Home
Indian Motorcycle
Motorcycle
Chief 2003
Indian Motorcycle Chief 2003 User Manual
4
of 1
of 1 rating
298 pages
Give review
Manual
Specs
To Next Page
To Next Page
Loading...
PRINTED P/N 99-846
CD P/N 99-821
2
Table of Contents
Default Chapter
3
Foreword
3
Organization and Content
3
Table of Contents
5
Finding the Information You Need
11
Features of the 2003 Indian Chief Motorcycle
11
Component and System Descriptions
11
Motorcycle Identification
14
Chassis VIN
14
Engine Serial Number
15
Transmission Serial Number
15
Maintenance
15
Maintenance Service, Repairs and Safety
15
Maintenance
17
Primary Service
17
Interval Service
17
Renewal Service
18
Troubleshooting
19
Chassis Troubleshooting
19
Brakes
19
Chassis
19
Engine Troubleshooting
20
Symptom-Related Diagnostics
20
Basic Engine Tests
21
Emission Control System Troubleshooting
22
Evaporative System Checks
22
Ignition System Troubleshooting
22
Spark Plug Condition
22
Electronic Ignition Diagnostics
22
Carburetor Troubleshooting
27
Transmission and Drive Troubleshooting
30
Transmission
30
Clutch
30
Electrical Troubleshooting
32
Electrical Troubleshooting Tables
32
Battery Testing
33
Battery Charging
33
Ground Path Tests
34
Current Draw/Leak Test
35
Rectifier/Regulator Current Leak Test
35
Charging System Tests
36
Starting System Tests
38
Wiring Circuit Tests
38
Front Suspension
42
Front Suspension Service
42
General Information
42
Fork Oil Replacement
43
Fork Tube Procedures
43
Steering Components
48
Steering Component Service
48
Steering Stem Inspection and Adjustment
48
Steering Stem Disassembly and Assembly
51
Handlebar Replacement
54
Rear Suspension
57
Rear Suspension Service
57
Shock Absorber
57
Swingarm
60
Wheels and Tires
62
Wheel and Tire Service
62
Front Wheel Removal and Installation
62
Rear Wheel Removal and Installation
65
Hub Bearing Cleaning and Inspection
68
Wheel Sprocket and Brake Rotor Removal and Installation
70
Wheel Rim, Hub and Spokes Inspection
71
Tire Inspection and Pressure Check
72
Tire and Tube Replacement
73
Wheel Lacing
75
Lacing 16-Inch, 60-Spoke Wheels
75
Aligning the Hub and Rim (Truing)
77
Brake System
79
Brake System Service
79
Brake Fluid Level and Condition
79
Brake Pad Replacement
80
Brake Caliper Service
83
Brake Rotor Service
86
Master Cylinder Service
86
Hydraulic Brake Line Replacement
90
Replacing Brake Fluid and Bleeding the Hydraulic System
91
Frame and Accessories
93
Frame and Accessories Service
93
Seat Removal and Installation
93
Fender Removal and Installation
94
Chassis Fairing Removal and Installation
96
Dash Removal and Installation
96
Front Turn Signal, Spotlight and Headlight Procedures
97
Fender-Mounted Light Procedures
100
Floorboard and Buddy Peg Removal and Installation
101
Mirror Assembly Removal, Installation and Adjustment
102
Kickstand Removal and Installation
102
Frame Inspection and Repair
103
Air Cleaner
105
Air Cleaner and Filter Element Service
105
Air Filter Element
106
Fuel System
110
Fuel System Service
110
Fuel Filtration Maintenance
110
Fuel Line Inspection and Replacement
111
Throttle Control Inspection and Maintenance
111
Fuel Tank Removal and Installation
113
Carburetor Service
117
Carburetor Circuit Description
117
Air Leaks
119
Carburetor Removal and Installation
119
Carburetor Maintenance
121
Carburetor Illustrations
123
Ignition System
127
Ignition System Service
127
Spark Plug Replacement
127
Ignition Coil and Spark Plug Wire Replacement
127
Ignition Cover Housing/Rotor Removal and Installation
128
Ignition Module Replacement
128
Ignition Timing Check and Adjustment
128
Lubrication System
129
Lubrication System Service
129
Engine Oil and Oil Filter Replacement
129
Cleaning the Tappet Screen
129
Oil Line Inspection and Replacement
130
Oil Pump Removal and Installation
131
Oil Tank Removal and Installation
132
Emission Control System
134
Emission Control System Service
134
Evaporative System
134
Carbon Canister Removal and Installation
135
Air Valve Solenoid Removal and Installation
135
Exhaust System
136
Exhaust System Service
136
Muffler, Heat Shields and Exhaust Header
136
Engine
137
Engine Removal and Installation
137
Removing Chassis Components and Engine Accessories
137
Engine Removal
140
Engine Installation
142
Installing Chassis Components and Engine Accessories
143
Engine Disassembly and Assembly
144
Rocker Box Procedures
144
Pushrod and Tube Removal and Installation
148
Pushrod Adjustment
150
Cylinder Head Procedures
151
Cylinder and Piston Assembly Procedures
156
Alternator Rotor/Stator Removal and Installation
161
Lifter Block Removal and Installation
161
Oil Pump Removal and Installation
162
Ignition Cover Housing/Rotor Removal and Installation
163
Cam, Breather Valve and Pinion Gear Removal and Installation
164
Crankcase Disassembly and Assembly
169
Primary Drive
174
Primary Drive Service
174
Primary Chain Inspection
174
Primary Drive Removal, Installation and Adjustment
175
Engine and Transmission Alignment
183
Rear Drive
185
Rear Drive Service
185
Rear Drive Belt Inspection, Removal and Installation
185
Rear Wheel Alignment and Drive Belt Tension Adjustment
186
Drive Belt Handling and Storage
189
Clutch
190
Clutch Service
190
Clutch Lever and Cable
190
Clutch Inspection and Adjustment
191
Clutch Plate Removal and Installation
193
Clutch Disassembly and Assembly
196
Transmission
199
Transmission Maintenance
199
Transmission Shift Control Linkage Maintenance and Adjustment
199
Transmission Oil Change
201
Transmission Removal and Installation
203
Transmission Removal
203
Transmission Installation
205
Transmission Overhaul
208
Tools Required
208
Transmission Disassembly
208
Installation of Shafts into Trapdoor
220
Shift Fork Inspection and Installation
226
Starting System
230
Starting System Service
230
General Information
230
Starter Drive Pinion Assembly
231
Starter Motor
232
Starter Solenoid
234
Starter Relay
234
Charging System
235
Charging System Service
235
General Information
235
Battery and Cables
235
Alternator Replacement
236
Voltage Regulator Replacement
239
Chassis Electrical
240
Power Distribution, Lighting and Instrument Service
240
Electrical Equipment Check
240
Circuit Breaker Replacement
240
Speedometer and Warning Light Replacement
241
Road Light Replacement
242
Handlebar Switch Replacement
242
Circuit Wiring Repair
246
Specifications
247
Chassis Specifications & Torque Values
247
Brakes
247
Wheels and Tires
247
Front Fork and Suspension
248
Rear Swingarm and Suspension
248
Frame and Accessories
249
Engine Specifications & Torque Values
250
General
250
Fits and Tolerances
250
Fastener Torque Values
253
Drivetrain Specifications & Torque Values
255
Primary, Clutch and Final Drive
255
Transmission
256
Electrical Component Fastener Specifications & Torque Values
257
Lubricants and Sealants
258
Engine Assembly
258
Chassis Assembly
258
Schematics
260
Chassis Wiring Diagrams
260
Ignition System Diagram
263
Lubrication Flow Diagram
263
Transmission Power Flow Diagrams
264
Indian 5-Speed Transmission
264
Assembly Drawings
267
Engine Part and Assembly Drawings
267
Tools and Equipment
289
Special Tools
289
Tool Drawings
290
4
Based on 1 rating
Ask a question
Give review
Questions and Answers:
Need help?
Do you have a question about the Indian Motorcycle Chief 2003 and is the answer not in the manual?
Ask a question
Indian Motorcycle Chief 2003 Specifications
General
Brand
Indian Motorcycle
Model
Chief 2003
Category
Motorcycle
Language
English
Related product manuals
2003 Chief Vintage
305 pages
Indian Chief 2024
200 pages
2016 Chief Vintage
185 pages
Indian Motorcycle Chief Classic
176 pages
Indian Motorcycle Chief Vintage
257 pages
Chief Roadmaster
325 pages
Indian Motorcycle 2016 Chieftain
185 pages
Indian Motorcycle Scout
134 pages
Indian Motorcycle Spirit
309 pages
Indian Motorcycle Indian Scout
122 pages
Roadmaster 2015
185 pages
SCOUT BOBBER 2021
162 pages
Need help?
General
To Next Page