2003 Indian Chief Motorcycle Service Manual – PDF DOWNLOAD
FILE DETAILS:
2003 Indian Chief Motorcycle Service Manual – PDF DOWNLOAD
Language : English
Pages : 298
Downloadable : Yes
File Type : PDF
Size: 105 MB
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2003 Indian Chief Motorcycle Service Manual – PDF DOWNLOAD
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.
TABLE OF CONTENTS:
2003 Indian Chief Motorcycle Service Manual – PDF DOWNLOAD
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
v
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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TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL
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
TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL
INDEX
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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