Content .. 21 22 23 24 ..

Indian motorcycle 2017. Service Manual - page 23

7.24

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

HHIIGGHHW

WAAYY BBAARR RREEM

MOOVVAALL

Place the motorcycle on the side stand. Turn the han-
dlebar all the way to the left.

CAUTION

Protect chrome and painted surfaces prior to

removal, particularly the front fender.

Using an 8 mm hex wrench, remove the lower two
fasteners

from the right and left side of the

highway bar assembly.

CAUTION

Hold the highway bar assembly in place while

removing the top fasteners so it doesn’t swing down

and damage the front fender.

Using a 6 mm hex wrench, remove the top two
fasteners

from the highway bar assembly.

Carefully maneuver the highway bar out from the
frame / fender area.

HHIIGGHHW

WAAYY BBAARR IINNSSTTAALLLLAATTIIOONN

Place the motorcycle on the side stand. Turn the han-
dlebar all the way to the left.

CAUTION

Protect chrome and painted surfaces prior to

removal, particularly the front fender.

Carefully maneuver the highway bar into position
and thread the upper mounting fasteners

finger tight.

Install the lower mounting fasteners

and torque

upper and lower fasteners to specification.

TORQUE

Upper Highway Bar Fasteners:

18 ft-lbs (24 Nm)

Lower Highway Bar Fasteners:

35 ft-lbs (48 Nm)

FRAME / BODY

7.25

LLOOW

WEERR FFAAIIRRIINNGG RREEM

MOOVVAALL -- ((RROOAADDM

MAASSTTEERR))

CAUTION

Painted surfaces can be easily scratched or damaged

during removal and installation. Be sure you have a

safe location to store painted body components

before they are removed.

1. Remove fasteners

and carefully remove the

outer fairing assembly.

2. Remove fasteners

from clamps securing the

inner fairing assembly to the highway bars.

3. Remove the inner fairing assembly and associated

clamps from the highway bars.

LLOOW

WEERR FFAAIIRRIINNGG IINNSSTTAALLLLAATTIIOONN --

((RROOAADDM

MAASSTTEERR))

1. Install the upper and lower fairing clamps onto the

highway bars as shown.

NOTE

• The upper fairing clamp is positioned against the

locating dowel

• The lower fairing clamp is positioned to the outside

of the locating mark

• The center (outer) fairing clamp is attached last

and does not have a locating mark.

2. Position the inner fairing assembly over the

highway bar so the clamps line up with the fastener
holes.

3. Install the upper and lower clamp fasteners finger

tight.

FRAME / BODY

7.26

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

4. Position the center (outer) fairing clamp onto the

highway bar and line up with the fastener hole in
the fairing.

5. Starting with the upper clamp, followed by the

lower

and

center

clamps,

torque

all

clamp

fasteners

to specification.

TORQUE

Lower Fairing Clamp Fasteners:

36 in-lbs (4 Nm)

6. Carefully position the outer fairing assembly over

the inner and align the fastener holes.

7. Install the five fasteners

securing the outer

fairing to the inner fairing finger tight.

8. Alternately

tighten

outer

fairing

fasteners

specified torque.

TORQUE

Inner to Outer Fairing Fasteners:

36 in-lbs (4 Nm)

FFRROONNTT FFEENNDDEERR RREEM

MOOVVAALL

NOTE

Motorcycle should be parked on a level surface

resting on the side stand.

CAUTION

Use care not to scratch or damage painted surfaces

during fender removal and / or installation.

Remove two acorn nuts

and fastener

from

each side of the motorcycle and remove the
caliper covers

Follow the fender light harness up into the fairing /
nacelle, locate the connector and disconnect.

Noting their position for reinstallation, cut the
cable ties that are securing the fender light wire
harness to the brake line.

Remove the three fasteners

from each side of

the fender.

FRAME / BODY

7.27

Stand in front of the motorcycle facing the front
fender and squeeze the sides together while
“rolling” the fender out from the fork legs.

IMPORTANT

Once fender has been removed from the

motorcycle, make sure the fender is stored safely

until it is reinstalled.

FFRROONNTT FFEENNDDEERR IINNSSTTAALLLLAATTIIOONN

NOTE

Motorcycle should be parked on a level surface

resting on the side stand.

CAUTION

Use care not to scratch or damage painted surfaces

during fender removal and / or installation.

1. Gently squeeze the sides of the front fender and

“roll” the fender into position so the fastener holes
line up.

2. Install the three fasteners

on each side of the

fender and torque to specification.

TORQUE

Front Fender Fasteners:

18 ft-lbs (24 Nm)

3. Route the fender light wire harness into the fairing

/ nacelle and reconnect.

4. Install cable ties to secure fender light harness

away from moving parts.

5. Install caliper cover. Torque to specification.

TORQUE

Caliper Cover Acorn Nuts:

18 in-lbs (2 Nm)

6. Turn the handlebar all the way to the left and right

verify

proper

operation

and

freedom

movement.

FRAME / BODY

7.28

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

FFRROONNTT FFEENNDDEERR RREEM

MOOVVAALL ((OOPPEENN SSTTYYLLEE

FFEENNDDEERR))

NOTE

Motorcycle should be parked on a level surface

resting on the side stand.

CAUTION

Use care not to scratch or damage painted surfaces

during fender removal and / or installation.

1. Remove the two fasteners

from each side of the

fender.

2. Stand in front of the motorcycle facing the front

fender and squeeze the sides together while
“rolling” the fender out from the fork legs.

IMPORTANT

Once fender has been removed from the

motorcycle, make sure the fender is stored safely

until it is reinstalled.

FFRROONNTT FFEENNDDEERR IINNSSTTAALLLLAATTIIOONN ((OOPPEENN SSTTYYLLEE

FFEENNDDEERR))

NOTE

Motorcycle should be parked on a level surface

resting on the side stand.

CAUTION

Use care not to scratch or damage painted surfaces

during fender removal and / or installation.

1. Gently squeeze the sides of the front fender and

“roll” the fender into position so the fastener holes
line up.

2. Install the two fasteners

on each side of the

fender and torque to specification.

TORQUE

Front Fender Fasteners:

18 ft-lbs (24 Nm)

3. Turn the handlebar all the way to the left and right

verify

proper

operation

and

freedom

movement.

FRAME / BODY

7.29

TTRRUUNNKK RREEM

MOOVVAALL,, RROOAADDM

MAASSTTEERR

1. If applicable, remove the left and right saddlebags

and remove the trunk lock fastener

from each

trunk latch.

2. Disconnect the trunk harness multi-plug

3. Lift the trunk latches

to unlock the trunk from the

mount.

4. Lift up on the rear of the trunk

and slide

rearward

release

the

trunk

from

the

motorcycle.

FRAME / BODY

7.30

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

TTRRUUNNKK IINNSSTTAALLLLAATTIIOONN,, RROOAADDM

MAASSTTEERR

CAUTION

Use care when installing the trunk assembly so that

no electrical wires / connectors get pinched.

1. Lift the flap at the rear of the passenger seat pad to

access the vehicle side of the trunk harness
connector and lay harness on fender.

2. Slide the trunk forward

onto the mounting

bracket and lower

the rear of the trunk until fully

seated.

3. Push the trunk locking levers

down until fully

seated and the trunk is held securely in place.

4. Reconnect the trunk harness connector

5. If applicable, install the mounting fasteners

into

left and right locking levers.

6. Install saddlebags, if equipped.

FRAME / BODY

7.31

TTRRUUNNKK LLOOCCKK RREEPPLLAACCEEM

MEENNTT -- RROOAADDM

MAASSTTEERR

NOTE

It is recommended that the trunk is removed from the

motorcycle prior to disassembly. See TRUNK

REMOVAL as outlined in this chapter.

REMOVAL

1. Remove the trunk from the motorcycle and place

on flat work surface.

2. Open the trunk lid completely.

3. Lift the trunk liner

up to remove from trunk base.

4. Insert body panel tool (PV-49955) or similar into

the relief holes

cut into the bezel and gently pry

bezel off of the trunk base.

NOTE

Bezel is held in place with pressure sensitive

adhesive. It will be necessary to replace the adhesive

with a suitable alternative (e.g. double sided tape)

when the bezel is reinstalled.

5. Remove the two fasteners

from the lock actuator

bracket and disconnect electrical connector.

6. Remove the four fasteners

securing the lock

assembly to the trunk.

7. Remove the latch and lock actuator together as an

assembly.

8. If replacing individual components, disconnect the

lock actuator cable from the latch assembly to
separate the components.

INSTALLATION

9. Install the latch / lock actuator assembly and

tighten fasteners finger-tight.

10. Torque latch fasteners to specification following the

torque sequence.

FRAME / BODY

7.32

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

TORQUE

Trunk Latch Fasteners:

36 in-lbs (4 Nm)

11. Torque lock actuator fasteners to specification.

TORQUE

Lock Actuator Fasteners:

13 ft-lbs (18 Nm)

12. If installing a new latch bezel:

• Peel protective layer off of pressure sensitive

adhesive

• Press bezel into place on the trunk bin with constant

and even pressure and hold for 30 seconds.

13. Install trunk liner.

14. Operate lock and latch assembly to verify proper

operation.

FRAME / BODY

7.33

RREEAARR FFEENNDDEERR RREEM

MOOVVAALL

1. Disconnect the antenna cable from the mast.

2. Remove seat. See Seat Removal / Installation - All

(except Roadmaster), page 7.21

3. Remove upper side panels. See Side Cover

(Upper), Removal / Installation, page 7.17.

4. Remove

lower

side

panels.

See

Side

Cover

(Lower), Removal / Installation, page 7.17.

5. Remove saddlebags, if equipped.

6. Using a 6mm hex wrench, remove the saddlebag

mounting cylinders

from both sides of the

fender, if equipped.

7. Remove the strut cover fasteners

and the strut

covers

from both sides of fender.

8. Remove fasteners

and

from both sides of the

fender.

9. Locate

the

rear

harness

connector

and

disconnect.

10. Loosen the four fasteners

on the underside of the

fender.

11. Remove the three plastic darts

on the upper,

forward lip of the fender.

12. Lift the fender off of the motorcycle.

NOTE

There is enough slack in the antenna wire to remove

fender, turn it over and clip the cable ties.

CAUTION

Be careful not to damage painted surfaces.

FRAME / BODY

7.34

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

RREEAARR FFEENNDDEERR IINNSSTTAALLLLAATTIIOONN

CAUTION

Use care not to scratch or damage painted surfaces

during fender removal and / or installation.

Route the rear harness and antenna cable along
the rear fender and secure with cable ties.

Place

the

rear

fender

assembly

onto

the

motorcycle so the top fastener holes line up and
install fasteners

so they are finger tight.

Line up the holes of the dust cover and install the
three plastic darts

as shown.

Install the four fasteners

on the inside of the

fender so they are finger tight.

Plug the rear harness connector

into the chassis

harness.

Install forward fender fasteners

on both sides of

the fender and torque to specification.

TORQUE

Forward Fender Fasteners

84 in-lbs (10 Nm)

FRAME / BODY

7.35

Torque top fender fasteners

to specification.

TORQUE

Top Fender Fastener

84 in-lbs (10 Nm)

Torque the lower inside fender fasteners

specification.

TORQUE

Inside Fender Fasteners

84 in-lbs (10 Nm)

Install strut covers

and strut cover fasteners

and torque to specification.

TORQUE

Strut Cover Fasteners:

84 in-lbs (10 Nm)

10. Install

saddlebag

mounting

cylinders

and

mounting cylinder fasteners

, if equipped, and

torque to specification.

TORQUE

Mounting Cylinder Fasteners:

25 in-lbs (34 Nm)

11. Install lower side panels. See Side Cover (Lower),

Removal / Installation, page 7.17.

12. Install upper side panels. See Side Cover (Upper),

Removal / Installation, page 7.17.

13. Install seat as outlined in this chapter.

14. Install saddlebags, if equipped.

15. Connect antenna cable to mast.

FFRROONNTT CCAASSTTIINNGG ((M

MAAIINN FFRRAAM

MEE)),, RREEM

MOOVVAALL

WARNING

Care should be taken to be sure the motorcycle will
not tip or fall while elevated. Severe personal injury

or death could occur if the motorcycle tips or falls.

1. Place the motorcycle in an upright position with the

front wheel clamped in a wheel vise.

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

4.15.

3. Disconnect the negative cable from the battery. See

Battery Removal, page 2.26.

4. Remove the lower side covers. See Side Cover

(Lower), Removal / Installation, page 7.17.

5. Remove the front triple clamps. See Triple Clamp

Removal, page 8.33.

6. Remove the driver floorboard assemblies. See

Floorboard Removal, page 7.18.

7. Remove the highway bar assembly. See Highway

Bar Removal, page 7.24.

8. Remove the head pipes. See Head Pipe Removal,

page 3.90.

9. If applicable, disconnect the oil cooler from the

down tubes. See Oil Cooler Removal, page 3.30.

10. Unclip the harness conduit from the front casting.

11. Remove the upper fasteners

from the left side

down tube.

FRAME / BODY

7.36

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

12. Loosen lower fasteners

and

enough so the

dowels can be released from the front casting.

13. Remove fasteners

from the mid casting.

14. Remove fastener

and loosen fasteners

and

on the right side mid-casting.

NOTE

Remove the upper spacer from between the mid-

casting and the engine.

15. Move the front casting toward the right hand side of

the motorcycle to release dowels

and

FRAME / BODY

7.37

16. Remove the front casting from the motorcycle.

FFRROONNTT CCAASSTTIINNGG ((M

MAAIINN FFRRAAM

MEE)),, IINNSSTTAALLLLAATTIIOONN

1. Lower the front casting into position over the

engine.

2. Move the front casting to the left side of the

motorcycle and engage the dowels

and

on the

mid-casting and down tube.

IMPORTANT

The upper engine spacer will

not

be installed during

the initial torque and measurement stage of this

procedure.

FRAME / BODY

7.38

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

3. Loosely install the upper down tube fasteners

through the front casting.

DO NOT install the upper engine spacer

this time;

Starting with the lower engine mount

torque mid-cast fasteners

and

to specification.

TORQUE

Upper Mid-Cast Fasteners

35 ft-lbs (48 Nm)

Lower Mid-Cast Fastener

75 ft-lbs (102 Nm)

5. Torque front casting fasteners

to specification.

TORQUE

Front Cast to Mid-Cast Fasteners

75 ft-lbs (102

Nm)

6. Torque left hand down tube fasteners

and

to specification.

TORQUE

Upper, LH Down Tube Fasteners

45 ft-lbs (60 Nm)

Lower, LH Down Tube Fasteners

45 ft-lbs (60

Nm)

FRAME / BODY

7.39

7. Torque lower right hand down tube fasteners

specification.

TORQUE

Lower, RH Down Tube Fasteners

45 ft-lbs (60 Nm)

8. Measure the gap

between the engine and mid-

cast where the upper spacer should be.

Upper Engine Spacer Gap:

6.5 mm — 10.0 mm

9. If the gap is correct, the upper spacer can be

installed and the upper fastener torqued to
specification.

TORQUE

Upper Engine Mount Fastener:

45 ft-lbs (60 Nm)

10. If the gap is incorrect, repeat STEPS 4-8 until gap

measurement is correct. Torque upper engine
mount fastener to specification.

11. Reverse STEPS 2 - 10 from the removal procedure

to complete installation.

FRAME / BODY

Content .. 21 22 23 24 ..