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Indian motorcycle 2017. Service Manual - page 26

8.13

FFRROONNTT W

WHHEEEELL -- SSPPOOKKEEDD

NUMBER

PART DESCRIPTION

TORQUE (IF APPLICABLE)

Outer Bearing Spacer

Pulse Wheel / Brake Disc Fastener (QTY.6)

22 ft-lbs (30 Nm)

ABS Pulse Wheel

Brake Disc

Seal

Wheel Bearing

Inner Bearing Spacer

STEERING / SUSPENSION

8.14

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

SSEERRVVIICCEE PPRROOCCEEDDUURREESS

HHAANNDDLLEEBBAARR,, RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

((AALLLL M

MOODDEELLSS EEXXCCEEPPTT CCHHIIEEFFTTAAIINN // RROOAADDM

MAASSTTEERR))

WARNING

Clutch cable must be routed, installed, and

adjusted correctly to function properly. Note how

cable is routed and secured before removing the

cable. Permanent cable damage may result if the

inner cable is bent or twisted during installation.

If the cable is incorrectly routed, installed, or

adjusted, serious injury or death may occur.

CAUTION

Cover painted or chrome parts to prevent damage.

Use care to protect fuel tank and front fender. Tank

removal is recommended. Secure, set aside, or

support parts as they are removed.

1. Place motorcycle in an upright position with the

front wheel clamped in a wheel vise.

Chieftain Dark Horse:

2. Remove outer fairing. See Outer Fairing Removal -

(Chieftain Dark Horse), page 7.45.

3. Remove instrument cluster. See Instrument Panel

Removal / Installation - (Chieftain Dark Horse),
page 7.50.

4. Remove four nuts

and washers securing the

inner fairing support to the triple clamp assembly.

5. Noting harness routing and connector locations,

disconnect all fairing electrical connectors and
remove inner fairing support.

Chief Classic / Chief Vintage / Chief Dark
Horse / Springfield:

6. Remove headlight nacelle and headlight bucket

assembly.

All Models (except Chieftain / Roadmaster):

7. Remove front brake master cylinder assembly. See

Front Master Cylinder Service, page 9.29.

CAUTION

Keep brake reservoir in an upright position to

prevent air from entering the system. Bleeding is

required if air enters the system.

8. Remove the clutch lever assembly. See Handlebar

Controls, page 8.6.

9. Place a soft piece of cloth or padded material on

the top of the fuel tank if tank has not been
removed.

10.

NOTE

Make an index mark on the handlebar along the

parting line of the riser cap to ensure proper

handlebar position upon reassembly.

If risers will be removed, remove handlebars /
risers as an assembly. If risers will not be removed,
hold the handlebars in place and loosen the rear
handlebar clamp fasteners

, and then the front

11. Remove the riser cap

12. Lift handlebars out of riser clamps (or the risers off

of the upper triple clamp).

13.

Installation is performed by reversing the
removal procedure.

14. Line up the handlebar index mark made in STEP 10

and torque riser caps, starting with the front
fasteners, to specification.

TORQUE

Riser Cap Fasteners:

18 ft-lbs (24 Nm)

Tighten Front fasteners First, Then Rear

STEERING / SUSPENSION

8.15

15. If handlebar assembly was removed with risers

intact, torque riser fasteners to specification.

TORQUE

Riser Fasteners:

60 ft-lbs (81 Nm)

Chieftain Dark Horse:

16. Install the inner fairing support and torque nuts

to specification.

TORQUE

Inner Fairing Support:

12 ft-lbs (16 Nm)

STEERING / SUSPENSION

8.16

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

HHAANNDDLLEEBBAARR RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

((CCHHIIEEFFTTAAIINN // RROOAADDM

MAASSTTEERR))

WARNING

Clutch cable must be routed, installed, and

adjusted correctly to function properly. Note how

cable is routed and secured before removing the

cable. Permanent cable damage may result if the

inner cable is bent or twisted during installation.

If the cable is incorrectly routed, installed, or

adjusted, serious injury or death may occur.

CAUTION

Cover painted or chrome parts to prevent damage.

Use care to protect fuel tank and front fender. Tank

removal is recommended. Secure, set aside, or

support parts as they are removed.

1. Place motorcycle in an upright position with the

front wheel clamped in a wheel vise.

2. Remove outer fairing. See Outer Fairing Removal -

(Chieftain / Roadmaster), page 7.51.

3. Remove four nuts

and washers securing the

inner fairing support to the triple clamp assembly.

4. Noting harness routing and connector locations,

disconnect all fairing electrical connectors and
remove inner fairing support.

5. Remove front brake master cylinder assembly. See

Front Master Cylinder Service, page 9.29.

CAUTION

Keep brake reservoir in an upright position to

prevent air from entering the system. Bleeding is

required if air enters the system.

6. Remove the clutch lever assembly. See Handlebar

Controls, page 8.6.

7. Place a soft piece of cloth or padded material on

the top of the fuel tank if tank has not been
removed.

NOTE

Make an index mark on the handlebar along the

parting line of the riser cap to ensure proper

handlebar position upon reassembly.

If risers will be removed, remove handlebars /
risers as an assembly. If risers will not be removed,
hold the handlebars in place and loosen the rear
handlebar clamp fasteners

, and then the front

9. Remove the riser cap

10. Lift handlebars out of riser clamps (or the risers off

of the upper triple clamp).

11.

Installation is performed by reversing the
removal procedure.

12. Line up the handlebar index mark made in STEP 8

and torque riser caps, starting with the front
fasteners, to specification.

TORQUE

Riser Cap Fasteners:

18 ft-lbs (24 Nm)

Tighten Front fasteners First, Then Rear

13. If handlebar assembly was removed with risers

intact, torque riser fasteners to specification.

TORQUE

Riser Fasteners:

60 ft-lbs (81 Nm)

14. Install the inner fairing support and torque nuts

to specification.

STEERING / SUSPENSION

8.17

TORQUE

Inner Fairing Support:

12 ft-lbs (16 Nm)

CCLLUUTTCCHH CCAABBLLEE,, RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

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

Clutch Cable Removal

Remove the side stand bumper fastener

and the

clutch cable E-clip

Protect the clutch release arm

with a shop towel.

Using an adjustable wrench, rotate the release arm
inward. Disconnect clutch cable from release arm.

Withdraw the clutch cable from the mounting boss
located on the primary cover.

At the handlebar, pull the clutch cable casing
straight out until clear of lever perch and rotate
cable outward to align inner cable wire with slot in
lever.

Pull lever slightly until slotted opening in lever is
clear of perch and slide cable barrel end down
and out of lever.

Note routing of clutch cable through frame.

Loosen the fasteners securing the LH frame
downtube to the engine and steering head.

Remove the clutch cable.

Clutch Cable Installation

CAUTION

Do not kink, bend, or twist the inner cable or outer

cable casing during installation

10. Route clutch cable in the same manner as

removed.

11. Torque the LH frame downtube fasteners to

specification. See Engine Brackets / Fasteners,
page 3.9.

12. Apply multi-purpose grease to the lever end of the

cable and install it in the clutch lever at the
handlebar.

13. Install the casing in the lever perch at the

handlebar.

14. Install cable in the mounting boss located on the

primary cover.

15. At the release arm end of the cable, pull the inner

cable until fully extended. Be sure the upper end
of the cable casing is seated in the lever perch at
handlebar end.

16. Apply multi-purpose grease to the lower barrel

end of the cable.

17. Rotate the release arm inward (as in STEP 3) until

cable can be installed in release arm.

18. Install the clutch cable E-clip at the mounting boss.

19. Install the side stand bumper and fastener. Torque

to specification.

TORQUE

Side Stand Bumper:

84 in-lbs (10 Nm)

20. Adjust clutch cable free play. See Clutch Lever

Free Play, page 2.13.

STEERING / SUSPENSION

8.18

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

FFRROONNTT W

WHHEEEELL,, RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

WARNING

This procedure requires raising and supporting

the motorcycle so that the front wheel is off the

ground. Precautions should be taken to ensure

the motorcycle is properly stabilized at all times.

Failure to properly support motorcycle may result

in personal injury or damage to the motorcycle.

CAUTION

Do not twist the brake hose or brake line. Do not

allow calipers to hang from the brake hose. Secure

calipers in such a way to avoid hose damage.

CAUTION

CALIFORNIA MODELS: Remove the charcoal canister

prior to raising motorcycle wheels off the ground. As

the swingarm lowers it can contact the canister hose

fittings and damage them.

Secure the motorcycle in an upright position with
tie-down straps and a platform jack positioned
beneath the engine cases.

NOTE

Do not operate the front brake lever with the calipers

or wheel removed.

Removal

Remove the front fender. See Front Fender
Removal, page 7.26.

Loosen axle pinch fasteners

on lower right fork

leg.

Support wheel and remove axle

. Be prepared

to catch spacers on each side of the wheel and
remove wheel.

Installation

Install front wheel and spacers into fork.

Install the axle and torque to specification.

TORQUE

Front Axle:

52 ft-lbs (71 Nm)

Tighten axle pinch fasteners to specification.

TORQUE

Axle Pinch Fasteners:

18 ft-lbs (24 Nm)

Install front fender. See Front Fender Installation,
page 7.27.

STEERING / SUSPENSION

8.19

FFRROONNTT AAXXLLEE IINNSSPPEECCTTIIOONN

Place

axle

V-blocks

and

inspect

runout.

Compare to specifications in this chapter. See
Service Specifications, page 8.5.

Replace axle if it fails inspection. Do not attempt to
straighten a bent axle.

FFRROONNTT W

WHHEEEELL IINNSSPPEECCTTIIOONN

Install front wheel in truing stand.

NOTE

Bearings must be in good condition to accurately

measure runout.

Set up a dial indicator to measure radial runout (up
and down) (A) and compare to specifications. See
Service Specifications, page 8.5.

Position dial indicator to measure axial runout
(side to side) (B) and compare to specifications.
See Service Specifications, page 8.5.

Visually inspect wheel for cracks.

Replace wheel if it fails visual or measured
inspection. Do not attempt to straighten cast or
wheels.

BBRRAAKKEE DDIISSCC RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

Remove front wheel. See Front Wheel, Removal /
Installation, page 8.18.

Position wheel with brake disc and ABS tone ring
facing up (protect the other disc and wheel when
removing opposite disc).

Remove and discard brake disc / tone ring
fasteners

Remove tone ring

and brake disc

from

wheel.

Flip wheel over and repeat procedure to remove
opposite side brake disc (no tone ring on RH side).

Installation is performed by reversing the
removal

procedure.

Use

new

brake

disc

fasteners for installation

Torque

new

brake disc fasteners to specification in

a star pattern.

TORQUE

Brake Disc Fasteners:

22 ft-lbs (30 Nm)

STEERING / SUSPENSION

8.20

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

FFRROONNTT W

WHHEEEELL BBEEAARRIINNGG IINNSSPPEECCTTIIOONN

NOTE

Inspect bearings installed in the wheel. Do not

remove to inspect. Bearings cannot be repacked.

Replace both wheel bearings if one or both fail

inspection, or if either bearing was removed.

Visually inspect bearing seals

on each side for

wear or damage.

Check bearings by turning inner race by hand.

• Look for signs of discoloration, scoring, galling, or

contamination from moisture or dirt. Replace
bearings if any of the above are present.

• Turn the inner race of the bearings. The bearings

should turn smoothly and quietly. The inner race
should be firm with minimal side to side movement
and no detectable up and down movement.

Discard bearings that fail any of the above
inspections.

CAUTION

Do not reuse bearings after removing them from the

wheel. Removal damages the bearings internally.

Inspect bearing fit into wheel hub. The outer race
of the bearing must fit tightly into the bore. You
should not be able to move it (or remove it) by
hand. Replace the wheel if outer race of a new
bearing does not fit tightly in the bore.

FFRROONNTT W

WHHEEEELL BBEEAARRIINNGG RREEPPLLAACCEEM

MEENNTT

CAUTION

Do not reuse bearings that have been removed.

NOTE

This procedure requires the Wheel Bearing Removal

/ Installation Kit

(PF-51324)

. Refer to special tool

manufacturer instructions for proper use of tool.

Remove front wheel. See Front Wheel, Removal /
Installation, page 8.18.

Remove brake discs. See Brake Disc Removal /
Installation, page 8.19.

Carefully remove both seals using a suitable seal
removal tool and discard. Be careful not to scratch
the seal bore.

Refer to special tool manufacturer instructions to
remove bearing from LH side of hub.

Remove bearing.

Remove spacer.

Extract or drive bearing from RH side of hub.

Installation:

Use the Wheel Bearing Removal /

Installation Kit

PF-51324)

to install new wheel

bearings. Refer to special tool manufacturer
instructions for proper use of tool.

Install

new

wheel bearing into the RH side of hub

followed by the inner bearing spacer.

10. Install

new

wheel bearing into the LH side of hub.

11. Install

new

seals and existing outer bearing

spacers into each side of the wheel hub.

12. Install the brake discs. See Brake Disc Removal /

Installation, page 8.19.

13. Install the front wheel. See Front Wheel, Removal /

Installation, page 8.18.

STEERING / SUSPENSION

8.21

FFRROONNTT FFOORRKK RREEM

MOOVVAALL ((AALLLL M

MOODDEELLSS))

WARNING

This procedure requires raising and supporting

the motorcycle so that the front wheel is off the

ground. Precautions should be taken to ensure

the motorcycle is properly stabilized at all times.

Failure to properly support motorcycle may result

in personal injury or damage to the motorcycle.

CAUTION

Do not twist the brake hose or brake line. Do not

allow calipers to hang from the brake hose. Secure

calipers in such a way to avoid hose damage.

CAUTION

CALIFORNIA & INTERNATIONAL MODELS: Remove

the charcoal canister prior to raising motorcycle

wheels off the ground. As the swingarm lowers, it can

contact the canister hose fittings and damage them.

1. Remove front fender. See Front Fender Removal,

page 7.26.

2. Secure the motorcycle in an upright position with

tie-down straps and a platform jack positioned
beneath the engine cases.

NOTE

Do not operate the front brake lever with the calipers

or wheel removed.

3. Remove front brake calipers and support them so

they do not hang by brake hoses. See Front Caliper
Service, page 9.31.

4. Remove front wheel. See Front Wheel, Removal /

Installation, page 8.18.

Chieftain Dark Horse:

5. Remove

fairing

assembly.

See

Outer

Fairing

Removal - (Chieftain Dark Horse), page 7.45.

Chieftain / Roadmaster:

6. Remove

fairing

assembly.

See

Outer

Fairing

Removal - (Chieftain / Roadmaster), page 7.51

Chief Classic / Chief Vintage / Chief Dark
Horse / Springfield:

7. Remove nacelle and headlight bucket.

ALL Models

8. If triple clamp will be removed, remove front brake

line guides from the upper and lower triple clamps.

9. Loosen upper triple clamp pinch fastener

for

each fork tube.

10. If disassembling the fork tube (s), loosen the fork

cap(s)

prior to loosening the lower triple clamp

fasteners.

STEERING / SUSPENSION

8.22

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

11. Loosen lower triple clamp pinch fasteners

for

each fork tube.

12. Slide fork legs down and remove.

FFRROONNTT FFOORRKK DDIISSAASSSSEEM

MBBLLYY

NOTE

The following procedure requires the use of Fork

Spring Compressor (PV-49463) and Fork Spring

Compressor Adapter (PV-49464).

NOTE

Refer to appropriate Front Fork Exploded View.

Clean fork tubes before disassembly.

Secure

Fork

Spring

Compressor

(PV-49463)

vertically in a vise with drive bolt

UP.

Loosen fork cap

approximately 1 turn. Do not

remove the cap.

WARNING

Wear eye / face protection. Be sure spring is

engaged properly with pegs of tool as you compress

the spring in the following steps.

STEERING / SUSPENSION

8.23

Mount

special

socket

(PV-49464)

spring

compressor. Center it in holding fixture with all
thumb fasteners

Place fork tube in spring compressor tool with
hole in bottom of fork slider over peg on bottom of
tool.

Adjust length of spring compressor by turning
drive bolt

as required until fork cap is captive in

socket.

Rotate tube until cap is unscrewed completely
from fork tube.

Back off spring compressor and remove special
socket. Re-adjust length of tool so thumb fasteners
are aligned with first or second coil at top of
spring.

Hold fork in center and engage slot of stationary
peg

with spring. Turn other fasteners in and

engage spring in notch.

Slowly compress spring by turning drive bolt of
compressor until cartridge rod nut is accessible.
DO NOT use air or power tools to rotate drive bolt.

STEERING / SUSPENSION

8.24

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

10. Hold nut and remove fork cap

from cartridge

shaft.

11. Remove washer

12. Remove spring from fork tube.

13. Pour fork oil out of tube assembly.

14. Move cartridge shaft through complete stroke

several times to drain cartridge (until damping is
gone).

NOTE

Fork seal replacement is recommended at oil

change. If you do not intend to replace fork seals

(fork oil change only) STOP HERE and proceed to

Step 14 of Front Fork Assembly. Inner fork tube

removal in the following steps will damage the oil

seal and require seal replacement. For complete fork

disassembly proceed to Cartridge Removal / Step

15.

Cartridge Removal

15. Hold cartridge through top of fork inner tube with

octagonal end of Cartridge Shaft Tool

(PV-49452)

Loosen cartridge fastener.

16. Remove cartridge from inner tube.

WARNING

DO NOT disassemble the cartridge. If damaged or

worn, it must be replaced as an assembly.

17. To clean cartridge when removed, submerge oil

holes in clean cartridge fork oil and pump
cartridge shaft.

18. Fully compress the fork tube. Carefully lift dust

seal out of outer fork tube with a small flat
screwdriver. KYB forks have access notch to
remove dust seal.

STEERING / SUSPENSION

8.25

19. Remove seal retaining ring. Use care not to scratch

the surface of the inner fork tube.

20. Push inner and outer tube together, then pull apart

quickly to produce a slide hammer motion to
remove the inner tube.

21. Separate the tubes.

22. If applicable, remove the lower bushing from the

inner tube.

23. Remove oil lock valve

and bushing

from

bottom of inner tube.

24. Protect top surface of fork slider and pry out oil

seal, using care not to scratch the seal bore.

25. Remove oil seal and backing washer.

Upper Bushing Removal

26. To remove upper bushing from fork slider, re-

install fork tube (with lower bushing attached) into
fork slider, working the bushing carefully past the
upper (slider) bushing.

27. Use a VERY LIGHT slide hammer motion to tap

slider bushing out of the slider.

28. Clean tubes and drain completely. Cartridge

removal is not required for seal and bushing
replacement. Cartridge can be cleaned by adding
clean fork oil to slider and pumping the cartridge
rod in the clean oil bath. Discard fork oil used to
flush the cartridge.

STEERING / SUSPENSION

8.26

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

FFRROONNTT FFOORRKK IINNSSPPEECCTTIIOONN

Measure fork spring free length and compare to
specifications on .

Inspect fork stanchion tube for scoring, heavy
scratches, dents due to rocks or other road debris,
or excessive wear. Replace tube (s) if deep
scratches, pitting, or dents are found.

Inspect slider for dents or other indentations due
to rocks or other road debris or damage. If
damage is found on exterior of slider, insert fork
tube into slider and move the tube through the
complete travel range. Check for resistance or
binding in the damaged area. If binding or
resistance is evident, replace the slider.

Inspect oil lock valve for scoring, excessive or
abnormal wear.

Visually inspect the damper rod piston ring.
Replace ring if scoring, deep scratches and/or
excessive wear is noted.

CAUTION

Ring is directional. Be sure to install it with stepped

edge toward damper rod and top-out spring as

shown.

Place fork tube in V-blocks and measure runout.
Replace the tube if runout exceeds service limit
listed on .

WARNING

Do not attempt to straighten bent fork tubes. Doing

so will weaken the tube and make the motorcycle

unsafe to operate.

STEERING / SUSPENSION

8.27

FFRROONNTT FFOORRKK AASSSSEEM

MBBLLYY

NOTE

Clean all parts prior to assembly.

Lubricate and install new upper bushing into fork
slider. Position gap

to left or right side of fork

slider.

Lubricate and install a new lower bushing

inner fork tube. Install oil lock valve

in bottom

of fork tube (tapered side to the tube as shown).

Rotate bushing so gap

will be opposite th gap of

slider bushing previously installed.

Apply a light film of fork oil to outside edge and
inside seal lips of new oil seal.

NOTE

Install oil seal with markings

facing UP (toward top

of tube and retaining ring).

STEERING / SUSPENSION

8.28

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

Lubricate the surface of the inner fork tube and
slide backing washer and new oil seal down tube
and into outer fork leg.

Use the Fork Seal Tool

(PV-49494)

(6) to install oil

seal until seated. Be sure top edge of seal is past
(below) retaining ring groove.

Install a new retaining ring

into groove of fork

tube. Be sure it is completely seated around the
entire circumference of the groove.

Wipe away any excess grease or oil. Install dust
seal (use opposite end of Fork Seal Tool

(PV-

49494)

until fully seated in outer tube.

Cartridge Installation

Be sure fastener threads in bottom of cartridge are
clean and not damaged.

10. Place cartridge assembly into fork slider, and

carefully align bottom of cartridge with recess in
bottom.

11. Install a new cartridge fastener and a new seal

washer.

12. Hold cartridge with the Cartridge Shaft Tool

(PV-

49452)

STEERING / SUSPENSION

Content .. 24 25 26 27 ..