGÁ4G7Á7QBU8ÁSQHT5E8RAHHSBG@ Sƒfy„xt„„t€y Rstq…„ÁAfƒi Problem Remedy Primary drive housing overfilled with lubricant. Drain and refill with proper amount of lubricant. Clutch dragging slightly. Check and adjust clutch and clutch cable. Transmission lubricant too heavy (operation in cold Run until transmission warms.
Page 30 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ 6w†…hsÁ7ƒfr„Á€ƒÁ7€p„ÁG€…ÁQpwpf„p Problem Remedy Clutch controls improperly adjusted. Adjust as necessary. Primary case lubricant level too high. Drain and refill with proper amount of lubricant. Clutch discs warped. Check and replace components as necessary. Primary chain badly misaligned.
Page 31 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8E86SQB64EÁSQHT5E8RAHHSBG@ 8wph…ƒthfwÁSƒ€†gwp„s€€…tyrÁ6sfƒ…„ 4w…pƒyf…€ƒ Alternator Does Not Charge Problem Remedy Voltage regulator not grounded. Inspect and repair ground as necessary. Engine ground wire loose or broken. Inspect and repair ground as necessary. Faulty voltage regulator. Test and replace as necessary.
Page 32 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ 5f……pƒÁSp„…tyr Always turn the battery load tester OFF before connecting leads to battery terminals. Connecting @pypƒfw leads with tester ON can cause a spark resulting in a battery explosion and result in serious personal Refer to CHARGING SYSTEM SERVICE for battery injury.
Page 33 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E T„tyrÁ…spÁ5f……pƒÁ6sfƒrpƒ Table 3: Battery Charging Rate Charge the battery if any of the following conditions Battery 2.1 Amp exist: Battery Rating Voltage Charge Rate • Vehicle lights are dim. 12.6 1.75 Hours • Starter motor cranks slowly or sounds weak.
Page 34 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ Figure 13 — Battery ground cable test 5f……pƒÁ…€ÁR…fƒ…pƒ Set your meter to ohms (resistance). Place a probe upon Figure 15 — Starter/transmission ground test the negative post of the battery and the other probe against the starter case.
Page 35 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Qph…tqtpƒQpr†wf…€ƒÁ6†ƒƒpy…Á EpfvÁSp„… Check the battery voltage. To perform this test, the battery must have a charge. With the battery connected to the charging system and the ignition key in the OFF position, disconnect the regulator wire harness at the stator terminal.
Page 36 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ R…f…€ƒÁQp„t„…fyhpÁ6sphv • While observing the voltage output, slowly increase the tester load until a steady 13-volt output reading Connect the leads of a volt-ohmmeter between one of is obtained. the two terminals at the stator. With the meter set to the •...
Page 37 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E R…fƒ…tyrÁR„…pxÁSp„…„ The following starting system tests are helpful in isolating the cause of a system problem at the solenoid, the starter motor or the circuit wiring. Note: The battery must be in good condition and at a full state of charge prior to conducting the following tests.
Page 38 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ Figure 22 — Techcycle starter on left, Compufire on right VtƒtyrÁ6tƒh†t…ÁSp„…„ Problem conditions within the chassis wiring circuits can result in circuit components operating poorly or not at all. Such conditions can be caused by: •...
Page 39 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E €ˆpƒÁf…Á8A6 Qp„t„…fyhpÁSp„…„ Start at the J-4 connector by unplugging the J-4 out of An ohmmeter can be used to check for continuity in the socket. Check the pin #3 at the EHC socket. You circuits and components to find open, shorted or should have 12v power.
Page 40 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQHT5E8RAHHS G@ Replace the battery power cable and perform the H…spƒÁU€w…frpÁ7ƒ€ÁSp„…„ voltage drop test again. Voltage drop tests can be performed on starter If the voltage drop is 0.5 volt DC or less, then the cable solenoids, switches, headlights, taillights and brake is operating satisfactory.
Page 41 SQHT5E8RAHHS G@ G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E R…fƒ…pƒÁR€wpy€tiÁSp„…ÁÉR…fƒ…pƒÁQpx€‡pi The starter solenoid can be tested with the starter removed. Use a 12-volt test battery and three jumper wires to make the following test connections: Battery fluid contains sulfuric acid. Do not allow this fluid to come in contact with eyes, skin or clothing.
Page 42 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9QHGSÁRTRI8GR HG QHGSÁRTRI8GRBHGÁR8QUB68 @pypƒfwÁByq€ƒxf…t€y The oil seal on the ILM suspension is recessed into the top of the fork slider and is retained with a snap ring. The Paioli suspension has a dust wiper which extends Early-production Indian Chief motorcycles are equipped above the fork slider.
Page 43 9QHGSÁRTRI8GR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9€ƒvÁ twÁQpwfhpxpy… 9€ƒvÁS†gpÁIƒ€hpi†ƒp„ S€€wÁƒp‚†tƒpi' S€€w„Áƒp‚†tƒpi' 5/32" hex bit 6 mm hex bit 1/2" hex bit Iƒ€hpi†ƒp 21 mm open end wrench Place a drain pan under the right fork tube. Remove the 5/8" wrench and/or socket drain plug and copper sealing washer from the lower rear of the fork using a 5/32"...
Page 44 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9QHGSÁRTRI8GR HG Using a tie, secure the caliper to the frame in a position Remove the fork tube cap from each fork tube, using a out-of-way. 1-3/8" wrench. Figure 34 — Securing caliper out-of-way Figure 36 — Remove fork tube cap Remove the front wheel.
Page 45 9QHGSÁRTRI8GR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9€ƒvÁS†gpÁ7t„f„„pxgw Figure 38 — Fork assembly If not already done, use a 5/32" hex bit to remove the Exercising care, slowly remove the plug from the fork drain plug and washer from the fork slider and drain the tube, using a 21 mm wrench.
Page 46 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9QHGSÁRTRI8GR HG 9€ƒvÁS†gpÁ4„„pxgw Clamping the assembly in a vise at any point other Coat all parts of the front fork assembly with fresh oil of than the axle end can bend, distort or otherwise the specified type for Indian motorcycles. permanently damage the fork tube or slider.
Page 47: Frame And Accessories Service
9QHGSÁRTRI8GR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Apply blue threadlock to the threads of the retainer Install the fork tube cap screw using a 1-3/8" socket and screw. Then, using a 6 mm hex bit, install the retainer tighten the screw to specification. screw and tighten to specification.
Page 48 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS88Q G@Á6HFIHG8GSR RS88QBG@Á6HFIHG8GSÁR8QUB68 The steering components consist of the upper and lower Note: Flat spotting of a bearing race may occur from fork brackets (triple clamp) and the handlebars. The a heavy blow, typically from wheelies, collisions with lower fork bracket has an integral stem that is the cars, the cycle being dropped from a truck, etc.
Page 49 RS88Q G@Á6HFIHG8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Return the wheel back to center and perform the same 5pfƒtyrÁIƒpw€fiÁ4iu†„…xpy… test to the left. Fall-away to the left will occur earlier because of the weight of the brake caliper. With the motorcycle supported on a lift and the front wheel off the ground, adjust bearing preload using this procedure.
Page 50 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS88Q G@Á6HFIHG8GSR R…ppƒtyrÁR…pxÁ7t„f„„pxgwÁfyiÁ Loosen but do not remove the fork crown nut, using a 1-1/2" wrench. 4„„pxgw If either triple clamp, the stem or bearings are worn or damaged in any way, the unit can be disassembled and parts replaced as required.
Page 51 RS88Q G@Á6HFIHG8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Flatten the tab of the washer used to secure the upper Remove the upper triple clamp and handlebar as an triple clamp crown nut, using a punch and hammer. assembly. Place the triple clamp and handlebar in a secure position out-of-way.
Page 52 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS88Q G@Á6HFIHG8GSR 5pfƒtyrÁQfhpÁQpx€‡fw Slide the lower triple clamp out of the frame. Remove the lower bearing from the triple clamp. To remove the upper race from the frame stem tube, place a suitable bearing race remover in position on the upper race.
Page 53 RS88Q G@Á6HFIHG8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Install the upper bearing and bearing dust cover over Install the upper triple clamp onto the stem. Install the the stem and into position on the upper bearing race. tab washer and crown nut to secure the upper triple clamp.
Page 54 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS88Q G@Á6HFIHG8GSR AfyiwpgfƒÁQpwfhpxpy… Using a 5/32" hex bit, remove the retaining screws from the throttle/switch housing and carefully separate the housing halves. The handlebar can be removed as an assembly with switches, brake, clutch and throttle controls remaining in place and positioned out-of-way for service of the steering stem bearings.
Page 55 RS88Q G@Á6HFIHG8GSR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Place the brake lever and master cylinder assembly in AfyiwpgfƒÁ y„…fwwf…t€y position at the right side of the handlebar. Install the retaining screws, using a 5/32" hex bit, and tighten the Apply blue threadlock to the threads of the four screws to specification.
Page 56 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Q84QÁRTRI8GR HG Q84QÁRTRI8GRBHGÁR8QUB68 Rs€hvÁ4g„€ƒgpƒ Figure 61 — Rear shock absorber assembly S€€w„Áƒp‚†tƒpi' 3/16" hex bit 1/4" hex bit 9/16" wrench and/or socket 1-1/16" wrench Spanner wrench with 2-3/4" pin centers Torque wrench...
Page 57 Q84QÁRTRI8GR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Pull the bolts out and remove the shock absorber from Rs€hvÁ4g„€ƒgpƒÁQpx€‡fw the chassis. Remove the seat, saddlebags and saddlebag brackets, rear engine guard and rear fender following the Rs€hvÁ4g„€ƒgpƒÁ y„ph…t€yÁfyiÁ4iu†„…xpy… procedures in the FRAME AND ACCESSORIES SERVICE section.
Page 58: Charging System Service
G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Q84QÁRTRI8GR HG Insert the mounting bolts and thread on the nuts. Figure 65 — Shock absorber installation Using a 1/4" hex bit to keep the mounting bolts from turning, tighten the nuts to specification with a 9/16" socket and torque wrench.
Page 59 Q84QÁRTRI8GR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Rˆtyrfƒx Figure 66 — Rear swingarm assembly S€€w„Áƒp‚†tƒpi' 3/8" hex bit 15/16" wrench and/or socket Bearing driver Torque wrench Arbor or hydraulic press...
Page 60 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Q84QÁRTRI8GR HG RˆtyrfƒxÁQpx€‡fw Remove the seat, rear engine guard, saddlebags and brackets and rear fender following the procedures in the FRAME AND ACCESSORIES SERVICE section. Remove the battery following the procedure in the CHARGING SYSTEM SERVICE section. Remove the shock absorber and battery box following the Shock Absorber Removal procedure in this section.
Page 61 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88EÁ4G7ÁSBQ8ÁR8QUB68 9ƒ€y…ÁVsppwÁQpx€‡fwÁfyiÁ Remove the axle nut, lock washer and flat washer from By„…fwwf…t€y the left side of the axle, using a 3/4" socket. Use a 1/2" hex bit to prevent the axle from turning as the axle nut is being removed.
Page 62 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R Note: One method of supporting the wheel and tire Note: The axle, spacers, washers and nut can be assembly for removal of the axle is to adjust the reinstalled in fork sliders for safe keeping until it is time motorcycle lift so that the front wheel is just touching the to install the wheel assembly.
Page 63 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Align the wheel hub with the axle and slide the axle Tighten the right-side axle pinch bolt to specification, through the wheel. Install the left-side spacer onto the using a 6 mm hex bit. axle before the axle is inserted into the left fork slider.
Page 64 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R Attach a magnetic based dial indicator set onto the outer Obtain the correction spacer, install the wheel, axle and edge of the brake rotor. Position the dial indicator spacer and tighten the axle to specification. against the axle center.
Page 65 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the cotter pin and, using a 15/16" wrench, Remove the rear drive belt from the wheel sprocket. loosen the retaining nut at the right side of the axle. Use a 15/16" wrench to keep the axle from turning as the nut is being removed.
Page 66 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R Adjust the drive belt tension by tightening the adjuster y„…fwwf…t€y nuts the same number of turns recorded for removal. If installed, remove the nut, washers, axle and spacers from the swingarm. Clean the parts and then apply a light coating of grease to the axle.
Page 67 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Align the brake caliper mounting bosses with the S€€w„Áƒp‚†tƒpi' mounting bosses in the caliper mounting bracket on the Seal removal tool (or screwdriver) right fork of the swingarm. Seal driver (or suitably-sized hex socket) Install the caliper mounting screws, using a 6 mm hex bit, and tighten the screws to specification.
Page 68 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R 5pfƒtyrÁfyiÁRpfwÁ y„…fwwf…t€y Note: The diameter of the driver or hex socket should be slightly smaller than the outside diameter of the seal. If the bearing is suitable for reuse, repack the bearing with a high quality waterproof bearing grease. Figure 90 —...
Page 69 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VsppwÁRƒ€hvp…ÁfyiÁ5ƒfvpÁQ€…€ƒÁ Place the rotor in position on the wheel hub. If the rotor Qpx€‡fwÁfyiÁBy„…fwwf…t€y is being reused, align it in the same position as originally installed. Apply red threadlock to the threads of the five mounting S€€w„Áƒp‚†tƒpi' screws.
Page 70 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R QpfƒÁVsppwÁRƒ€hvp… The wheel sprocket is attached to the rear wheel hub on the left side with five screws. Using a 3/8" hex bit, remove the five mounting screws and separate the sprocket and spacer from the wheel hub.
Page 71 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Tighten spokes that are found to be loose, using a 6 mm open-end wrench. Tap each spoke as it is tightened, noting the tone. Figure 97 — Tightening spokes Once the spokes are tight, visually inspect the rim and hub for dents, cracks and out-of-roundness.
Page 72 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R As the tire heats up, air inside the tire expands, raising StƒpÁ y„ph…t€y the tire pressure. Typically, this rise is on the order of two to six psi with the bike fully loaded and traveling at Visually inspect the tire for any cuts, cracks and bubbles high speeds on a 90-degree day.
Page 73 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Using the tire irons and protectors, pry the lower bead StƒpÁQpx€‡fw over the rim edge and into the center. Press the bead against the lower seat of the rim. Release the air from the tire and remove the valve core from the tube stem.
Page 74 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R VA88EÁE46BG@ EfhtyrÁ#ByhsÁ#R€vpÁ The specified offset is: Vsppw„ • Front wheel — 29/32" • Rear wheel — 15/16" This procedure applies for both front and rear wheels. Repeat the process at two more locations on the rim. References to left and right sides of the wheel refer to its The 60-spoke wheels are fitted with hook-type spokes, mounting on the motorcycle.
Page 75 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E reference when assembling the spokes to the rim. For Note: Gather spokes in the right (upper) flange into the front wheel, the valve stem hole is on the side small groups and secure them with tape or rubber bands opposite the brake rotor mounting surface of the hub.
Page 76 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E VA88ERÁ4G7ÁS Q8R 4wtrytyrÁ…spÁA†gÁfyiÁQtxÁ ÉSƒ†tyr S€€w„Áƒp‚†tƒpi' 1/4" spoke wrench 3/16" hex bit Wheel stand with pointer (e.g., Chrome Specialties, No. 400341) Straightedge 4wtryxpy…ÁIƒ€hpi†ƒp Figure 106 — Measuring lateral clearance Starting at the valve stem hole, divide the spokes into 10 groups of six.
Page 77 VA88ERÁ4G7ÁS Q8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Repeat this process at the three remaining tape-marked Slowly turn the rim and check for uniform clearance groups. between the pointer and the tire bead seat. The clearance should not vary by more than 1/32" between For spokes outside of the four marked groups, turn the high and low spots.
Page 78 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F 5Q4D8ÁRXRS8FÁR8QUB68 5ƒfvpÁ9w†tiÁEp‡pwÁfyiÁ6€yit…t€y The fluid level should be within 1/4" from the top of the reservoir. Add fluid if needed. Brake fluid level and condition must be checked at the 500-mile service interval and thereafter, at each 2500-mile interval.
Page 79 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E View the bottom of the reservoir for any debris. Remove Check the thickness of the brake pads. the old fluid and flush the system if necessary. The fluid level should be within 1/4" from the top of the reservoir.
Page 80 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F 5ƒfvpÁRstxÁ fƒ…ÁG†xgpƒ„ 5ƒfvpÁ6fwtpƒÁRstxxtyr S€€w„Áƒp‚†tƒpi' Thickness Part No. Feeler gauge Shim, .396″ ID x .812″ OD x .010″ thick″ 97-010 Torque wrench Shim, .396″ ID x .812″ OD x .030″ thick 97-011 Ratchet driver Shim, .396″ ID x .812″ OD x .060″ thick 97-012 6 mm Allen socket By„ph…t€y...
Page 81 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E A mis-aligned caliper might be evidence of a more serious problem and should be investigated for a possible cause. When the correct clearance is achieved, apply Blue Loctite 242 to the caliper mounting screws (5) and tighten to 23-30 foot-pounds.
Page 82 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F Align the retaining pin with the through hole in each pad. Push the retaining pin through each hole and over the brake pad clip. Install the push pin to retain. Slip the caliper over the rotor and align with the mounting holes in the left fork slider.
Page 83 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 122 — Front brake caliper assembly By„…fwwf…t€y Position the brake line fitting to the caliper. Make sure one copper sealing washer is on each side of the fitting. Slide the caliper over the front brake rotor and into Thread the fitting bolt into the caliper and tighten to position on the left fork slider.
Page 84 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F Inspect the caliper dust boots for tears or other damage. QpfƒÁ6fwtpƒÁQpx€‡fwÁfyiÁ y„…fwwf…t€y Inspect the caliper for leaks in the piston area and between caliper halves. Replace the caliper as necessary. Note: There are no serviceable components for these calipers.
Page 85 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5ƒfvpÁQ€…€ƒÁRpƒ‡thp Support the master cylinder outlet fitting, using a 9/16" wrench, while removing the brake line. Remove the outlet fitting and copper sealing washer Q€…€ƒÁ y„ph…t€y from the master cylinder, using a 9/16" wrench. Inspect the washer and replace as necessary.
Page 86 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F By„…fwwf…t€y Install the outlet fitting with copper sealing washer and tighten to specification, using a 9/16" wrench. Insert the pushrod through the dust boot and into the Thread the hydraulic brake line onto the outlet fitting. master cylinder piston.
Page 87 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E By„…fwwf…t€y QpfƒÁFf„…pƒÁ6wtyipƒÁQpx€‡fwÁfyiÁ y„…fwwf…t€y Slide the rear master cylinder over the end of the brake pedal pushrod and align the cylinder with the screw Qpx€‡fw holes in the support bracket. For easier removal and installation of the rear master Apply red threadlock to the two rear master cylinder cylinder, remove the front engine guard.
Page 88 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F 9ƒ€y…ÁFf„…pƒÁ6wtyipƒÁ6wpfytyrÁfyiÁBy„ph…t€y QpfƒÁFf„…pƒÁ6wtyipƒÁI†„sƒ€iÁ9ƒppÁIwf Inspect the cover gasket, dust boot, cup and piston Grasp the brake pedal and gently move the pedal O-ring for wear, softening, enlargement, cuts and tears. forward and backward. You should feel a small amount Replace these parts as necessary.
Page 89 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Aiƒf†wthÁ5ƒfvpÁEtypÁ QpfƒÁFf„…pƒÁ6wtyipƒÁ7t„f„„pxgw Qpwfhpxpy… Remove the rear master cylinder assembly from the support bracket. Refer to Rear Master Cylinder Removal and Installation in this section for procedures. S€€w„Áƒp‚†tƒpi' Remove the dust boot and then, remove the snap ring 3/8"...
Page 90 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 5Q4D8ÁRXRS8F By„…fwwf…t€y By„…fwwf…t€y Thread the new brake line onto the outlet fitting of the Route the new rear brake line as noted during removal. master cylinder and tighten to specification, using a Make sure the line reaches both front and rear 7/16"...
Page 91 5Q4D8ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the protective cap from the front caliper S€€w„Áƒp‚†tƒpi' bleeder screw and install the 1/4" diameter clear tubing Suction gun onto the screw. 11 mm wrench Place the opposite end of the tube into a clear catch container.
Page 92 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R Q4F8Á4G7Á4668RRHQB8RÁR8QUB68 Rpf…ÁQpx€‡fwÁfyiÁBy„…fwwf…t€y Lift up on the rear of the seat and pull the seat rearward to disengage the seat front retainer bracket from the frame. Remove the seat. S€€wÁƒp‚†tƒpi' 5/32" hex bit Qpx€‡fw Remove the seat from the frame by removing the two chrome button head screws, using a 5/32"...
Page 93 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9pyipƒÁQpx€‡fwÁfyiÁBy„…fwwf…t€y Carefully remove the front fender to avoid scratching the paint surface. It is helpful to apply light pressure to the sides of the fender, squeezing them inward just enough S€€w„Áƒp‚†tƒpi' to clear the mounting pads on the sliders. 1/4"...
Page 94 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R QpfƒÁ9pyipƒÁQpx€‡fw Remove the seat, saddlebags and brackets and rear engine guards following the appropriate instructions. Refer to Seat Removal and Installation, Saddlebags and Brackets and Engine Guards in this section. Cut the tie strap holding the four-pin rear light harness connector to the connector anchor.
Page 95 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 7f„sÁQpx€‡fwÁfyiÁBy„…fwwf…t€y Connect the rear light harness at the four-pin connector and secure the connector with a tie strap. 6sf„„t„Á9ftƒtyrÁQpx€‡fwÁfyiÁ S€€wÁƒp‚†tƒpi' By„…fwwf…t€y 5/32" hex bit Iƒ€hpi†ƒp S€€wÁƒp‚†tƒpi' To remove the dash, remove the screw at the rear of the 5/32"...
Page 96 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R 9ƒ€y…ÁS†ƒyÁRtryfwÁR€…wtrs…ÁfyiÁ Carefully pull the harness through its routing, after Apfiwtrs…ÁIƒ€hpi†ƒp„ removing any tie straps or shrink wrap securing the harness. S€€w„Áƒp‚†tƒpi' #1 Phillips screwdriver #2 Phillips screwdriver 5/64" hex bit 5/32" hex bit 3/16"...
Page 97 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Carefully pull the harness from its routing after Remove the spotlight stabilizer bar, using a 3/16" hex removing any tie straps or shrink wrap securing the bit. harness. Using a 3/16" hex bit, loosen but do not remove the upper and lower mounting screws securing the spotlight bracket to the fork assembly.
Page 98 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R Remove the headlight and trim ring assembly as Apfiwtrs…Á4„„pxgwÁQpwfhpxpy… necessary. Refer to Headlight Assembly Replacement in this section. Remove the headlight and trim ring assembly, using a 5/64" hex bit to remove the two upper screws and a #2 Carefully pull the headlight and trim ring from the Phillips screwdriver to remove the screw at the bottom headlight housing.
Page 99 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9pyipƒF€†y…piÁEtrs…Á To install the housing assembly, reverse the order of Iƒ€hpi†ƒp„ disassembly. Route the wire lead along the six nylon mounting blocks and through the hole at the left side of the fender. Make sure the rubber grommet is in place at the hole.
Page 100 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R To install the housing assembly, reverse the order of 5†iiÁIprÁIƒ€hpi†ƒp removal. Route the wiring harness through the rubber splash guard and secure it with new tie straps at the five If equipped, the buddy pegs provide folding foot rests nylon mounting blocks.
Page 101 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R Dthv„…fyiÁQpx€‡fwÁfyiÁ Lift the windshield from its mounting. By„…fwwf…t€y S€€w„Áƒp‚†tƒpi' 6 mm hex bit Spring pliers Motorcycle lift Iƒ€hpi†ƒp Using a suitable lift, raise the motorcycle off the ground. Make sure that the lift is positioned in a way that allows full access to the kickstand components.
Page 102 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R Remove the mounting screws one at a time and apply Remove the fork cover plate mounting screws, using a blue threadlock to the threads. With all mounting screws 1/8" hex bit. installed, tighten to specification, using a 3/16" hex bit. Figure 158 —...
Page 103 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E When removing and installing the support bracket, the ground wire and screw must be removed and installed, using a #2 Phillips screwdriver. Figure 161 — Removing front fender tip Slip the front fender tip from the fender. By„…fwwf…t€y Figure 160 —...
Page 104 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R E†rrfrpÁQfhvÁQpx€‡fwÁfyiÁ QpfƒÁ9pyipƒÁStÁQpx€‡fw By„…fwwf…t€y Remove the four rear fender tip screws and nuts, using a 3/32" hex bit and an 11/32" wrench. S€€wÁƒp‚†tƒpi' 5/32" hex bit Qpx€‡fw Remove the four mounting screws securing the luggage rack, using a 5/32"...
Page 105 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E A€ƒyÁ6€‡pƒÁfyiÁA€ƒyÁQpx€‡fwÁ Remove the nylock nut from the stud on the frame horn fyiÁBy„…fwwf…t€y and cover bracket, using a 1/2" socket or wrench. S€€w„Áƒp‚†tƒpi' 5/32" hex bit 1/2" socket/wrench Iƒ€hpi†ƒp Remove the two horn cover mounting screws, using a 5/32"...
Page 106 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R Remove the two front engine guard lower mounting To install the front engine guard, place the engine guard bolts, using a 1/4" hex bit. Remove the washers along into position on the engine guard mounting brackets of with the bolts.
Page 107 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the rear engine guard upper mounting bolt, RfiiwpgfrÁQpx€‡fwÁfyiÁ y„…fwwf…t€y using a 1/4" hex bit. The upper mounting bolt also Qpx€‡fw supports the front of the saddlebag mounting bracket. Remove the rear engine guard by sliding the upper Unbuckle the three saddlebag straps to open the bracket out from behind the saddlebag mounting saddlebag.
Page 108 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R Remove the two screws located at the upper back of the Locate the rubber dampers and fender washers into saddlebag, using a 5/32" hex bit. position on the saddlebag bracket. The rubber dampers go against the bracket and the fender washers are placed on top of the dampers against the saddlebag.
Page 109 9Q4F8Á4G7Á4668RRHQ 8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Loosen and remove the upper bracket and fender Apply blue threadlock to the front saddlebag bracket mounting bolts, using a 5/16" hex bit. Support the mounting bolt. saddlebag bracket during bolt removal. Install the front saddlebag bracket mounting bolt through the bracket and rear engine guard.
Page 110 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9Q4F8Á4G7Á4668RRHQ 8R 9ƒfxpÁBy„ph…t€yÁfyiÁQpftƒ Figure 181 — Indian Chief Vintage frame The frame is the backbone of the motorcycle. It is a very Inspect bearing seats in the steering tube and swingarm durable component requiring little attention providing pivots for wear, distortion or other damage.
Page 111 4 QÁ6E84G8Q G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4BQÁ6E84G8QÁ4G7Á BES8QÁ8E8F8GSÁR8QUB68 4tƒÁ6wpfypƒ To gain access to components such as the carburetor or engine for service, remove the air cleaner as a unit. S€€w„Áƒp‚†tƒpi' 1/2" combination wrench Slip-joint pliers Flat-blade screwdriver Qpx€‡fw Loosen the two 5/16" nuts securing the air cleaner brackets to the engine mounting bracket, using a 1/2"...
Page 112 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4 QÁ6E84G8Q Align the air cleaner brackets with the studs on the engine mounting bracket and under the nuts and washers. Push the air cleaner onto the carburetor air inlet until fully seated. Figure 185 — Remove air cleaner cover Remove the bottom two air filter element cover screws, using a 1/8"...
Page 113 4 QÁ6E84G8Q G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the three screws securing the filter element rear cover and air cleaner housing to the air cleaner-to- carburetor adapter. Use a 1/8" hex bit to remove the screws. Figure 190 — Remove air cleaner housing-to-bracket nuts Figure 188 —...
Page 114 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4 QÁ6E84G8Q Clean the front and rear filter element covers and Align the filter element rear cover with the air cleaner inspect for damage. housing. Note the orientation of the rear cover to the housing. The location of the crankcase vent fittings is to the left.
Page 115 4 QÁ6E84G8Q G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Install the air filter element and front cover onto the Position the air cleaner cover over the air filter element filter element rear cover in the air cleaner housing. Align and air cleaner housing. the holes in the cover with the threaded lugs of the air Install and tighten the five air cleaner cover screws to cleaner housing.
Page 116 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F T8EÁRXRS8FÁR8QUB68 9†pwÁ9tw…ƒf…t€yÁFfty…pyfyhp Turn the petcock (fuel supply valve) to the off position. @pypƒfwÁ yq€ƒxf…t€y Just like the engine, the fuel tank will contain a small amount of debris that needs to be removed. To accomplish this need, the fuel system is equipped with a filter screen in the petcock (fuel supply valve) to trap the particulates.
Page 117 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Clean the screen using a tank solvent. Stubborn material Turn the petcock (fuel supply valve) to the on position can sometimes be removed with carburetor cleaner. and view all joints for leakage. Tighten the clamp securely at any joint where leaking is found.
Page 118 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Remove the throttle/switch housing screws, using a Carefully place the top throttle housing section onto the 5/32" hex bit. Slowly remove the top housing half, being bottom section. Install the two mounting screws and careful not to inadvertently dislodge the small ferrules tighten very lightly.
Page 119 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Start the engine and let it idle. Move the handlebars left Ssƒ€……wpÁ6fgwpÁ4iu†„…xpy… and right to the fork stops. The rpm of the engine should not increase. If it does, loosen the forward Adjustment of throttle cable free play is accomplished throttle cable adjuster until the engine rpm does not rise using the threaded adjusters located under the throttle/ when the handlebars are turned.
Page 120 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Remove the screw at the rear of the dash panel, using a Disconnect and remove the vent and crossover tubes. 5/32" hex bit. Figure 209 — Fuel crossover tube and fuel supply line Figure 207 — Dash panel rear retaining screw Remove the screw in the dash panel, using a 5/32"...
Page 121 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Support the tank and remove the mounting screws at Remove the right tank in the same manner by removing the upper front and center of the tank, using a 1/2" the three mounting screws at the lower front, upper wrench.
Page 122 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Connect the fuel line from the shutoff valve on the left Using a 5/32" hex bit, tighten the rear screw to tank to the carburetor. specification. Figure 216 — Fuel crossover tube and fuel supply line Figure 218 —...
Page 123 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 64Q5TQ8SHQÁR8QUB68 6fƒg†ƒp…€ƒÁ6tƒh†t…Á7p„hƒt…t€y SspÁ iwpÁ6tƒh†t… The idle circuit is in operation between closed throttle The carburetor is divided into four interdependent and approximately 1/8 throttle opening. Some notable systems or circuits that provide the appropriate components of the idle circuit are: air/fuel mixture for all engine operating ranges.
Page 124 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Cp…ÁGppiwpÁÉ!Á…€Á !Á…sƒ€……wp Do not disassemble the throttle lever linkage. It is not normally necessary to remove the throttle shaft bolt to change position of the jet needle. If the bolt is removed, perform the following: 1.
Page 125 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4hhpwpƒf…€ƒÁ †xÁRp……tyr„ÁfyiÁ4iu†„…xpy…„ Gasoline is flammable and explosive. Work in a The #1 screw is normally adjusted to establish a gap of well-ventilated area when draining gasoline and approximately 0.080" (2 mm) between the white plastic drain it into an approved container for gasoline lever and the end of the pump rod.
Page 126 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Remove the enrichener (choke) control cable from the upper engine mounting bracket, using a 9/16" wrench. Use a 7/16" wrench to keep the jam from turning if necessary. Figure 226 — Carburetor removal y„…fwwf…t€y Install the carburetor with the throttle-bore flange Figure 224 —...
Page 127 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Connect the throttle control cables to the carburetor. Figure 230 — Air cleaner mounting brackets To secure the air cleaner, tighten the two bracket nuts to Figure 228 — Throttle cables installed specification, using a 1/2" combination wrench. Install the enrichener (choke) control cable on the engine mounting bracket, using a 9/16"...
Page 128 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F The distance from the bottom surface of the carburetor Place the clip in the first groove from the top of the to the top of the float should be 16–20 mm. needle. Place the clip, open-end up, against a hard surface. Again, cover the clip area with your hand and press down on the needle to snap the clip into place.
Page 129 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6fƒg†ƒp…€ƒÁBww†„…ƒf…t€y„ Figure 232 — Carburetor (right side)
Page 130 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Figure 233 — Carburetor (left side)
Page 131 9T8EÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 234 — Carburetor exploded view...
Page 132 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9T8EÁRXRS8F Carburetor Exploded View Legend 1. Top Cover Screw 22. Bolt Lock Tab Plate 43. Throttle Stop Screw 64. Pilot Jet 2. Top Cover Screw 23. Screw 44. Throttle Stop Nut 65. Main Jet Extender 3.
Page 133 @G S HGÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E B@GBSBHGÁRXRS8FÁR8QUB68 RfƒvÁIw†rÁQpwfhpxpy… Using a 3/8" wrench, remove the retaining nuts and wires from the primary terminals at each end of the coil. Carefully twist and pull to disconnect the spark plug S€€w„Áƒp‚†tƒpi' wires from the terminals at the back of the coil.
Page 134 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E @G S HGÁRXRS8F Place a new gasket in position and install the ignition Note: For easier access to the spark plugs and wires at cover housing. Apply blue threadlock to the threads of the right side of the motorcycle, remove the air cleaner the cover screws and install the screws.
Page 135 ET5Q 64S HGÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E ET5QB64SBHGÁRXRS8FÁR8QUB68 8yrtypÁ twÁfyiÁ twÁ9tw…pƒÁ Screw the filter into the filter mount until the gasket Qpwfhpxpy… contacts the seating surface. Tighten another 1/2–3/4 of a revolution. Engine oil should be checked when warm and the S€€w„Áƒp‚†tƒpi' motorcycle is vertical.
Page 136 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E ET5Q 64S HGÁRXRS8F Clean the screen with a suitable oil removal product. y„ph…t€yÁf…ÁHtwÁSfyv Inspect the screen for any metal chips. Chips may be removed with brake clean, carburetor clean, etc. If chips The oil tank has four points of inspection. If a leak is cannot be removed, replace the screen with a new part found, the 90-degree fitting can be tightened to (#01-185).
Page 137 ET5Q 64S HGÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E y„ph…t€yÁf…Á6fxÁ6€‡pƒÁfyiÁ8yrtypÁ5w€hv The cam cover and engine block each have one point of inspection. If leaking, tighten the oil fitting at the bottom of the cam cover or bottom of the engine block, using a 12 mm open-end wrench.
Page 138 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E ET5Q 64S HGÁRXRS8F twÁSfyvÁQpx€‡fwÁfyiÁBy„…fwwf…t€y Figure 245 — Oil tank assembly Loosen the clamps, using a flat-blade screwdriver, and S€€w„Áƒp‚†tƒpi' disconnect the four oil lines at the right front corner of 5/32" hex bit the tank. Tag the lines for identification and proper reconnecting when the oil tank is installed.
Page 139 ET5Q 64S HGÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Connect the four oil lines at the right front corner of the tank and tighten the clamps securely. Proper connection is as follows: Cam cover vent — top left Pump bypass — top center Filter return —...
Page 140 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8F RR HGÁ6HGSQHEÁRXRS8F 8FBRRBHGÁ6HGSQHEÁRXRS8FÁR8QUB68 8‡f€ƒf…t‡pÁR„…px Figure 246 — Evaporative system The evaporative system prevents fuel vapors 7p„hƒt…t€y (hydrocarbons) from escaping into the atmosphere. The system consists of an air valve at the inlet port on the To control emissions in the state of California, Indian back of the air cleaner housing, tank vapor valve, a motorcycles are equipped with an evaporative emissions...
Page 141 8F RR HGÁ6HGSQHEÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E When the engine is shut down and the ignition switch is To remove the carbon canister, use a flat-blade “off,” the air valve at the air cleaner intake is closed, screwdriver to release the lock tabs on the canister blocking the outflow of fuel vapors.
Page 142 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8F RR HGÁ6HGSQHEÁRXRS8F Remove the five air cleaner cover screws, using a 1/8" Disconnect the solenoid actuating rod at the butterfly hex bit. Retain the screws and any washers for reuse. assembly lever, using 0.050" hex bit. Figure 249 —...
Page 143 8WA4TRSÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8WA4TRSÁRXRS8FÁR8QUB68 F†qqwpƒÁApf…ÁRstpwi„ÁfyiÁ Remove the muffler from the exhaust pipe, exercising 8‰sf†„…ÁApfipƒ care to avoid damaging the exhaust pipe assembly. To install the muffler, reverse the order of disassembly. Tighten the muffler mounting bolts to specification. S€€w„Áƒp‚†tƒpi' 8‰sf†„…ÁApfipƒÁQpx€‡fwÁfyiÁ...
Page 144 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 8G@BG8ÁQ8FHU4EÁ4G7ÁBGRS4EE4SBHG S€€w„Áƒp‚†tƒpi' 5/32" hex bit 3/16" hex bit 1/4" hex bit 3/8" hex bit 1/2" socket/wrench 9/16" socket/wrench 3/4" socket/wrench 1-1/2" socket Drain pan Figure 253 — Instrument panel rear retaining screw ® Engine stand, 1006T (available from JIMS Flat-blade screwdriver, medium Phillips screwdriver...
Page 145 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Using a 3/16" hex bit, remove the two bright-finish Remove the tanks. mounting screws at the bottom front of the fuel tanks. Then, using a 1/2" wrench, remove the mounting screws at the top center and front of the tanks. Gasoline is flammable and explosive.
Page 146 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Remove the screws securing the air cleaner housing to Remove the upper support bracket from the cylinder the upper engine-mounting bracket and remove the air heads and the frame. The ignition coil can remain cleaner as an assembly from the carburetor.
Page 147 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Using a 1/2" wrench, remove the two bolts retaining the Disconnect the shift rod from the transmission lever, muffler to the bracket. Remove the exhaust pipe using a 3/16" hex bit. assembly. Figure 264 — Transmission shift rod Figure 263 —...
Page 148 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Using a 3/16" hex bit, remove the 15 screws at the perimeter of the outer primary housing. Remove the outer housing. Remove the rubber seal or flat gasket from the housing and inspect it. Discard the seal (or gasket) if it is distorted or damaged.
Page 149 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the breather clamps and hoses from the fittings Remove the rear engine mounting bolts, using a 9/16" at the breather valve and the bottom of the cam cover. socket. Disconnect the oil supply line at the oil pump. Figure 272 —...
Page 150 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 ® ® Apply a thin coat of Loctite 598 or Permatex Place the right footrest assembly in position on the Ultrablack sealant to the inner seal surface of the inner frame. Install the mounting screws, using a 5/16” hex primary drive housing.
Page 151 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Place the left fuel tank in position at the side of the upper frame tube and install the two top retaining screws and washers, using a 1/2" socket. Tighten the screws to specification. Install the bottom front retaining screw and bright-finish collar, using a 3/16"...
Page 152 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 8G@BG8Á7BR4RR8F5EXÁ4G7Á4RR8F5EX Q€hvpƒÁ5€‰ÁIƒ€hpi†ƒp„ The procedures covered under Disassembly and Assembly can be done as separate operations with the engine mounted in-chassis or as a complete rebuild with The following procedures apply for both the front and the engine removed from the chassis.
Page 153 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E • Check the rocker arms, shafts and support brackets Qpx€‡fw for cracks, nicks or other damage. Check the contact pads for wear. Using a 3/16" hex bit, remove the four screws retaining the rocker cover. •...
Page 154 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Slide the slotted end of the shafts into the right support Q€hvpƒÁRsfq…Á4„„pxgw bracket and align the slots with the mounting screw holes. Slide the left support bracket onto the other end Apply clean engine oil to the rocker shafts and insert of the shafts.
Page 155 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E If removed for service, place the rocker shaft assembly y„…fwwf…t€y in position on the base. Make sure that the three dowel pins are in place and that the slots in the rocker shafts Clean the mating surfaces of the rocker box base and are properly aligned with the mounting screw holes in the cylinder head.
Page 156 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 I†„sƒ€iÁfyiÁS†gpÁQpx€‡fwÁfyiÁ By„…fwwf…t€y S€€wÁƒp‚†tƒpi' Small flat-blade screwdriver Figure 282 — Pushrod and tube assemblies (early 2003 models)
Page 157 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Inspect the three O-rings and washer and discard if Qpx€‡fw damaged. Remove the pushrods from the bores in the cylinder Remove the second pushrod tube repeating the head. Be sure to note the location of each pushrod as it previous steps.
Page 158 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 I†„sƒ€iÁ4iu†„…xpy… With spring pressure released, slide the lower pushrod tubes upward to reveal the pushrods. Use elastic bands and clips to hold the lower tubes up and out of the way On engines equipped with fixed-length pushrods, the for adjustment.
Page 159 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E With pushrod shortened to achieve end play and Repeat the above procedure for the other front cylinder locknut (2) loose, lengthen the pushrod by holding the pushrod. ball end adjuster (3), using either a 3/8" or 7/16" With adjustment finished, remove the elastic bands and wrench, and turning the pushrod (3) with your fingers.
Page 160 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Figure 290 — Cylinder head assembly...
Page 161 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Turn the driving screw out to release pressure on the Qpx€‡fw spring and remove the cylinder from the tool. Remove the rocker box assembly (see Rocker Box Remove the upper collar and spring set from the top of Procedures).
Page 162 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 If the valve guide is to be removed, use valve guide Ream the bore of the new guides to the following ® tool, JIMS 34740-84, and a hammer to drive the guide specified diameters, then finish hone and thoroughly out from the head.
Page 163 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Next, clean out all oil and debris from the internal y„…fwwf…t€y threads using a can of carburetor/brake cleaner fitted with a spray tube. Fully insert the spray tube into the Install the two dowel pins in the cylinder and install a bolt and work out from the base of the threads.
Page 164 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 6wtyipƒÁfyiÁIt„…€yÁ4„„pxgwÁ Iƒ€hpi†ƒp„ S€€w„Áƒp‚†tƒpi' ® Dental pik, 2361 (available from JIMS ® Piston lock ring tool (available from JIMS • Driver, 96780-58A-2 (requires modification) • Collar, 96781-72-2 (requires modification) Refer to the SPECIAL TOOL REQUIREMENTS section for tool modification prints.
Page 165 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6wtyipƒÁfyiÁIt„…€yÁQpx€‡fw 6wtyipƒÁ y„ph…t€y Remove the cylinder heads (see Cylinder Head Check that the cylinder gasket surfaces are free from Procedures). burrs and scratches. Turn the sprocket shaft until both pistons are positioned Check the cylinder-to-cylinder head and cylinder-to- at mid-stroke in the cylinders.
Page 166 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Check the side clearance for each piston ring. Replace It„…€yÁ y„ph…t€yÁfyiÁQtyrÁQpwfhpxpy… the rings, the piston, or both if the ring side clearance is not within specification (see Specifications). Use a carbon scraper to remove excessive carbon deposits from the pistons.
Page 167 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Install the second compression ring with the dot facing Remove the rod alignment tool from the connecting rod upward. and lubricate the wrist pin and connecting rod with clean engine oil. Place the piston in position on the connecting rod with the notched skirt facing the middle of the engine.
Page 168 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Insert the tool into the piston and wrist pin and drive Make sure the dowel pin is in position on the crankcase the spiral lock into place in the piston pin bore. and install the cylinder base gasket. Different gaskets are used for the front and rear cylinders.
Page 169 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4w…pƒyf…€ƒÁQ€…€ƒR…f…€ƒÁQpx€‡fwÁ Place blue threadlock on the stator plug setscrew. Install fyiÁBy„…fwwf…t€y and tighten the setscrew to 2–2-1/2 turns from lightly seated. Etq…pƒÁ5w€hvÁQpx€‡fwÁfyiÁ S€€w„Áƒp‚†tƒpi' By„…fwwf…t€y 5/32" hex bit Torque wrench S€€w„Áƒp‚†tƒpi' Qpx€‡fw 3/16" hex bit Remove the alternator rotor from the sprocket shaft.
Page 170 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 twÁI†xÁQpx€‡fwÁfyiÁ 6wpfytyrÁfyiÁ y„ph…t€y By„…fwwf…t€y Clean the lifter blocks with a suitable oil removal product. Remove the tappet screen plug, using a 1/4" hex bit. Inspect the lifters and lifter blocks for wear or damage. Then, remove the spring and tappet screen.
Page 171 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Bryt…t€yÁ6€‡pƒÁA€†„tyrQ€…€ƒÁ Inspect the leads and connector for the sensor sealed in Qpx€‡fwÁfyiÁBy„…fwwf…t€y the cover. If damaged, repair or replace as necessary. Position the rotor on the end of the camshaft with the alignment pin in the shaft slot. Apply blue threadlock to S€€w„Áƒp‚†tƒpi' the threads of the retaining screw and install the screw, using a 1/8"...
Page 172 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 6fxÁ5ƒpf…spƒÁUfw‡pÁfyiÁItyt€yÁ Pinion gear installer/puller (available from @pfƒÁQpx€‡fwÁfyiÁBy„…fwwf…t€y ® JIMS • Screw, 96830-51-2 S€€w„Áƒp‚†tƒpi' • Puller, 96830-51-3 3/16" hex bit Rod alignment tool, 1010 (available from ® JIMS Cam cover puller (to be fabricated — see Required Tools section) Small hammer and drift Mainshaft sprocket locknut wrench, 94660-37A...
Page 173 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Qpx€‡fw Note: If the engine is not being disassembled and only the breather valve or cam is to be removed, then align the Remove the rocker box assemblies, pushrods and tubes, timing marks on the gears before removing the breather lifter block assemblies and ignition cover and rotor valve or cam.
Page 174 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 To remove the pinion gear nut, the crankshaft must be To remove the pinion gear, install the pinion nut puller ® locked in position. Use a mainshaft sprocket locknut and screw, JIMS 96830-51-3 and 96830-51-2, as shown. ®...
Page 175 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E y„…fwwf…t€y Install the inner key, oil pump gear, spacer, and outer key and pinion gear on the pinion shaft. Figure 324 — Pinion shaft, cam and breather valve assemblies Apply a thin coating of red threadlock to the threads on Lubricate the pilot bearing in the crankcase and the end the pinion shaft.
Page 176 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Make sure that the timing marks of the breather valve Apply blue threadlock to the threads of the cam cover and camshaft gears are properly aligned. mounting screws. Install the cam cover and the seven screws around the perimeter of the cover.
Page 177 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6ƒfyvhf„pÁ7t„f„„pxgwÁfyiÁ 7t„f„„pxgw 4„„pxgw ® Mount the sprocket shaft holder, JIMS 1034, in a vise. Place the crankcase assembly, sprocket shaft down, in the holder. S€€w„Áƒp‚†tƒpi' 7/16" 12-point socket 1/2" 12-point socket Brass hammer Cam bearing tool, 97272-80-1 (available from ®...
Page 178 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 ® With the case bolts removed, tap the case with a brass Install the crank disassembly/removing tool, JIMS hammer to separate the halves and lift the right case half 1047-TP, on the left case half and tighten the mounting (pinion side) off the assembly.
Page 179 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Inspect the case alignment dowels for damage and 6wpfytyrÁfyiÁ y„ph…t€y secure fit in the case. Clean the right and left case halves in a suitable cleaning ® Apply a thin coating of Teflon thread dope to the drain solution to remove all oil, dirt and debris.
Page 180 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@ G8 Install the outer bearing and spacer on the output shaft, 4„„pxgw using the sprocket shaft bearing installation tool set, ® JIMS 97225-55, and the mainshaft sprocket locknut Inspect the flywheel and crankshaft assembly to make ®...
Page 181 8G@ G8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Lubricate and install the sprocket shaft spacer and Make sure that the connecting rods are centered in the position the seal in the case. The seal must be cylinder bores and place the right case half in position positioned with the rounded edge facing outward, away on the pinion shaft.
Page 182 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IQ F4QXÁ7Q U8 IQBF4QXÁ7QBU8ÁR8QUB68 IƒtxfƒÁ6sftyÁBy„ph…t€y The primary drive chain should be inspected and the primary housing lubricant should be drained and refilled at the first 500-mile (800 km) service interval and thereafter, at the 5,000-mile (8 000 km) service interval. Inspect the primary chain for excessive wear, looseness or damage.
Page 183 IQ F4QXÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IƒtxfƒÁ7ƒt‡pÁQpx€‡fwÁ Using a 3/16" hex bit, remove the 15 screws around the By„…fwwf…t€yÁfyiÁ4iu†„…xpy… perimeter of the outer primary drive housing. The primary chain, compensator and sprocket and clutch assembly and sprocket must be removed as an assembly.
Page 184 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IQ F4QXÁ7Q U8 Figure 346 — Chain tensioner assembly Loosen the chain tensioner nylock nut, using a 9/16" Slide the tensioner assembly down, to provide hex socket or wrench. maximum slack in the chain. Figure 347 — Removing chain tensioner nylock nut Figure 348 —...
Page 185 IQ F4QXÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Bend over the locking tabs from the two lower bolts. Working at the clutch end of the primary chain, remove Remove the two lower bolts, using a 7/16" wrench. the six clutch pressure plate retaining screws and Remove the upper nylock nut and washer.
Page 186 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IQ F4QXÁ7Q U8 Remove the clutch hub retaining nut, using a 1-3/16" Remove the starter motor drive pinion assembly from hex socket. the inner primary drive housing. Figure 353 — Remove clutch hub retaining nut Figure 355 —...
Page 187 IQ F4QXÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the inner primary drive housing from the y„…fwwf…t€y engine and transmission flanges. Slide the housing bearing evenly off the transmission input shaft. Install a new O-ring in the groove on the engine-to- inner primary housing mounting flange on the engine crankcase.
Page 188 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IQ F4QXÁ7Q U8 Tighten the six inner screws to specification, using a Slide the large spacer for the engine compensator 1/2" hex socket. To prevent the screws from backing sprocket onto the splines of the crankshaft and next to out, bend the tabs of the lock washers back over a flat the alternator rotor.
Page 189 IQ F4QXÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Install the clutch pressure plate onto the clutch hub and sprocket assembly. Correct application of threadlock to the compensator retaining nut must be achieved. Note: If the clutch friction and steel discs have been Applying excessive threadlock can cause an removed, refer to the CLUTCH SERVICE section for incorrect torque reading and cause severe binding...
Page 190 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IQ F4QXÁ7Q U8 Loosely tighten the two lower bolts into the chain Note: If the tensioner has been adjusted to its upper tensioner. Loosely install the nylock nut and washer limit and the chain cannot be properly adjusted, the onto the carriage bolt.
Page 191 IQ F4QXÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Position the outer housing to the inner housing and Make sure all fasteners and drain plug are tightened and install the 15 screws with washers. Apply blue that no leaks are evident. threadlock to the first four threads of the housing screws Reconnect the shift rod to the shift lever.
Page 192 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E IQ F4QXÁ7Q U8 • If needed, add shims to the transmission fifth nut TpƒÁ8yrtypÁF€†y…Á5€w…ÁS€ƒ‚†pÁRp‚†pyhp (17). Available sizes are: • Lightly snug the two engine mount bolts (18, 19). The engine mount must be loose enough to allow P/N: 97-001, 0.015"...
Page 193 Q84QÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Q84QÁ7QBU8ÁR8QUB68 QpfƒÁ7ƒt‡pÁ5pw…ÁBy„ph…t€yÁ To access the rear drive belt, remove the primary drive Qpx€‡fwÁfyiÁBy„…fwwf…t€y components, starter motor and other necessary components. y„ph…t€y The rear drive belt should be inspected and adjusted if necessary, at the first 500-mile (800 km) service interval and thereafter, at the 2,500-mile (4 000 km) service interval.
Page 194 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Q84QÁ7Q U8 Slip the rear drive belt over the wheel sprocket. y„…fwwf…t€y Slip the rear drive belt over the transmission sprocket. Align the cogs in the belt with the cogs in the sprocket. Figure 378 — Installing rear drive belt over wheel sprocket When reassembled, adjust the rear wheel alignment and Figure 376 —...
Page 195 Q84QÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Measure the center-to-center distance between the QpfƒÁVsppwÁ4wtryxpy… swing arm pivot bolt and the axle, using the alignment tool. The rear wheel must be correctly aligned before belt tension is adjusted. Remove the plastic thread protectors from the right-hand and left-hand axle adjusting studs.
Page 196 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Q84QÁ7Q U8 If adjustment is required, loosen or tighten the axle adjusting nuts on both sides equally, using a 1/2" In severe cases of excessive drive belt travel or wrench. This adjusts rear drive belt tension, while at the force, the belt can completely ride off the sprocket.
Page 197 Q84QÁ7Q U8 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 7ƒt‡pÁ5pw…ÁAfyiwtyrÁfyiÁR…€ƒfrp Similarly, DO NOT bend the belt backward (teeth spreading) in a circle any smaller than 10" in diameter. The rear drive belt is extremely durable when handled and installed properly. Damage can occur, however, if the incorrect tools are used to remove and install a belt or it is stored improperly.
Page 198 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6ETS6A 6ETS6AÁR8QUB68 The Indian Chief Vintage motorcycle is equipped with a wet-type clutch that is controlled by a hand lever (on left handlebar) and cable. The clutch assembly incorporates 9 steel discs sandwiched between 10 friction discs keyed to the rear drive sprocket.
Page 199 6ETS6A G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6w†…hsÁEp‡pƒÁ5ƒfhvp…ÁQpx€‡fwÁfyiÁ 4iu†„…xpy…ÁIƒ€hpi†ƒp y„…fwwf…t€y Raise the motorcycle to a comfortable working height, using a lift. The clutch lever bracket, clutch cable and mirror can easily be removed from the handlebar as an assembly. Place a drain pan under the primary drive housing under the drain plug.
Page 200 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6ETS6A Loosen the cable adjustment jam nut, using a 7/16" Grasp the cable end ferrule and pull it away from the wrench on the jam nut while holding the cable ferrule clutch lever bracket. At the same time, turn the cable nut with a 1/2"...
Page 201 6ETS6A G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Using a 3/16" hex bit, remove the chain adjuster access Qpx€‡fw cover from the outer primary housing and discard the gasket. Raise the motorcycle to a comfortable working height, using a lift. To remove the complete clutch assembly (clutch pack, hub and sprocket case), refer to the PRIMARY DRIVE SERVICE section for instructions.
Page 202 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6ETS6A Remove the pressure plate. Remove the judder spring and judder spring seat. Figure 397 — Removing pressure plate Figure 399 — Judder spring and seat Remove the 10 friction and 9 steel discs from the clutch Clean and inspect the discs, springs and pressure plate hub and sprocket case.
Page 203 6ETS6A G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Install the 10 friction discs and 9 steel discs, alternately, Place the pressure plate in position on the clutch hub. If on the hub. not already done, loosen the clutch adjuster jam nut and back out or remove the adjusting screw.
Page 204 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6ETS6A 6w†…hsÁ7t„f„„pxgwÁfyiÁ Apply blue threadlock to the five clutch cover screws. Place a new gasket in position on the clutch cover and 4„„pxgw install the cover. Tighten the cover screws to specification, using a 3/16" hex bit. If the complete clutch assembly (clutch pack, hub and sprocket case) has been removed, it can be serviced by cleaning, inspecting and replacing parts as required.
Page 205 6ETS6A G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Inspect the sprocket case for wear in the friction disc tab slots. Deep notches can prevent the discs from DO NOT remove the spiral lock ring and washer separating properly when releasing the clutch. Replace from the inside bore of the hub.
Page 206 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6ETS6A Figure 409 — Clutch assembly...
Page 207 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRFBRRBHGÁF4BGS8G4G68 Sƒfy„xt„„t€yÁRstq…Á6€y…ƒ€wÁ Loosen the shift lever pinch bolt, using a 1/4" hex bit. EtyvfrpÁFfty…pyfyhpÁfyiÁ Push the shift lever inward to create clearance between the inner primary housing and pivot bolt head. If this 4iu†„…xpy…...
Page 208 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Remove the rear pivot bolt, using a 3/16" hex bit. Note: It may be necessary to loosen the jam nut and adjust the shift rod length at the rear pivot to maintain adequate thread engagement at both socket ends.
Page 209 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E If adjustment is needed, loosen the locknut, using a The fill plug dipstick is located at the front on the 17 mm box-end wrench. chrome right-side housing cover. The magnetic drain plug is also located on the right side of the transmission, in the trapdoor just below the housing cover.
Page 210 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG If equipped, install the exhaust pipe-to-transmission Check the oil level on the dipstick. The level should be bracket and fasteners, using a 1/2" wrench and a 1/4" between the two notches on the dipstick. hex bit.
Page 211 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRFBRRBHGÁQ8FHU4EÁ4G7ÁBGRS4EE4SBHG When it is necessary, the transmission can be removed • If the transmission oil has been drained, remove from the chassis for overhaul or replacement. chrome clutch-control cover and secure it out-of-way.
Page 212 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Remove the shift rod rear pivot bolt, using a 3/16" hex Remove the starter motor. Refer to the STARTING bit. SYSTEM SERVICE section for the removal procedure. Figure 423 — Removing shift rod pivot bolt Figure 425 —...
Page 213 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Loosen the axle adjusting nuts at the ends of the swing Lift the transmission up from the mounting pad and arm, using a 1/2" wrench. The nuts should be loosened remove it from the motorcycle. in equal increments.
Page 214 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Place the transmission in position on the mounting pad, Install the inner primary housing and primary drive making sure the mounting studs are aligned with the assembly following the procedure in the PRIMARY holes and all shims are in place.
Page 215 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Install the fairings at each side of the rear swing arm Lower the motorcycle to the ground and remove the lift. stanchion. Install the left fairing first, then the right. Install the oil tank following the procedure in the LUBRICATION SYSTEM SERVICE section.
Page 216 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG SQ4GRFBRRBHGÁHU8QA4TE S€€w„Áƒp‚†tƒpi' 3/16" hex bit socket 1/4" hex bit 5 mm hex bit socket ® 1-7/8" socket available from JIMS 1-1/16" socket Internal retaining ring pliers External retaining ring pliers Arbor or hydraulic press ®...
Page 217 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the shift drum cover from the top of the Pull the shift pawl away from the pins in the shift drum. transmission, using a 3/16" hex bit socket. Lift the shift drum and end supports from the transmission housing.
Page 218 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Remove the drive sprocket nut using a 1-7/8" Mainshaft Loosen the nuts on the end of the mainshaft and ® Sprocket Locknut Wrench from JIMS and pneumatic countershaft, using a 1-1/16" socket. Do not remove the gun.
Page 219 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the mainshaft and countershaft with all the Remove the sprocket spacer from the splined gear (5th gears by pulling on the trapdoor. If the trapdoor is gear or main gear) protruding from the left side of ®...
Page 220 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG ® Remove the main bearing using a JIMS 5-Speed Main Bearing Remover or press. The bearing must be replaced after using this tool. Figure 451 — Removing main drive gear FftyÁ@pfƒÁÉ"…sÁ@pfƒÁQ€wwpƒÁ5pfƒtyrÁ Qpx€‡fwÁfyiÁQpwfhpxpy… Figure 453 —...
Page 221 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E ® The JIMS tool will set the seal to the correct depth. Figure 455 — Pressing in main bearing Figure 457 — Installing new main seal Install a new retaining ring with the sharp edge facing out, toward the main seal.
Page 222 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Place the mainshaft on the left side just as it came from FftyÁ@pfƒÁÉ"…sÁ@pfƒÁGppiwpÁ5pfƒtyrÁ the transmission. y„ph…t€yÁfyiÁQpwfhpxpy… Inspect both main gear (5th gear) needle bearings for pitting or grooving of the needles. Press both the bearings from the 5th gear, using a hydraulic press.
Page 223 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Slip 2nd gear and thrust washer from the countershaft Remove the 3rd gear retaining ring. and inspect each for damage. Figure 464 — Removing the 3rd gear retaining ring Remove the 3rd gear from the countershaft and inspect for damage.
Page 224 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Slip 2nd gear from the mainshaft and inspect for Gently pry the split cage roller bearing from the damage. mainshaft and inspect the needles for pitting or grooving. Figure 466 — Removing 2nd gear from mainshaft Remove the 3rd gear retaining ring and then, remove the thrust washer from the mainshaft.
Page 225 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Press the mainshaft from the trapdoor bearing, using Gently pry the split cage roller bearing from the ® JIMS Transmission Cover Bearing Remover and mainshaft and inspect the needles for pitting or Installer.
Page 226 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Lubricate the outside diameter of each new bearing. Place a retaining ring onto the mainshaft capturing 1st Orient the bearing to have the numbers legible from the gear, using snap ring pliers. outside of the trapdoor.
Page 227 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Slip 1st gear onto the countershaft with engagement 6€†y…pƒ„sfq… dogs first. Figure 481 — Countershaft {trapdoor end to right} Slip a thrust washer onto the countershaft from the trapdoor side of the shaft. Figure 484 —...
Page 228 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG By„…fwwf…t€yÁ€qÁRsfq…„Áty…€Á Sƒfi€€ƒ Ffty„sfq… Orient the trapdoor on the bench with the alignment pins down and the drain plug hole away from you. If ® available, place the trapdoor on the JIMS Transmission Cover Remover and Installer as an aid in assembly.
Page 229 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Slip 3rd gear onto the mainshaft with the engagement @pfƒÁR…fhvtyr dogs facing upward (away from trapdoor). Slip another thrust washer onto the mainshaft followed by a retaining Place the trapdoor on the bench with the shafts facing ring.
Page 230 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Slip a new split cage roller bearing onto the 6€†y…pƒ„sfq… countershaft. Slip 3rd gear onto the countershaft with the shift fork groove facing away from the trapdoor. Figure 496 — Installing split bearing onto countershaft Slip 2nd gear onto the countershaft with engagement Figure 494 —...
Page 231 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Slip 5th gear onto the countershaft followed by a With the shafts facing upward, lower the transmission retaining ring. case over the shafts. Align the mainshaft with the main gear and the countershaft with the needle bearing. Align 5th gear of the mainshaft to 5th gear of the countershaft.
Page 232 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Place a new square-cut seal onto the main drive gear (transmission output). Figure 504 — Installing spacer onto main drive gear Figure 501 — Square-cut seal Grease a new main drive gear seal on the inside and outside diameter.
Page 233 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Slip the driver over the guide and seat the seal, using a Tap the driver with a mallet until the seal is fully seated. ® hammer. The tool is designed to set the seal to a depth The JIMS driver sets the seal to the correct depth.
Page 234 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG Rstq…Á9€ƒvÁBy„ph…t€yÁfyiÁ Orient the transmission with the trapdoor to the left. By„…fwwf…t€y Load all forks with the pin facing you. Loading sequence is from left to right. Load the 4th gear fork onto the groove in 1st gear of the y„ph…t€y mainshaft.
Page 236 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRF RR HG If adjustment is needed, loosen the locknut, using a 6w†…hsÁ6€‡pƒÁ y„…fwwf…t€y 17 mm socket or box end wrench. Replace the clutch cable O-ring with a new one. Thread the clutch cable into the clutch cover. Figure 517 —...
Page 237 SQ4GRF RR HG G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Flip the ramp back over and place in the original Clean the threads of the sprocket nut and mating position within the housing. threads on the mainshaft with alcohol or brake cleaner. Apply red threadlock to the threads of the nut.
Page 238 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS4QS G@ÁRXRS8F RS4QSBG@ÁRXRS8FÁR8QUB68 @pypƒfwÁByq€ƒxf…t€y Procedures for removal and installation of system components are included in this section. Procedures for testing the system are included under Electrical System The starting system includes the starter motor, the drive Tests in the TROUBLESHOOTING section.
Page 239 RS4QS G@ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E R…fƒ…pƒÁ7ƒt‡pÁItyt€yÁ4„„pxgw Remove the 15 screws at the perimeter of the outer primary housing, using a 3/16" hex bit. Remove the outer housing half and discard the gasket. S€€w„Áƒp‚†tƒpi' 3/16" hex bit 5/16" hex bit 7/16"...
Page 240 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS4QS G@ÁRXRS8F Install a new gasket and install the outer primary 7ƒt‡pÁItyt€yÁ y„…fwwf…t€y housing and retaining screws, using a 3/16" hex bit. Tighten the screws to specification. Place the drive pinion and shaft assembly (pinion, spring, coupling, snap ring and shaft) in the inner Apply blue threadlock to the shift rod screw.
Page 241 RS4QS G@ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Disconnect the battery positive cable from the solenoid R…fƒ…pƒÁ y„…fwwf…t€y terminal, using a 12 mm socket. Disconnect the start switch wire lead at the solenoid terminal by unplugging Place the starter motor in position against the the spade terminal.
Page 242 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RS4QS G@ÁRXRS8F R…fƒ…pƒÁR€wpy€ti S€€w„Áƒp‚†tƒpi' 5/32" hex bit S€€w„Áƒp‚†tƒpi' Small flat-blade screwdriver 3/8" wrench/socket R…fƒ…pƒÁQpwfÁQpwfhpxpy… 12 mm wrench/socket Remove the seat from the motorcycle following the Flat-blade screwdriver procedure in the FRAME AND ACCESSORIES SERVICE section. R€wpy€tiÁQpx€‡fw Disconnect the battery cables at the battery terminals, Disconnect the battery ground cable from the negative...
Page 243 6A4Q@ G@ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4Q@BG@ÁRXRS8FÁR8QUB68 @pypƒfwÁByq€ƒxf…t€y Battery fluid contains sulfuric acid. Do not allow The charging system includes the alternator assembly, a this fluid to come in contact with eyes, skin or transistorized voltage regulator, the battery and cables, clothing.
Page 244 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4Q@ G@ÁRXRS8F 4w…pƒyf…€ƒÁQpwfhpxpy… Disconnect and remove the battery hold-down strap from the battery box. Remove the battery from the motorcycle. S€€w„Áƒp‚†tƒpi' 5/32" hex bit 3/16" hex bit 5/16" hex bit 9/16" socket 3/4" wrench and/or socket 1-1/2"...
Page 245 6A4Q@ G@ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the 15 screws at the perimeter of the outer Using a 1-1/2" socket, remove the compensator retaining primary housing, using a 3/16" hex bit. Remove the nut and remove the assembly from the sprocket shaft. outer housing half.
Page 246 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4Q@ G@ÁRXRS8F Using a 3/32" hex bit, loosen the set screw retaining the Install the inner primary drive housing, the starter motor connector in the engine crankcase. Push the stator and drive pinion and the primary drive chain, sprockets connector through the crankcase flange and remove the and tensioner.
Page 247 6A4Q@ G@ÁRXRS8F G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E U€w…frpÁQpr†wf…€ƒÁQpwfhpxpy… Disconnect the regulator battery wire leads at the connector under the frame crossmember at the front engine mount. The regulator is a non-serviceable part. If it is faulty, it must be removed and replaced. Using a 7/16"...
Page 248 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4RR RÁ8E86SQ 64E IHV8QÁ7BRSQB5TSBHGÁEB@ASBG@Á4G7ÁBGRSQTF8GSÁR8QUB68 8wph…ƒthfwÁ8‚†txpy…Á6sphv Toggle the Engine Stop switch to the RUN position. Make sure the green transmission neutral light is on. Pull the clutch lever in and quickly depress the START The ignition key switch controls the ignition and lights button.
Page 249 6A4RR RÁ8E86SQ 64E G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E The four circuit breakers that are an integral part of the 7f„sÁQpx€‡fw electronic control module are not replaceable. If there is a fault in any one of the four, there is a problem with To gain access to the speedometer and warning lights, the control module, and the module must be replaced as the dash panel must be removed.
Page 250 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4RR RÁ8E86SQ 64E AfyiwpgfƒÁRˆt…hsÁQpwfhpxpy… Rppi€xp…pƒ To remove the speedometer assembly, place the dash The following procedure covers the replacement of an panel upside down on the pad. Remove the two nuts individual switch in one of the switch housings as well retaining the assembly in the instrument bezel, using a 9 as the replacement of a complete switch and harness mm wrench.
Page 251 6A4RR RÁ8E86SQ 64E G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Remove the throttle/switch housing screws, using a Tighten the two housing mounting screws, using a 5/32" hex bit. Slowly remove the top housing half and 5/32" hex bit. then remove the small ferrules to disconnect the throttle Again, check for proper throttle rotation.
Page 252 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4RR RÁ8E86SQ 64E Match the wires from the switch to the proper harness Cut the nylon tie strap, release the tabs and lift the wire ends. Twist the wires together and solder the joint, electronic control module from its housing. using rosin core solder.
Page 253 6A4RR RÁ8E86SQ 64E G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Loosen and remove the mounting screws and clamp When the harness terminal ends clear the opening at the securing the brake lever assembly and/or the clutch handlebar grip, disconnect and remove the harness from control assembly, using a 5/32"...
Page 254 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4RR RÁ8E86SQ 64E By„…fwwtyrÁ…spÁQtrs…ÁAfyiwpgfƒÁRˆt…hsp„ Carefully place the top housing section onto the bottom section. Install the two mounting screws and tighten Install the switches (start, engine stop, turn signal and very lightly. Align the switch housing so that the parting brake light) in the respective housing sockets and install line is parallel with the ground and tighten the two the retaining brackets, using a Phillips screwdriver.
Page 255: General Data
RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4RRBRÁRI86B B64SBHGRÁ4G7ÁSHQPT8ÁU4ET8R 7txpy„t€y„ÁfyiÁVptrs… Item Specification Dry weight 733 lbs. (332 kg) GVWR 1257 lbs. (570 kg) GAWR Front: 474 lbs. (215 kg), Rear: 783 lbs. (355 kg) Seat height 28.5 in. (724 mm) Ground clearance 6.7 in.
Page 256 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR Vsppw„ÁfyiÁStƒp„ GENERAL DATA Item Description/Specification Wheels 3.5 in. x 16 in., 60-spoke (front and rear) Tires Maxxis whitewall MT90 16F 74H TL (front and rear) Inner tube Maxxis 5.00/5.10 In.-16. Tire inflation pressure (cold) Maxxis: With single rider —...
Page 257 RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 9ƒfxpÁfyiÁ4hhp„„€ƒtp„ÁS€ƒ‚†pÁUfw†p„ FASTENER TORQUE Part Torque Values Buddy pegs (if equipped) 78 ft-lbs Center fairing screws 6–9 in-lbs Clutch cable guide screw 22 in-lbs Dash panel mounting screws 5 ft-lbs Floorboard retaining nut 22 in-lbs Foot control mounting screws (left and right) 30–35 lbs...
Page 258 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR 8G@BG8ÁRI86B B64SBHGR @pypƒfw GENERAL DATA Item Description/Specification Engine type 4-cycle, 45-degree V Number of cylinders Bore and stroke 3.875 in. x 4.25 in. Displacement 100 cu-in Compression ratio Pre #1908 engine Post #1908 Engine 9.5:1 9.2:1...
Page 259 RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6wtyipƒÁApfiÁfyiÁUfw‡p„ Item Standard Fit Wear Limits Cylinder head displacement range • Pre #1800 engine 82–83 cc — • Post #1800 engine 86–87 cc — Cylinder head flatness (gasket surface) 0.003 in. 0.005 in.
Page 260 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR HtwÁI†xÁ4„„pxgw Item Description/Specification Oil pressure (at normal operating temperature and 2000 rpm) 12–35 psi 6ƒfyvhf„p Item Standard Fit Wear Limits Breather valve gear end play 0.008–0.032 in. Exceeds 0.037 in. Camshaft bearing race-to-crankcase (press fit) 0.0005–0.0010 in.
Page 261 RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8yrtypÁ9f„…pypƒÁS€ƒ‚†pÁUfw†p„ Part Torque Value Air filter element back plate screws 19–24 ft-lbs Airbox assembly nuts 17–19 ft-lbs Airbox evaporator door retaining screws (to shaft) 17–19 ft-lbs Airbox housing cover retaining screws 19–24 in-lbs Airbox housing retaining nuts 5 ft-lbs...
Page 262 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR Part Torque Value Petcock (fuel fitting at tank) 30 ft-lbs Pinion gear nut 40 ft-lbs Pinion shaft nut 170 ft-lbs Plug (in rocker cover) 8–12 ft-lbs Rocker base mounting screws 8–12 ft-lbs Rocker shaft support bracket screws 16–20 ft-lbs Spark plugs...
Page 263 RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 7QBU8SQ4BGÁRI86B B64SBHGRÁ4G7ÁSHQPT8ÁU4ET8R IƒtxfƒÁ6w†…hsÁfyiÁ9tyfwÁ7ƒt‡p GENERAL DATA Item Description/Specification Primary drive Chain drive with a wet clutch; 1.54:1 ratio Engine sprocket 24 teeth Clutch sprocket 37 teeth Final drive Belt drive; 2.03:1 ratio Transmission sprocket 32 teeth Rear wheel sprocket...
Page 264 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR Sƒfy„xt„„t€yÁRphtqthf…t€y„ÁfyiÁS€ƒ‚†pÁUfw†p„ GENERAL DATA Reference Mainshaft Countershaft Ratio 1st gear 18 teeth 31 teeth 3.24:1 2nd gear 23 teeth 27 teeth 2.21:1 3rd gear 27 teeth 23 teeth 1.60:1 4th gear 19 teeth 29 teeth 1.23:1 5th gear...
Page 265 RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8E86SQB64EÁ6HFIHG8GSÁ 4RS8G8QÁRI86B B64SBHGR FASTENER TORQUE Item Torque Value Battery box bracket screws 17–19 ft-lbs Battery box screws 17–19 ft-lbs Battery terminal screws 60 in-lbs Circuit breaker stud nut 18–20 in-lbs Coil/cover mounting screws 12–14 ft-lbs Ground cable terminal screw (to frame) 17–19 ft-lbs...
Page 266 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR ET5QB64GSRÁ4G7Á ETB7R Part Specified Lubricant or Fluid Quantity Engine oil 20W-50 SG weight 3 qts. (2.84 L) with filter Transmission oil 80–90 weight 20–24 U.S. ozs. (670–720 cc) Fork oil 10 weight (165 sus @ 100°F) Dry: 10.1 U.S.
Page 267 RI86 9 64S HGR G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6sf„„t„Á4„„pxgw Part Specified Lubricant or Sealant Airbox assembly nut threads Blue threadlock Airbox housing retaining nut threads Blue threadlock Battery box bracket screw threads Blue threadlock Battery box mounting screw threads Blue threadlock Battery terminal screws Di-electric grease...
Page 268 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86 9 64S HGR Part Specified Lubricant or Sealant Saddlebag mounting bracket bolt threads Blue threadlock Saddlebag mounting screw threads Blue threadlock (small amount) Seat mounting screw threads (side and rear) Blue threadlock Shift rod jam nut threads Blue threadlock Sissybar retaining screw threads Blue threadlock...
Page 269 R6A8F4S 6R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 6A4RRBRÁVBQBG@Á7B4@Q4FR Figure 552 — Front chassis harness diagram...
Page 270 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E R6A8F4S 6R Figure 553 — Rear chassis harness diagram...
Page 271 R6A8F4S 6R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E B@GBSBHGÁRXRS8FÁ7B4@Q4F Figure 554 — POWERPLUS™ 100 engine ignition system...
Page 272 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E R6A8F4S 6R ET5QB64SBHGÁ EHVÁ7B4@Q4F Figure 555 — POWERPLUS™ 100 engine lubrication system ™ In the POWERPLUS 100 engine lubrication system, the From the breather valve, the oil is sprayed into the cam pump draws oil from the tank and supplies the oil to the gearcase to lubricate the cam and pinion gears.
Page 273 R6A8F4S 6R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SQ4GRFBRRBHGÁIHV8QÁ EHVÁ7B4@Q4FR ByitfyÁ"RppiÁSƒfy„xt„„t€y The 5-speed is a single-countershaft transmission with an output drive gear that rotates freely on the mainshaft input. Both the mainshaft and countershaft incorporate free-rotating gears that are engaged or disengaged by sliding gears splined to the shafts.
Page 274 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E R6A8F4S 6R 3rd gear — In 3rd gear, the countershaft sliding 3rd 5th gear — On the mainshaft, the sliding 1st gear is gear is disengaged from other countershaft gears. disengaged from the 4th gear and the sliding 2nd gear is However, on the mainshaft, the sliding 2nd gear is moved into engagement with the output drive gear for moved into engagement with the 3rd gear, allowing...
Page 275 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 8G@BG8ÁI4QSÁ4G7Á4RR8F5EXÁ7Q4VBG@R Figure 562 — Intake manifold Item Part Number Part Description Qty. 01-396 Intake manifold 01-212 Flange, intake 01-213 D-ring, intake 96-142 Screw, socket head, 5/16"-18 x 7/8" 01-217 Mounting flange 96-822 Bolt, hex head, 5/16"-18 x 1-1/4" 97-005 Nut, hex nylock, 5/16"-18 01-149...
Page 276 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 563 — Intake manifold Item Part Number Part Description Qty. 02-284 Nut, 1/4"-20, 12 pt...
Page 277 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 564 — Crankcase Item Part Number Part Description Qty. 01-001 Engine case Race, right case 01-017 Plug, case drain 29-101 Hose fitting, 90° 01-189 Oil filter bung 01-106 Bearing cam, inner 01-060 Dowel pin, 1/4"...
Page 278 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Item Part Number Part Description Qty. 01-282 Bolt, 1/4"-28 x 5.38" 01-285 Bolt, 5/16"-24 x 5.07" 01-283 Nut, 5/16"-24 96-894 Washer, flat 1/4" 96-394 Nut, 1/4"-28 01-090 Switch, oil pressure 01-085 Screen, tappet 01-086 Spring, tappet screen 01-087...
Page 279 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 565 — Crankcase Item Part Number Part Description Qty. 01-003 Cylinder stud, 3/8"-16 x 6" 94-033 Rotor, alternator 94-035 Stator, alternator 96-965 Screw, socket head, 10-24 x 1"...
Page 280 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 566 — Crankcase Item Part Number Part Description Qty. 29-101 Hose fitting, 90° 01-280 Bolt, 5/16"-24 x 5.63" 01-282 Bolt, 1/4"-28 x 5.38" 01-285 Bolt, 5/16"-24 x 5.07"...
Page 281 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 567 — Flywheel assembly Item Part Number Part Description Qty. 01-030 Flywheel set 01-031 Shaft, left side (output) 01-033 Nut, sprocket shaft 01-034 Nut, pinion shaft 01-035 Key, right shaft & crank pin 01-036 Key, shaft (left flywheel) 01-912...
Page 282 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 568 — Camshaft gearcase cover Item Part Number Part Description Qty. 01-252 Gasket, cam cover 97-121 Screw, socket head, 1/4"-20 x 3/4" 97-120 Screw, socket head, 1/4"-20 x 1-1/4" 01-254 Gasket, ignition cover 00-033 Ignition rotor 96-290...
Page 283 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 569 — Camshaft and breather valve Item Part Number Part Description Qty. 01-081 Key, gear case 01-048 Gear, oil pump 01-049 Spacer, oil pump drive gear 01-068 Gear, pinion (red) 01-064 Nut, pinion gear 01-097-01 Cam shim (0.050") 01-097-02...
Page 284 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 570 — Camshaft gearcase cover Item Part Number Part Description Qty. 01-905 Base assembly, cam cover 01-134 Cam cover, outer 01-251 Seal, cam cover 01-056 Form ring, bottom 01-057 Form ring, middle 01-058 Form ring, top 01-141...
Page 285 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 571 — Oil pump Item Part Number Part Description Qty. 01-262 Gasket, oil pump 29-101 Hose fitting, 90° 96-879 Screw, socket head, 1/4"-20 x 1-3/4" 96-828 Elbow, barbed hose...
Page 286 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 572 — Oil pump and filter mounting Item Part Number Part Description Qty. 96-021 Oil filter...
Page 287 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 573 — Front lifter block assembly Item Part Number Part Description Qty. 01-926 Lifter block, front 01-179 Gasket, lifter block (front) 01-180 Lifter 96-013 Screw, socket head, 1/4"-20 x 7/8" 01-167 Pushrod cover assembly 01-191 Clip, pushrod cover...
Page 288 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 574 — Rear lifter block assembly Item Part Number Part Description Qty. 01-925 Lifter block, rear 01-178 Gasket, lifter block (rear) 01-180 Lifter 96-013 Screw, socket head, 1/4"-20 x 7/8" 01-167 Pushrod cover assembly...
Page 289 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 575 — Front cylinder head assembly Item Part Number Part Description Qty. 01-236 Front head assembly 01-145 Intake valve, 1.940" 01-150 Exhaust valve, 1.610" 01-165 Stud, exhaust port 01-256 Gasket, head 01-261 Valve seal 01-160 Valve spring set...
Page 290 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 576 — Rear cylinder head assembly Item Part Number Part Description Qty. 01-237 Rear head, assembly 01-150 Exhaust valve, 1.610" 01-165 Stud, exhaust port 01-256 Gasket, head 01-160 Valve spring set 05-002 Spark plug 01-159 Keepers...
Page 291 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 577 — Cylinder head installation Item Part Number Part Description Qty. 01-170 Head bolt, long 01-171 Head bolt, short...
Page 292 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 578 — Front cylinder rocker assembly Item Part Number Part Description Qty. 01-257 Gasket, lower right 01-258 Gasket, lower left 01-260 O-ring, small 96-296 Screw, socket head, 1/4"-20 x 7/8" 96-297 Screw, socket head, 5/16" x 18 x 1-3/4" 01-259 O-ring, large 97-121...
Page 293 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 579 — Rear cylinder rocker assembly Item Part Number Part Description Qty. 01-257 Gasket, lower right 01-258 Gasket, lower left 01-260 O-ring, small 96-296 Screw, socket head, 1/4"-20 x 7/8" 96-297 Screw, socket head, 5/16"-18 x 1-3/4" 01-259 O-ring, large 97-121...
Page 294 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 580 — Rocker shafts Item Part Number Part Description Qty. 01-151 Rocker arm assembly (front cylinder exhaust, rear cylinder intake) 01-152 Rocker arm assembly (front cylinder intake, rear cylinder exhaust) 96-298 Screw, socket head, 5/16"-18 x 2" 96-297 Screw, socket head, 5/16"-18 x 1-3/4"...
Page 295 4RR8F5EXÁ7Q4V G@R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E Figure 581 — Rocker covers Item Part Number Part Description Qty. 01-290 Gasket, breather housing 01-321 Seal, O-ring 01-325 Plug, stainless 01-318 Valve umbrella 96-965 Screw, socket head, 10-24 x 1"...
Page 296 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E 4RR8F5EXÁ7Q4V G@R Figure 582 — Engine assembly...
Page 297 SHHERÁ4G7Á8PT IF8GS G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E RI86B4EÁSHHER ® JIMS Tool No. Description (unless specified otherwise) Cam bearing tool (use with 33416-80-1) 97272-60 Cam cover puller (Fabricate locally) Crank disassembly removing tool 1047-TP Engine stand 1006T Flywheel rebuilding jig 1071 (Rowe HD 09-1194) Ignition diagnostic kit with software and cable IMC No.
Page 298 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E SHHERÁ4G7Á8PT IF8GS S€€wÁ7ƒfˆtyr„ The following drawings provide dimensions for ® fabricating a cam cover puller and modifying JIMS piston lock ring tools. Figure 583 — Cam cover puller dimensions ® Figure 584 — Modification to JIMS piston lock ring tools 96780-58A-2 and 96781-72-2...
Page 299 GHS8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E...
Page 300 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E G78W ACCELERATOR PUMP ....115 CARBURETOR TROUBLESHOOTING ..17 ACCELERATOR PUMP NOZZLE ..119 CASE NEEDLE BEARING INSPECTION ADJUSTING JET NEEDLE E-RING AND REPLACEMENT .
Page 301 G78W G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E CYLINDER LEAKAGE TEST ... 11 EVAPORATIVE SYSTEM CHECKS ..12 DASH INSTALLATION ....241 EXHAUST HEADER REMOVAL AND DASH REMOVAL .
Page 302 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E G78W FRONT FENDER TIP REMOVAL AND IGNITION COVER HOUSING/ROTOR INSTALLATION ....94 REMOVAL AND FRONT FORK AND SUSPENSION TORQUE INSTALLATION .
Page 303 G78W G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E OTHER VOLTAGE DROP TESTS ..31 REPAIR ......101 PILOT JET .
Page 304 G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E G78W SPARK PLUG REPLACEMENT ..124 TIGHTENING LOOSE SPOKES (FRONT SPARK PLUG WIRE REMOVAL AND AND REAR WHEELS) ... . . 61 INSTALLATION .
Page 305 GHS8R G7 4GÁ6A 89ÁU GS4@8ÁR8QU 68ÁF4GT4E...

Indian Motorcycle 2003 Chief Vintage Service Manual

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Summary of Contents for Indian Motorcycle 2003 Chief Vintage

Page 19: Troubleshooting

Page 47: Frame And Accessories Service

Page 58: Charging System Service

Page 255: General Data