Indian Motorcycle 2003 Chief Vintage User manual

PRINTED P/N 99-846
CD P/N 99-821

INDIAN CHIEF SERVICE MANUAL FOREWORD
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FOREWORD
To stay in peak running condition, Indian™
motorcycles require regular maintenance in accordance
with the recommendations of Indian Motorcycle
Company. This manual describes all the necessary
inspection and maintenance procedures that should be
performed at specific intervals. It also provides the
detailed troubleshooting and repair procedures
necessary when problems arise or are uncovered at the
recommended service intervals.
Organization and Content
The organization and content of the manual is formed
around the following major sections:
GENERAL INFORMATION provides information
about the major features and characteristics of the
Indian Chief motorcycle. It also provides general
information relating to the maintenance service and
repair procedures including an explanation of the
types of safety information presented.
TROUBLESHOOTING provides symptom-related
diagnostic information and system and component
tests. Areas covered include the basic engine, as well as
emission control, ignition and fuel systems. In
addition, there is coverage for chassis, drive,
transmission and chassis electrical.
MAINTENANCE AND REPAIR PROCEDURES are
included under the page banner headings for the
respective system or component involved, for example,
FRONT SUSPENSION, STEERING, etc. Under each of
the respective headings, there are procedures for
routine maintenance inspections and adjustments.
Procedures for removal and installation, disassembly,
cleaning and inspection of component parts and
assembly are included when more extensive repairs or
a complete overhaul is required.
SPECIFICATIONS for all systems and components are
included in one place near the end of the manual. The
section provides assembly clearances and wear limits
under Fits and Tolerances, as well as fastener torque
values and specified sealants for engine, chassis and
electrical systems and components.
SCHEMATICS covering chassis wiring and engine
ignition and lubrication systems are included here. In
addition, there are power flow diagrams for the
transmission.
ASSEMBLY DRAWINGS are included for the major
engine sub assemblies. These are detailed exploded
views showing the relative position of components and
the critical fastener torque values.
TOOLS AND EQUIPMENT provides a listing of all
special tools and the corresponding tool numbers that
are required to perform specific service and repair
procedures in a precise, efficient and safe manner. Most
of the required tools are readily available from JIMS

Machining. In addition to the tool listing, there are
drawings for fabricating or modifying tools for use in
servicing the engine.
Finding the Information You Need
The manual includes a Table of Contents and an
alphabetical Index as well. Both listings are based on
first and second level headings included in the text.

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NOTES INDIAN CHIEF SERVICE MANUAL

INDIAN CHIEF SERVICE MANUAL TABLE OF CONTENTS
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GENERAL INFORMATION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Organization and Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Finding the Information You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FEATURES OF THE 2003 INDIAN CHIEF MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Component and System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Chassis VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
MAINTENANCE
MAINTENANCE SERVICE, REPAIRS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Primary Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Interval Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Renewal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING
CHASSIS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Symptom-Related Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Basic Engine Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EMISSION CONTROL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Evaporative System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Spark Plug Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Electronic Ignition Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
CARBURETOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
TRANSMISSION AND DRIVE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ELECTRICAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Electrical Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Ground Path Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Current Draw/Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Rectifier/Regulator Current Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Charging System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Starting System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Wiring Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
FRONT SUSPENSION
FRONT SUSPENSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL
Fork Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fork Tube Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
STEERING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
STEERING COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Steering Stem Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Steering Stem Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Handlebar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REAR SUSPENSION
REAR SUSPENSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
WHEELS AND TIRES
WHEEL AND TIRE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Front Wheel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Rear Wheel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Hub Bearing Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Wheel Sprocket and Brake Rotor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Wheel Rim, Hub and Spokes Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Tire Inspection and Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Tire and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
WHEEL LACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lacing 16-Inch, 60-Spoke Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Aligning the Hub and Rim (Truing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
BRAKE SYSTEM
BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Brake Fluid Level and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Brake Caliper Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Brake Rotor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Master Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Hydraulic Brake Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Replacing Brake Fluid and Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
FRAME AND ACCESSORIES
FRAME AND ACCESSORIES SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Fender Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Chassis Fairing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Dash Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Front Turn Signal, Spotlight and Headlight Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fender-Mounted Light Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Floorboard and Buddy Peg Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Mirror Assembly Removal, Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Kickstand Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Frame Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

INDIAN CHIEF SERVICE MANUAL TABLE OF CONTENTS
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AIR CLEANER
AIR CLEANER AND FILTER ELEMENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
FUEL SYSTEM
FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Fuel Filtration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Fuel Line Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Throttle Control Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Carburetor Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Carburetor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Carburetor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Carburetor Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
IGNITION SYSTEM
IGNITION SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Spark Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Ignition Coil and Spark Plug Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Ignition Cover Housing/Rotor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Ignition Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Ignition Timing Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
LUBRICATION SYSTEM
LUBRICATION SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Engine Oil and Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Cleaning the Tappet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Oil Line Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Oil Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Oil Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
EMISSION CONTROL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Evaporative System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Carbon Canister Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Air Valve Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
EXHAUST SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Muffler, Heat Shields and Exhaust Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ENGINE
ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Removing Chassis Components and Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Installing Chassis Components and Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
ENGINE DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

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Rocker Box Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Pushrod and Tube Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Pushrod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Cylinder Head Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Cylinder and Piston Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Alternator Rotor/Stator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Lifter Block Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Oil Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Ignition Cover Housing/Rotor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Cam, Breather Valve and Pinion Gear Removal and Installation . . . . . . . . . . . . . . . . . . . . . . .154
Crankcase Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
PRIMARY DRIVE
PRIMARY DRIVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Primary Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Primary Drive Removal, Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Engine and Transmission Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
REAR DRIVE
REAR DRIVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Rear Drive Belt Inspection, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Rear Wheel Alignment and Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Drive Belt Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Clutch Lever and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Clutch Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Clutch Plate Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Clutch Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
TRANSMISSION
TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Transmission Shift Control Linkage Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . .189
Transmission Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
TRANSMISSION REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Tools required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Installation of Shafts into Trapdoor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Shift Fork Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
STARTING SYSTEM
STARTING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Starter Drive Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224

INDIAN CHIEF SERVICE MANUAL TABLE OF CONTENTS
vii
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
CHARGING SYSTEM
CHARGING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Battery and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Voltage Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER DISTRIBUTION, LIGHTING AND INSTRUMENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . .230
Electrical Equipment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Speedometer and Warning Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Road Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Handlebar Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Circuit Wiring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
CHASSIS SPECIFICATIONS & TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
Front Fork and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Rear Swingarm and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Frame and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
ENGINE SPECIFICATIONS & TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Fits and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
DRIVETRAIN SPECIFICATIONS & TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Primary, Clutch and Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
ELECTRICAL COMPONENT FASTENER SPECIFICATIONS & TORQUE VALUES . . . . . . . . . . . . . . . . .247
LUBRICANTS AND SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
SCHEMATICS
CHASSIS WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
ASSEMBLY DRAWINGS
IGNITION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
LUBRICATION FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
TRANSMISSION POWER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Indian 5-Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
ENGINE PART AND ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
TOOLS AND EQUIPMENT
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Tool Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280

viii
TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283

INDIAN CHIEF SERVICE MANUAL GENERAL INFORMATION
1
FEATURES OF THE 2003 INDIAN CHIEF MOTORCYCLE
The Indian Chief motorcycle is a classic design with its
heritage going back to the beginning of the twentieth
century. Today, the motorcycle carries forth the
tradition and craftsmanship with four models.
• Indian Chief (standard)
• Indian Chief Deluxe
• Indian Chief Roadmaster
• Indian Chief Springfield
Component and System
Descriptions
Chassis
Front suspension — The Chief is fitted with a
conventional-style front suspension with hydraulic
compression and rebound damping. Early-production
models were equipped with an ILM-manufactured
fork assembly. Current-production models are
equipped with Paioli assembly. Both are similar in
design. However, on the Paioli fork, the caliper-
mounting bracket is an integral part of the fork slider.
The 41 mm upper fork tubes (stanchions) of the Paioli
assembly are hard chromed with fork sliders that are
forged EN-AW-6082 aluminum. The fork sliders are
finished with tri-plate chrome.
Steering — The rake of the front forks is 34 degrees.
This rake provides a front-wheel trail dimension of
5.92” with the standard 130/90-16 sized tires.
Rear suspension — The rear swingarm is suspended at
the top on a single KW rising-rate spring and shock
absorber that provides 4.25” of travel. Spring preload is
adjustable.
Brakes — Single-disc brakes are used on both the front
and rear wheels at the left and right sides respectively.
Both feature Brembo, differential bore, four-piston
calipers in combination with 11.5” rotors.
Wheels and tires — The wheels are chrome with 60
spokes and 16” x 3.5” rims. These are fitted with size
130/90-16 tires at both front and rear locations.
Frame — The substantial frame is constructed of high-
tensile steel and protected with a black powder-coated
finish. Fitted with the standard rear swingarm and
front suspension, the frame provides a wheelbase of
68.4”.
Engine and Related Systems
Basic engine — At the core of the motorcycle is its
engine. The Chief is powered by the Indian
POWERPLUS
™
engine and is a four-cycle,
two-cylinder engine with a 45-degree V-configuration.
Its large bore and stroke give it a displacement of 100
cubic inches. The design is also traditional, carrying
forward the characteristic “round” cylinders found in
early Indian Chief motorcycles. At a compression ratio
of 9.2:1, the engine produces 78 foot-pounds of torque
at 3800 rpm and 67 hp at 4750 rpm.
Figure 1 — Indian POWERPLUS
™
engine
The piston connecting rods are a fork-and-blade style
connected to a common crank pin joining two
flywheels. The crank pin is set between the pinion shaft
flywheel to the right and the sprocket shaft flywheel to
the left. The sprocket shaft drives the compensator
sprocket in the primary case at the left side of the
motorcycle. The sprocket shaft carries the alternator
rotor, between the engine crankcase and the
compensator. The pinion shaft drives the camshaft, oil
pump and breather valve through gearing at the right
side of the engine.
The camshaft actuates the intake and exhaust valves
through a valve train that includes roller lifters,
pushrods and rocker shaft assemblies. The roller lifters,
following the cam lobes, raise the pushrods and rocker
arms to open the intake and exhaust valves at the
appropriate times in the intake and exhaust cycles.
Lubrication system — The lubrication system
incorporates a gerotor-type oil pump located at the
front of the cam housing. The pump, which is driven
by a worm gear fitted on the pinion shaft, provides
positive lubrication to the engine. At the rear of the
cam housing is a full-flow, spin-on type filter to screen
the lubricating oil as it circulates through the system.

2
GENERAL INFORMATION INDIAN CHIEF SERVICE MANUAL
Fuel system — The fuel system includes dual tanks
with a total capacity of 5.5 gallons including the
1.2-gallon reserve. Fuel is gravity fed to a Mikuni HSR
carburetor mounted at the left side of the engine
between the cylinder heads. The carburetor features a
42 mm bore with a flat-slide throttle valve.
Ignition system — Combustion is controlled with a
computerized electronic ignition system. The system’s
electronic module and timing sensor controls output to
the spark plugs in the cylinders. The ignition rotor,
attached to the end of the pinion shaft, in combination
with the sensor in the ignition cover, provides the
“trigger” signal for the electronic ignition system.
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. Together, these
components effectively seal the air intake and fuel
system, preventing the escape of hydrocarbons into the
atmosphere.
Exhaust system — The exhaust system features a
single chrome muffler with a dual inlet for the two
pipes from the cylinders. A three-section chrome heat
shield covers the pipes between the cylinder heads and
the muffler.
Engine Component Locations
The following views identify the location of major
chassis and engine-related parts and accessories
referenced in this manual.
Figure 2 — Indian Chief Motorcycle (right side)
Figure 3 — Indian Chief Motorcycle (left side)
1. Rear cylinder
2. Ignition coil and upper engine support
3. Front cylinder
4. Oil pump (behind front exhaust pipe)
5. Cam cover
6. Ignition cover
7. Oil filter
8. Oil filler and dipstick
1. Air cleaner housing
2. Transmission shift rod
3. Outer primary housing
4. Primary chain inspection cover

INDIAN CHIEF SERVICE MANUAL GENERAL INFORMATION
3
Transmission and Drive
Primary drive — A dual-track drive chain links the
engine compensator sprocket with the clutch sprocket.
The wet-type clutch utilizes 10 friction plates to
transfer engine power smoothly to the transmission.
The 24-tooth compensator sprocket in combination
with the 37-tooth clutch sprocket provides a reduction
of 1.54:1.
Transmission — The transmission is a proprietary
single-countershaft design with input and output
drives on the same side. The constant mesh, 5-speed
gearing, provides a range of ratios, from 3.24:1 in first
gear to 1:1 direct in fifth gear.
Rear drive — The rear drive uses a cogged, arimid-
reinforced belt, 1-7/16” wide, connecting the
transmission output drive sprocket with the rear wheel
sprocket. The combination of the 32-cog drive sprocket
and 65-cog rear wheel sprocket provides a final
reduction of 2.03:1.

4
GENERAL INFORMATION INDIAN CHIEF SERVICE MANUAL
MOTORCYCLE IDENTIFICATION
There are three significant identification numbers on
the motorcycle. The numbers include the chassis
Vehicle Identification Number (VIN) along with
individual serial numbers for the engine and
transmission.
Chassis VIN
The primary number used to identify the motorcycle is
the chassis VIN. This is a 17-position alphanumeric
number conforming to governmental standards for
identification of motorized vehicles.
Within the first 11 positions, the number provides
information such as vehicle type, make, model, model
year, engine, etc. The last six numeric positions identify
the build sequence.
Location — The VIN is stamped into a plate welded to
the front frame tube on the right side near the fork
pivot. It is also printed on the mylar certification label
affixed to the frame tube just below the VIN plate.
Use the following table to interpret the VIN Example.
•Model: All
•Year: All
• VIN Example: 5CDNNCAJ_3G000002
Position Description Code Code Description
1 WMI 5 Supplied by SAE
2 WMI C Supplied by SAE
3 WMI D Supplied by SAE
4Type
C
N
M
Motorcycle — Stretched and raked smoothtail (Chief 99–01)
Motorcycle — Single downtube monoshock frame (Chief 02 +)
Motorcycle — Single downtube smoothtail (Scout/Spirit 01 +)
5 Line (Model)
N
3
X
R
V
T
C
5
Chief Standard Model/Springfield
Chief Centennial
Chief Deluxe
Chief Roadmaster
Chief Vintage
Scout Standard/Deluxe/Springfield
Scout Centennial
Spirit Standard/Deluxe/Roadmaster/Springfield
6 Engine Type B
C
Engine 88 CID
Engine 100 CID
7 Horsepower 5
A
85 HP (S&S 88)
75 HP (Indian POWERPLUS™ 100)
8 Engine Make 1
J
S&S
Indian
9 Check Digit _
10 Model Year
X
Y
1
2
3
1999
2000
2001
2002
2003
11 Plant G Gilroy manufacturing plant
12–17 Production Sequence Six-digit production sequence number

INDIAN CHIEF SERVICE MANUAL GENERAL INFORMATION
5
Engine Serial Number
Location — The 6-digit engine serial number is
stamped into a pad on the left side of the engine
crankcase, just above the primary housing and at the
base of the rear cylinder.
Transmission Serial Number
Location — The transmission serial number is a
7-position alphanumeric number stamped into the
transmission case on the top edge of the starter-
mounting flange.
MAINTENANCE SERVICE, REPAIRS AND SAFETY
This is a complete manual, providing the information
necessary to perform full overhaul and rebuild
operations in addition to the very routine maintenance
service and adjustments. Procedures are included for
servicing components and subassemblies off the
motorcycle from disassembly, cleaning and inspection
to reassembly.
Generally, all specifications including torque values are
given in English measurements. Where applicable,
however, metric measurements and values are
provided.
Note: Indian Motorcycle Corporation continuously
strives for improvements in product design, quality and
performance. As a result of running changes made during
the production cycle, the information, illustrations and
descriptions in this manual may differ from the motorcycle
that is in for service.
For your own safety and proper service of the
motorcycle, follow the instructions and warnings
contained in this manual. Ignoring them could result in
damage to the motorcycle or personal injury to you or
others.
A “warning” indicates the possibility of personal
injury to yourself or others if the instructions
presented are not followed.
A “caution” indicates the possibility of damage to the
motorcycle if the instructions presented are not
followed.
Note: A “note” (placed in italic type) indicates
information that may be important in understanding the
significance of a procedure or useful in performing the
maintenance, adjustment or repair procedure.

6
NOTES INDIAN CHIEF SERVICE MANUAL

INDIAN CHIEF SERVICE MANUAL MAINTENANCE
7
MAINTENANCE
Maintenance requirements for the Indian Chief motorcycle include three levels of service performed at specific mile-
age intervals. The three levels of service include the following:
Primary Service — at 500 miles, 5,000 miles and every 10,000 miles thereafter
Interval Service — at 2,500 miles and every 5,000 miles thereafter
Renewal Service — at 10,000 miles and every 10,000 miles thereafter
Primary Service
Perform the following 30 Primary Service checks and
procedures at 500 miles, 5,000 miles, 15,000 miles and
at every 10,000 miles thereafter.
1. Change the engine oil and replace the oil filter
( page 117 ).
2. Change the transmission fluid and clean the
magnetic drain plug.
3. Check the brake fluid level and condition ( page 68 ).
4. Inspect the oil lines and brake system for leaks
( page 118 ).
5. Lubricate the front brake hand lever, throttle con-
trol cable, throttle control grip, clutch control cable
and clutch control hand lever ( pages 99, 101 and
178 ).
6. Clean the magnetic speedometer sensor.
7. Lubricate the kickstand, gear shifter and brake
lever bushings ( page 187 ).
8. Check the rear brake pedal adjustment ( page 77 ).
9. Inspect the brake pads and discs for wear ( page
69 ).
10. Inspect the inner primary chain ( page 162 ).
11. Change the primary drive oil.
12. Check and adjust the rear drive belt ( page 174 ).
13. Inspect the clutch control cable and adjust as
required ( page 179 ).
14. Inspect the air filter and replace it as required
( page 94 ).
15. Inspect the fuel filter screen; clean or replace it as
required ( page 98 ).
16. Check the enrichner operation and adjust it as
required ( page 109 ).
17. Check the engine idle speed adjustment ( page 109 ).
18. Inspect the fuel valve (petcock), fuel lines and fit-
tings for leaks ( pages 98 and 99 ).
19. Clean the battery connections ( page 223 ).
20. Check the operation of electrical equipment and
switches ( page 228 ).
21. Check the condition of the spark plugs ( page 12 ).
22. Check the ignition timing ( page 12 ).
23. Check the tires for proper inflation pressure and
for signs of wear ( page 61 ).
24. Check wheel spoke tightness ( page 60 ).
25. Check the rear shock absorber ( page 47 ).
26. Check the swingarm pivot bolts for proper tight-
ness ( page 49 ).
27. Check the steering head bearing adjustment
( page 37 ).
28. Check alignment.
29. Check the tightness of all fasteners, except the
engine cylinder head bolts.
30. Conduct a road test.
Interval Service
Perform the following 13 Interval Service checks and
procedures at 2,500 miles, 7,500 miles and at every
5,000 miles thereafter.
1. Change the engine oil and replace the oil filter
( page 117 ).
2. Check the level and condition of the transmission
fluid ( page 190 ).
3. Check the level and condition of the primary drive
oil.
4. Check the battery and clean the battery terminal
connections ( page 223 ).
5. Inspect the fuel valve (petcock), fuel lines and fit-
tings for leaks ( page 98 ).
6. Check the operation of the enrichner and throttle.
7. Check the operation of electrical equipment and
switches ( page 228 ).
8. Check the rear drive belt ( page 173 ).
9. Check the brake fluid level and condition ( page 68 ).
10. Clean the magnetic speedometer sensor.
11. Inspect the brake pads and discs for wear ( page
69 ).
12. Check the tires for proper inflation pressure and
for signs of wear ( page 61 ).
13. Conduct a road test.

8
MAINTENANCE INDIAN CHIEF SERVICE MANUAL
Renewal Service
Perform the following 33 Renewal Service checks and
procedures at 10,000 miles and at every 10,000 miles
thereafter.
1. Change the engine oil and replace the oil filter
( page 117 ).
2. Change the transmission fluid and clean the mag-
netic drain plug.
3. Replace the brake fluid ( page 68 ).
4. Inspect the oil lines and brake system for leaks
( page 118 ).
5. Lubricate the front brake hand lever, throttle con-
trol cable, throttle control grip, clutch control cable
and clutch control hand lever ( pages 99, 101 and
178 ).
6. Clean the magnetic speedometer sensor.
7. Lubricate the kickstand, gear shifter and brake
lever bushings ( page 187 ).
8. Check the rear brake pedal adjustment ( page 77 ).
9. Inspect the brake pads and discs for wear ( page
69 ).
10. Inspect the primary chain for proper adjustment
( page 162 ).
11. Change the primary drive oil.
12. Check and adjust the rear drive belt ( page 174 ).
13. Inspect the clutch control cable and adjust as
required ( page 179 ).
14. Inspect the air filter and clean or replace it as
required ( page 94 ).
15. Inspect the fuel filter screen; clean or replace it as
required ( page 98 ).
16. Check the enrichner operation and adjust it as
required ( page 109 ).
17. Check the engine idle speed adjustment ( page 109 ).
18. Inspect the fuel valve (petcock), fuel lines and fit-
tings for leaks ( page 98 ).
19. Clean the battery and clean the battery connec-
tions ( page 223 ).
20. Check the operation of electrical equipment and
switches ( page 228 ).
21. Replace the spark plugs ( page 115 ).
22. Check the ignition timing ( page 116 ).
23. Check the tires for proper inflation pressure and
for signs of wear ( page 61 ).
24. Check wheel spoke tightness ( page 60 ).
25. Check the rear shock absorber ( page 47 ).
26. Check the swingarm pivot bolts for proper tight-
ness ( page 49 ).
27. Replace the front fork oil ( page 32 ).
28. Lubricate the steering head bearings and check the
bearing adjustment ( page 37 ).
29. Repack the wheel bearings ( page 57 ).
30. Check alignment.
31. Check the tightness of all fasteners, except the
engine cylinder head bolts.
32. Inspect the fuel tank mount grommets.
33. Conduct a road test.

INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING
9
CHASSIS TROUBLESHOOTING
Brakes
Chassis
Brakes Weak or Do Not Hold Normally
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. Check brake lever or
pedal free-play. Adjust, repair or replace as necessary.
Air in hydraulic system. Bleed brakes. Refill with recommended brake fluid.
Master cylinder/caliper pistons/bores worn or seized. Repair or replace components as necessary.
Contaminated brake pads (grease/oil). Clean and inspect rotors. Replace brake pads.
Brake pads excessively worn. Clean and inspect rotors. Replace brake pads.
Brake rotors excessively worn or warped. Clean, inspect and replace as necessary.
Handling Irregularities
Problem Remedy
Motorcycle improperly loaded with excessive equip-
ment or luggage.
Eliminate excessive equipment and/or reduce luggage
to below gross vehicle weight rating.
Damaged tire(s) or improper front/rear tire combina-
tion.
Replace front tire and/or rear tire with recommended
size and type.
Irregular front or rear tire wear pattern. Replace front tire and/or rear tire with recommended
size and type.
Incorrect tire inflation pressure. Fill tires to recommended inflation pressure.
Rear shock absorber and spring assembly damaged
worn or spring rate incorrectly adjusted.
Clean, inspect, adjust, repair or replace components as
necessary.
Loose wheel axle nuts. Tighten to recommended torque specification.
Rear wheel out of alignment with front wheel or frame. Adjust rear wheel to correct alignment.
Excessive wheel bearing end play. Clean, inspect and adjust bearings as necessary.
Tire and wheel assemblies unbalanced. Balance tire and wheel assemblies.
Steering head bearings improperly adjusted. Clean, inspect and adjust bearings as necessary.
Wheel rims and/or tires out-of-round or eccentric with
wheel hub.
True wheel rims (adjust spokes) and reposition or
replace tires as necessary.
Excessive lateral runout of wheel rims and/or tires. True wheel rims (adjust spokes) and reposition tires.
Rear swing arm pivots binding, damaged or seized. Clean, inspect and repair as necessary.

10
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL
ENGINE TROUBLESHOOTING
Symptom-Related Diagnostics
Carburetor
Engine floods:
• Excessive pumping of throttle before or while
starting
•Fuel valve (petcock) left open while bike is parked
Electrical System
Alternator charge rate is below normal:
• Low battery voltage
• Loose or corroded connections
• Excessive periods of idling or low-speed riding
Alternator does not charge:
• Engine ground wire loose or broken
• Loose or broken wires in charging circuit
•Voltage regulator not grounded
Engine
Engine knocks or pings:
• Incorrect fuel (use 91 octane or higher)
• Incorrect spark plugs
• Incorrect ignition timing
Engine overheats:
• Insufficient air reaching the cylinders from slow
operation
• Insufficient oil supply
• Oil not circulating due to restricted lines, filter or
fittings
• Heavy carbon depositing from lugging the engine
• Incorrect ignition timing
• Fuel mixture to lean
Engine starts but runs irregularly or misses:
• Battery low on charge
• Spark plugs in bad condition, have improper gap
or are partially fouled
• Incorrect spark plugs
• Spark plug cables in bad condition and shorting
• Damaged wire or loose connection at battery
terminals or at coil
• Damaged wire insulation causing short circuit
• Fuel system clogged by water or dirt
• Fuel vent system plugged
Engine difficult to start:
• Battery low on charge
• Spark plugs in bad condition, have improper gap
or are partially fouled
• Incorrect spark plugs
• Spark plug cables in bad condition and shorting
•Damaged wire or loose connection(s) at one of the
battery terminals or at the coil
• Carburetor not adjusted correctly, especially the
enrichener
• Improper engine oil
• Incorrect ignition timing
Engine turns over but does not start:
• Fuel tank empty
• Fuel valve (petcock) in OFF position
• Fuel valve or fuel filter clogged
• Discharged battery or loose battery terminal
connections
• Fouled spark plugs
• Engine flooded with fuel from overuse of
enrichener
• Throttle held open when enrichener was used
• Spark plug cable connections loose or in bad
condition
• Loose or corroded wire or cable connection(s) at
coil or battery
• Fuel tank vent plugged or fuel line closed off
• Fuel system clogged by water or dirt
Engine vibrates excessively or seems to vibrate:
•Front engine mount bolts loose
• Rear engine mount bolts loose
•Broken frame
• Rear drive belt badly worn
• Wheels and/or tires damaged or out-of-true
•Vehicle not properly aligned
•Top engine mount loose or broken
Spark plugs foul repeatedly:
• Incorrect spark plugs
• Fuel mixture too rich
• Enrichener used too much