Indian Motorcycle Roadmaster 2003 Manuals

Manuals and User Guides for Indian Motorcycle Roadmaster 2003. We have 1 Indian Motorcycle Roadmaster 2003 manual available for free PDF download: Service Manual

Indian Motorcycle Roadmaster 2003 Service Manual

Indian Motorcycle Roadmaster 2003 Service Manual (298 pages)

Brand: Indian Motorcycle | Category: Motorcycle | Size: 110 MB

Table of Contents

Foreword
3
- Organization and Content
  3
- Table of Contents
  5
- Finding the Information You Need
  11
- Features of the 2003 Indian Chief Motorcycle
  11
  - Component and System Descriptions
    11
- Motorcycle Identification
  14
  - Chassis VIN
    14
  - Engine Serial Number
    15
  - Transmission Serial Number
    15
Maintenance

15
- Maintenance Service, Repairs and Safety
  15
- Maintenance
  17
  - Primary Service
    17
  - Interval Service
    17
  - Renewal Service
    18
Troubleshooting

19
- Chassis Troubleshooting
  19
  - Brakes
    19
  - Chassis
    19
- Engine Troubleshooting
  20
  - Symptom-Related Diagnostics
    20
  - Basic Engine Tests
    21
- Emission Control System Troubleshooting
  22
  - Evaporative System Checks
    22
- Ignition System Troubleshooting
  22
  - Spark Plug Condition
    22
  - Electronic Ignition Diagnostics
    22
- Carburetor Troubleshooting
  27
- Transmission and Drive Troubleshooting
  30
  - Transmission
    30
  - Clutch
    30
- Electrical Troubleshooting
  32
  - Electrical Troubleshooting Tables
    32
  - Battery Testing
    33
  - Battery Charging
    33
  - Ground Path Tests
    34
  - Current Draw/Leak Test
    35
  - Rectifier/Regulator Current Leak Test
    35
  - Charging System Tests
    36
  - Starting System Tests
    38
  - Wiring Circuit Tests
    38
Front Suspension

42
- Front Suspension Service
  42
  - General Information
    42
  - Fork Oil Replacement
    43
  - Fork Tube Procedures
    43
Steering Components

48
- Steering Component Service
  48
Rear Suspension

57
- Rear Suspension Service
  57
  - Shock Absorber
    57
  - Swingarm
    60
Wheels and Tires

62
- Wheel and Tire Service
  62
- Wheel Lacing
  75
  - Lacing 16-Inch, 60-Spoke Wheels
    75
  - Aligning the Hub and Rim (Truing)
    77
Brake System

79
- Brake System Service
  79
Frame and Accessories

93
- Frame and Accessories Service
  93
Air Cleaner

105
- Air Cleaner and Filter Element Service
  105
  - Air Filter Element
    106
Fuel System

110
- Fuel System Service
  110
- Carburetor Service
  117
  - Carburetor Circuit Description
    117
  - Air Leaks
    119
  - Carburetor Removal and Installation
    119
  - Carburetor Maintenance
    121
  - Carburetor Illustrations
    123
Ignition System

127
- Ignition System Service
  127
Lubrication System

129
- Lubrication System Service
  129
Emission Control System

134
- Emission Control System Service
  134
Exhaust System

136
- Exhaust System Service
  136
  - Muffler, Heat Shields and Exhaust Header
    136
Engine

137
- Engine Removal and Installation
  137
- Engine Disassembly and Assembly
  144
Primary Drive

174
- Primary Drive Service
  174
Rear Drive

185
- Rear Drive Service
  185
Clutch

190
- Clutch Service
  190
  - Clutch Lever and Cable
    190
  - Clutch Inspection and Adjustment
    191
  - Clutch Plate Removal and Installation
    193
  - Clutch Disassembly and Assembly
    196
Transmission

199
- Transmission Maintenance
  199
  - Transmission Shift Control Linkage Maintenance and Adjustment
    199
  - Transmission Oil Change
    201
- Transmission Removal and Installation
  203
  - Transmission Removal
    203
  - Transmission Installation
    205
- Transmission Overhaul
  208
  - Tools Required
    208
  - Transmission Disassembly
    208
  - Installation of Shafts into Trapdoor
    220
  - Shift Fork Inspection and Installation
    226
Starting System

230
- Starting System Service
  230
  - General Information
    230
  - Starter Drive Pinion Assembly
    231
  - Starter Motor
    232
  - Starter Solenoid
    234
  - Starter Relay
    234
Charging System

235
- Charging System Service
  235
  - General Information
    235
  - Battery and Cables
    235
  - Alternator Replacement
    236
  - Voltage Regulator Replacement
    239
Chassis Electrical

240
- Power Distribution, Lighting and Instrument Service
  240
  - Electrical Equipment Check
    240
  - Circuit Breaker Replacement
    240
  - Speedometer and Warning Light Replacement
    241
  - Road Light Replacement
    242
  - Handlebar Switch Replacement
    242
  - Circuit Wiring Repair
    246
Specifications

247
- Chassis Specifications & Torque Values
  247
  - Brakes
    247
  - Wheels and Tires
    247
  - Front Fork and Suspension
    248
  - Rear Swingarm and Suspension
    248
  - Frame and Accessories
    249
- Engine Specifications & Torque Values
  250
  - General
    250
  - Fits and Tolerances
    250
  - Fastener Torque Values
    253
- Drivetrain Specifications & Torque Values
  255
  - Primary, Clutch and Final Drive
    255
  - Transmission
    256
- Electrical Component Fastener Specifications & Torque Values
  257
- Lubricants and Sealants
  258
  - Engine Assembly
    258
  - Chassis Assembly
    258
Schematics

260
- Chassis Wiring Diagrams
  260
- Ignition System Diagram
  263
- Lubrication Flow Diagram
  263
- Transmission Power Flow Diagrams
  264
  - Indian 5-Speed Transmission
    264
Assembly Drawings

267
- Engine Part and Assembly Drawings
  267
Tools and Equipment

289
- Special Tools
  289
  - Tool Drawings
    290

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