Indian motorcycle 2017. Service Manual

4.12

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

SSEENNSSOORRSS —

— PPOOW

WEERRTTRRAAIINN M

MAANNAAGGEEM

MEENNTT

NUMBER

SENSOR / LOCATION

TORQUE (IF

APPLICABLE)

TPMS (Tire Pressure Monitoring System) — Sensor located 180° from valve
stem

44 in-lbs (5 Nm)

Wheel Speed Sensor, Rear — Located at the rear caliper carrier

96 in-lbs (11 Nm)

ECM (Engine Control Module) — Located inside the lower RH side cover,
behind the drive sprocket

—

Fuse Box — Located inside the LH upper side cover. NOTE: High current J-Case
Fuse Box located behind battery box

—

ABS (Anti-Lock Brake) Module — Located in front of the rear tire

—

Canister Purge Valve (CA models only) — Located inside the RH upper side
cover

—

Oil Pressure Switch — Located at the rear of the LH engine case

88 in-lbs (10 Nm)

Gear Position Switch — Located inside the drive sprocket cover, below the
drive sprocket

43 in-lbs (5 Nm)

Oxygen Sensor, Rear — Located on the rear head pipe

14 ft-lbs (19 Nm)

Side Stand Switch — Located behind the side stand hinge

43 in-lbs (5 Nm)

CPS (Crank Position Sensor) — Located on the front of the engine by the oil
filter

89 in-lbs (10 Nm)

Oxygen Sensor, Front — Located on the front head pipe

14 ft-lbs (19 Nm)

Detonation “Knock” Sensor — Located on the rear face of the front cylinder
heat sink

15 ft-lbs (20 Nm)

CHT (Cylinder Head Temperature) Sensor — Located on the rear face of the
front cylinder head

71 in-lbs (8 Nm)

Fuel Injectors — Located at the cylinder head intake ports

—

Ignition coil — Located behind the horn assembly on the RH side of the engine

84 in-lbs (10 Nm)

TMAP — (Temperature / Manifold Absolute Pressure) Sensor — Located on the
back side of the intake manifold

62 in-lbs (7 Nm)

FUEL DELIVERY / EFI

4.13

FFUUEELL DDEELLIIVVEERRYY SSEERRVVIICCEE

IINNTTAAKKEE M

MAANNIIFFOOLLDD,, RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.

Remove the fuel tank. See Fuel Tank Removal,
page 4.15.

Remove the air box / throttle body assembly. See
Air Box Removal, page 3.4.

Remove the fuel injectors. See Fuel Injector,
Removal / Installation, page 4.42.

Loosen the two clamps

securing the intake

manifold to the rubber boots at the front and rear
cylinders.

Remove the four fasteners securing the intake
boots to the cylinder head.

Rotate the air box mounting flange up as shown
and remove the intake manifold from the engine.

INSTALLATION is performed by reversing the
removal procedure.

Torque the intake manifold clamps and boots to
specification.

TORQUE

Intake Manifold Clamps:

20 in-lbs (2 Nm)

TORQUE

Intake Manifold Boots:

89 in-lbs (10 Nm)

FFUUEELL PPUUM

MPP PPRREESSSSUURREE IINNSSPPEECCTTIIOONN

WARNING

Gasoline is extremely flammable. Work in a well

ventilated area. Open flames, sparks and cigarettes

must be kept away from gasoline. KEEP GASOLINE

OUT OF THE REACH OF CHILDREN!

CAUTION

Wear safety glasses or a face shield when working

around the fuel system to protect your eyes.

Depressurize fuel system and disconnect fuel line
at fuel rail. SeeFuel System Depressurization, page
4.14 .

Install fuel pressure gauge

PU-43506– A

and fuel

pressure gauge adapter

PV-48656

Start engine and record fuel pressure (or press the
power switch ON and cycle the Engine Stop switch
to read pressure when pump cycles for 2-3
seconds).

Minimum Fuel pressure 3.51 BAR (351 kPa) (51

psi)

FUEL DELIVERY / EFI

4.14

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

Turn ignition switch off. Disconnect gauge adapter
and re-connect fuel line (Fuel Tank Installation,
page 4.19).

FUEL PRESSURE TROUBLESHOOTING

FUEL PRESSURE TOO

LOW: INSPECT

FUEL PRESSURE TOO

HIGH: INSPECT

* Low fuel level (add
fuel)
* Pump not running
(Fuel pump or circuit
malfunction)
* Restricted fitting, fuel
supply line, or gauge
adapter hose
* Fuel line kinked or
restricted (from tank
fitting to rail)
* Fuel line leaking
(leaking air in or fuel
out)
* Vent restriction
* Plugged fuel pickup
filter (located in fuel
tank)
* Pressure regulator
malfunction (located on
pump)
*Fuel pump malfunction
(Pump should run for
about 2 seconds the
instant that the key
switch and Engine Stop
switch are turned ON.

* Plugged fuel return
(in tank on pressure
regulator)
* Pressure regulator
malfunction (located
on pump).

FFUUEELL SSYYSSTTEEM

M DDEEPPRREESSSSUURRIIZZAATTIIOONN

WARNING

Allow engine and exhaust to cool completely before

disconnecting fuel line or removing tank. Wear eye

protection.

Remove the horn. See Horn Removal / Installation,
page 10.56.

Wrap a clean shop towel around fuel line fitting

Squeeze both release buttons (one on each side of
fitting) and hold. Gently slide fitting straight off
fuel rail.

Cover fuel fittings to keep debris out.

FUEL DELIVERY / EFI

4.15

FFUUEELL TTAANNKK RREEM

MOOVVAALL

WARNING

Allow engine and exhaust to cool completely before

disconnecting fuel line or removing tank. Protect fuel

tank finish when removing, storing, and installing

tank.

Be prepared to place the fuel tank in a secure location
with a drain pan positioned to catch any fuel that may
leak or drip from disconnected hoses or fittings.

1. Remove seat. See Seat, Removal / Installation -

Classic / Vintage / Chieftain, page 7.21

2. Remove the two fasteners

, washer and rubber

isolator at the rear of the fuel tank.

3. Lift

the

rear

the

tank

and

slide

back

approximately 2” to expose the front console cover
fastener.

4. Remove console cover fasteners

and the plastic

dart

•

Chieftain / Roadmaster

For these models the front fastener does not have
to be removed. Remove rear fastener and slide
console forward to release it from the front
mounting grommet.

5. Disconnect electrical connectors at the security

light, central locking and system power buttons
and remove console cover.

6. Disconnect the fuel pump electrical connector

and the evaporative vent line

7. With a shop rag wrapped around the fuel fitting,

remove the fuel line

from the fuel pump.

FUEL DELIVERY / EFI

4.16

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

8. Lift the rear of the fuel tank and slide rearward to

release from the front isolators.

9. Lift the tank off of the motorcycle and store safely.

FFUUEELL PPUUM

MPP RREEM

MOOVVAALL

WARNING

Replace all mounting fasteners and pump seal O-ring

any time pump is removed for service. Do not kink or

bend fuel pickup hose upon removal. Review

gasoline warnings outlined in the beginning of this

chapter. See EFI System Precautions, page 4.5.

CAUTION

Be careful when performing this procedure to avoid

damaging the fuel level float arm, jet pipe, fuel

pump, electrical wiring, or hoses when removing the

pump assembly. Always inspect wires and hoses

closely for damage after removing the fuel pump.

1. Remove the console cover from the fuel tank. See

STEPS 1–5 of Fuel Tank Removal, page 4.15.

2. Disconnect the fuel pump electrical connector and

move out of the way.

3. Disconnect the fuel tank vent line

by sliding the

rubber elbow off of the fitting.

4. Wrap a shop rag around the fuel supply line

connector

and disconnect from fitting.

5. Remove fuel pump access cover nuts

in an

alternating or “star” pattern.

6. Raise the fuel pump access cover enough to

disconnect the fuel pump electrical connector and
the supply line

FUEL DELIVERY / EFI

4.19

FFUUEELL TTAANNKK IINNSSTTAALLLLAATTIIOONN

Place a protective cloth on the front of the tank when
assembling tank to frame.

Install fuel cap assembly if removed.

Install the inner isolator / spacer assemblies

the rear fuel tank mounts as shown.

Verify that forward tank isolators

are in position

on the frame mounts and lower tank into position.
DO NOT slide forward into position at this time.

Connect the fuel pump electrical connector

vent line

and fuel supply line

Install the console cover and torque fasteners to
specification.

TORQUE

Console Cover Fasteners:

84 in-lbs (10 Nm)

Slide tank forward until fully seated on forward
isolators.

Lower the rear of the tank into position over the
rear mounting bracket.

Install the outer isolators and washers onto the
rear tank mount and install mounting fasteners

Verify that the fuel tank vent line is routed
properly and torque the fuel tank mounting
fasteners to specification.

TORQUE

Fuel Tank Mounting Fasteners:

84 in-lbs (10 Nm)

10. Install seat and side covers.

FUEL DELIVERY / EFI

4.20

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

FFUUEELL LLEEVVEELL SSEENNSSOORR RREESSIISSTTAANNCCEE TTEESSTT

OVERVIEW OF OPERATION: Fuel level readings are
measured by a variable resistance fuel level sensor

The fuel level sensor is located inside the fuel tank on
the fuel pump.

If fuel level readings are inaccurate when the
motorcycle is powered up, or if the fuel gauge isn’t
indicating fuel level at all, perform the following test
and refer to resistance values located at the end of this
procedure.

1. Remove the fuel pump. See Fuel Pump Removal,

page 4.16.

2. Set multimeter to measure resistance. Attach

suitable test probe adaptors to meter leads (

from

kit PV-43526

3. On the

fuel pump

side of the connector, measure

resistance across the sensor and compare to the
table.

LEVEL SENSOR ARM

POSITION

APPROXIMATE

RESISTANCE LIMITS

Full (Top of Range)

97–103

Empty (Bottom of
Range)

445–455

FFUUEELL PPUUM

MPP SSUUPPPPLLYY VVOOLLTTAAGGEE TTEESSTT

Before performing this test, verify that battery is fully
charged and in good operating condition.

Remove the console cover and disconnect the fuel
pump / level sensor electrical connector. See Fuel
Pump Removal, page 4.16 steps 1–5.

Connect meter across terminals A & B on the

wire

harness

side of connector.

Press the POWER ON button to power up the
motorcycle electrical system.

Turn Engine Stop switch to RUN and read DC
voltage on meter when switch is first turned on.
Voltage reading should be close to battery voltage
for 2-3 seconds after switching Engine Stop switch
to RUN.

If low or no voltage is delivered to the fuel pump,
verify ground wire (Pin B, Black) has good
continuity to battery (-) post.

If ground is OK, check Gray wire from fuel pump
relay to ECM pin #42 . The Gray wire receives a
momentary

ground

from

the

ECM

(for

2-3

seconds) and activates the fuel pump relay which
supplies power to the pump on the VT/YE wire.

Trace

both

power

and

ground

circuits

determine fault if battery voltage is not present for
2-3 seconds after power button and STOP / RUN
switch are turned on.

When a CPS signal is received by the ECM
(engine is cranking or running) the ECM maintains
the ground on Pin 42 (Gray wire), keeping the
pump powered.

FUEL DELIVERY / EFI

4.21

FFUUEELL PPUUM

MPP CCUURRRREENNTT DDRRAAW

W TTEESSTT

NOTE

Fuel pump current draw is an indicator of pump

condition. Perform draw test if fuel pump operation is

suspect, or if fuel pump fuse is found open (blown).

NOTE

When meter leads are inserted the pump will run,

and current draw will be displayed on the meter,

even with key and stop switch off. Fuel tank must be

completely installed and have enough fuel in it to

cover the fuel pickup screens for an accurate test.

Remove the LH upper side cover and fuse box
cover

Remove fuel pump relay

by pulling straight

upward.

Set meter to DC Amps. Be sure red meter lead is in
the 10A jack, and black meter lead is in common
(-) jack.

Insert one meter lead in pin socket (4) and other
meter lead in pin socket (7) of relay block.

Read fuel pump current draw on meter and
compare to specification.

Inspect fuel pump circuit wiring or replace fuel
pump if current draw exceeds specification.

SPECIFICATION: Fuel Pump Current Draw

Maximum

6 DC Amps

FUEL DELIVERY / EFI

4.22

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

PPRRIIM

MIINNGG TTHHEE FFUUEELL SSYYSSTTEEM

Prime procedure should be performed:

• If a new fuel pump is installed or if tank is run

completely dry.

• Whenever fuel system is serviced (fuel line is

disconnected).

• Whenever battery disconnected.

Fill the fuel tank.

Turn Engine Stop switch OFF.

Press

the

power

button

power

the

motorcycle.

Turn stop switch to RUN.

Allow switch to remain in RUN position until pump
stops running (about 2-3 seconds).

Turn stop switch OFF.

Press the power button to power down motorcycle.

WAIT

approximately 10 seconds.

Repeat Steps 4-8 about 4 times to complete the
priming procedure.

NOTE

Fuel level in tank must be high enough to submerge

pickup screen on fuel pump.

FUEL DELIVERY / EFI

4.23

EEFFII SSEERRVVIICCEE

FFUUEELL IINNJJEECCTTIIOONN SSYYSSTTEEM

M -- OOVVEERRVVIIEEW

W OOFF

OOPPEERRAATTIIOONN

The Electronic Fuel Injection (EFI) system functions to
provide the engine with precisely metered fuel under
varying loads and conditions.

The Engine Control Module or “ECM”, is located
beneath the battery box. It is programmed to provide
the correct fuel/air mixture and ignition timing based
on several sensor input signals (engine load, temp,
altitude, manifold pressure etc.). The ECM also
provides grounds or voltage to other

EFI related

circuits of the electrical and fuel delivery systems.

An Electronic Throttle Control (ETC) system takes the
place of a conventional, cable-operated throttle body.
The ETC controls throttle blade angle and provides
rate-of-change feedback to the ECM.

The ETC also serves as a plausibility check for the
TMAP sensor. The MAP portion of the TMAP sensor is
the primary air flow and load sensing device.

An electric fuel pump, mounted inside the fuel tank
supplies fuel pressure to the injectors continuously
when the engine is running or cranking. A pressure
regulator incorporated on the pump keeps fuel
pressure steady at approximately 3.51 Bar (350 kPa /
51 PSI). The fuel pump cycles “ON” for 2-3 seconds
when the motorcycle is powered up and the Engine
Stop switch is turned ON to pressurize the system for
start-up.

The fuel injectors inject fuel when they are grounded
by drivers inside the ECM. The duration of an injector
pulse (length of time the injector circuit is grounded)
is controlled by the ECM. Pulse duration determines
the amount of fuel delivered to the engine (longer
cycles = more fuel). The ECM selects the correct fuel
injector pulse by calculating the airflow from the MAP
sensor

measurement

and

referencing

three

dimensional “map” for the desired air-to-fuel ratio
(AFR). The ECM calculates an injection time based on
the measured airflow and desired AFR.

Although TMAP and engine RPM are the most
influential inputs for selecting a map reference point,
the ECM also evaluates feedback from minor sensors
in the system, to obtain a more accurate “picture” of
the fuel needs at any given moment.

The fuel control system is closed loop. When the
engine is at a warm idle and typical cruising engine
speeds and loads, the ECM will operate in “closed
loop fuel control” mode. The oxygen sensors in each
headpipe will provide feedback to the ECM and the
injection time will be adjusted for each cylinder to
achieve the target AFR.

The locations of sensors and other EFI system related
components are outlined in this chapter. See Sensors
— Powertrain Management, page 4.12.

FUEL DELIVERY / EFI

4.24

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

EECCM

M CCOONNNNEECCTTOORR M

MAAPP

PIN

ECM 1

COLOR

FUNCTION

PIN

ECM 2

COLOR

FUNCTION

NOT USED

CPS NEGATIVE SIGNAL

NOT USED

GY/DB

REAR O2 SNR OUTPUT

YE/BK

PPS 2 RETURN

OG/YE

TPS 1 OUTPUT

BN/GN

MAP SENSOR RETURN

THERMISTOR RETURN

BN/WH

TPS RETURN

BG/WH

REAR O2 SNR RETURN

WH/BK

PPS 1 RETURN

BK/BU

FUEL SENDER GROUND

NOT USED

FRONT O2 SNR RETURN

NOT USED

OG/BN

CHT RETURN

NOT USED

WH/RD

PPS 1 – 5 VOLT REF

YE/GN

PPS 2 OUTPUT

NOT USED

BK/DG

FUEL LEV SNR OUTPUT

LEFT FRONT TS OUTPUT

WH/OG

CPS POSITIVE SIGNAL

NOT USED

GY/BK

ENGINE RELAY CNTL

OG/DB

CHT SENSOR OUTPUT

K15

RH WARMER THERMISTOR

NOT USED

YE/VT

REAR BRAKE SWT OUTPUT

NOT USED

OG/WH

TIPOVER SENSOR

DB/OG

CLUTCH SWT OUTPUT

OG/BN

MAP SENSOR OUTPUT

NOT USED

VT/RD

TPS 2 SIGNAL

FUEL DELIVERY / EFI

4.25

PIN

ECM 1

COLOR

FUNCTION

PIN

ECM 2

COLOR

FUNCTION

WH/GN

PPS 1 OUTPUT

NOT USED

DB/PK

RUN / STOP SWITCH

BN/PK

TMAP POWER

WH/RD

RR BRK SWT OUTPUT

DB/RD

RIGHT FRONT TS OUTPUT

YE/RD

PPS 2 – 5 VOLT REF

NOT USED

RD/BU

TIPOVER SNR – 5 VOLT REF

WH/DG

LH WARMER THERMISTOR

NOT USED

OG/DG

IAT SENSOR OUTPUT

NOT USED

GY/RD

FRONT O2 SENSOR OUTPUT

NOT USED

CAN HIGH

NOT USED

CRUISE SFTY SWT OUTPUT

NOT USED

DB/BK

CANISTER PURGE VALVE

NOT USED

LEFT REAR TS OUTPUT

NOT USED

KNOCK SENSOR A

BN/DB

TPS – 5 VOLT REF

KNOCK SENSOR B

NOT USED

GY/YE

REAR O2 SENSOR CONTROL

VT/DB

AUX RELAY CONTROL

NOT USED

OG/BN

STARTER RELAY CNTL

NOT USED

FUEL PUMP RELAY CNTL

NOT USED

WH/GY

REAR FUEL INJECTOR DRIVER

CAN LOW

WH/DB

FRONT FUEL INJECTOR DRIVER

NOT USED

GY/WH

FRONT O2 SENSOR CONTROL

BG/BK

SIDESTAND SWT SIGNAL

BK/WH

ECM GROUND

NOT USED

DB/RD

RIGHT REAR TS OUTPUT

NOT USED

YE/RD

TRUNK BRAKE LAMP

DB/WH

ECM GROUND

PK/DB

BRAKE LIGHT POWER

PK/RD

ETC MOTOR (+)

DG/YE

TAIL LIGHT POWER

ETC MOTOR (-)

BK/WH

ECM GROUND

NOT USED

BK/WH

ECM GROUND

REAR COIL SIGNAL

VT/PK

ENG RELAY PWR OUTPUT

NOT USED

VT-PK

ENG RELAY PWR OUTPUT

FRONT COIL SIGNAL

FUEL DELIVERY / EFI

4.26

9927618 R03 - 2017 Indian Motorcycle (Full-Size) Service Manual

TTRROOUUBBLLEE CCOODDEESS

SPN

FMI

COMPONENT

CONDITION

MIL

P-CODE

Accelerator Position 2

Voltage Too High

P1228

Voltage Too Low

P1227

Not Plausible

P1225

Throttle Position Sensor 1

Voltage Too High

P0123

Voltage Too Low

P0122

Signal Out of Range (Not Plausible)

P0121

Voltage Above Critical Level

P1123

Voltage Below Critical Level

P1122

Abnormal Rate of Change

P0120

Calibration / Adaption Failure

P1120

Vehicle Speed Signal

Vehicle Speed Too High

P0500

C1057

Vehicle Speed Too Low

P0502

Data Erratic or Intermittent (or Missing)

P0503

C1058

Sensor Frequency Outside Normal Range

P0501

Abnormal Update Rate

P160A

Received Vehicle Speed has error

C1069

P106B

Accelerator Position 1

Voltage Too High

P0228

Voltage Too Low

P0227

Not Plausible

P0225

Fuel Level Signal

Voltage Too High

P0463

Voltage Too Low

P0462

Above Normal Operating Range

P1462

Below Normal Operating Range

P1463

Signal Fault

P0461

Engine Oil Level Sensor Switch

Pressure Too High

P1527

Pressure Too Low

P1526

Oil Level Low

OFF

P250F

102

Manifold Absolute Pressure
Sensor

Voltage Too High

P0108

Voltage Too Low

P0107

Signal Out of Range

P0106

Abnormal Rate of Change

P0109

Pneumatic Fault

P1106

105

Intake Air Temperature Sensor

Voltage Too High

P0113

Voltage Too Low

P0112

FUEL DELIVERY / EFI

4.27

SPN

FMI

COMPONENT

CONDITION

MIL

P-CODE

Abnormal Rate of Change

P0114

Signal Out of Range

P0111

110

Engine Temperature Sensor

Voltage Too High

P0118

Voltage Too Low

P0117

Signal Out of Range

P0116

Abnormal Rate of Change

P0119

Temperature Too High

OFF

P0217

Engine Overheat Shutdown

OFF

P1217

Temperature Above Normal Range

OFF

P1116

Temperature Too Low

P0128

168

System Power (Battery Potential
/ Power Input)

Voltage Too High

OFF

P0563

C1063

Voltage Too Low

OFF

P0562

C1064

Voltage Above Critical Level

P1562

Voltage Above Warning Level

P1564

Voltage Below Critical Level

P1563

Voltage Below Warning Level

OFF

P1565

190

Engine Speed

Speed Exceeded Max Limit

P0219

Engine Speed Too High

OFF

C1059

Engine Speed Too Low

OFF

C1060

Data Erratic or Intermittent (or Missing)

OFF

C1061

CVT Threshold Exceeded

P1219

Error in Engine Speed Computation

P121C

Received Engine Speed has Error

OFF

C1066

523

Gear Sensor Signal

Voltage Too High

P0917

Voltage Too Low

P0916

Abnormal Update Rate

P1914

Signal Fault

P0914

527

Cruise Control Panel Switches

Switch/Switches Stuck

P153D

596

Cruise Control Enable Switch

Switch Stuck

P1590

598

Clutch Switch Signal

Signal Fault

P0704

599

Cruise Control Set/Decel Switch

Switch Stuck

P1591

601

Cruise Control Resume/Accel
Switch

Switch Stuck

P1592

628

ECU Memory

EEPROM Read / Write Failure

P1602

636

Crankshaft Position Sensor

Circuit Fault

P0336

Plausibility Fault

P0335

FUEL DELIVERY / EFI

Indian motorcycle 2017. Service Manual - page 14