Indian Motorcycle FTR 1200 2019 - User Manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most
recent version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer
®
technicians in a properly equipped shop and should be kept available for reference. All references to left and
right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with the service procedures before starting any repair. Certain procedures require the use of special tools. Use
only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures
outlined in this Service Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more
useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit
feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature
Question'.
Consumers, please provide your feedback in writing to: Indian Motorcycle Company ATTN: Service Publications
Department, 2100 Hwy 55, Medina, MN 55340.
Publication Printed December 2018 (PN 9929391 R01)
© Copyright 2018 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due
to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the
information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for
omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2019 FTR 1200
Service Manual

Summary

CHAPTER 1 GENERAL; SPECIFICATIONS

VEHICLE INFORMATION

Details on model number, engine number, VIN, and labels.

GENERAL SPECIFICATIONS

Key physical and performance specifications for the 2019 FTR 1200 models.

VEHICLE LOADING

Information on Gross Vehicle Weight Rating (GVWR) and maximum load capacity.

SPECIAL TOOLS

Tools required for specific maintenance procedures.

CHAPTER 2 MAINTENANCE

MAINTENANCE QUICK REFERENCE GUIDE

Summary of key maintenance specifications and fluid types.

MAINTENANCE INTERVALS

Recommended service intervals for maintenance items.

BREAK-IN PROCEDURE

Guidelines for the initial engine break-in period.

MAINTENANCE PROCEDURES

Step-by-step procedures for common maintenance tasks.

ENGINE COMPRESSION TEST

How to perform an engine compression test.

BATTERY CHARGING AND MAINTENANCE

Recommendations for charging and maintaining AGM batteries.

DRIVE CHAIN TENSION

Procedure for checking and adjusting drive chain tension.

VALVE CLEARANCE INSPECTION

Procedure to inspect valve clearance.

VALVE CLEARANCE ADJUSTMENT

Procedure to adjust valve clearance using tappets.

CHAPTER 3 ENGINE; COOLING; EXHAUST

AIR CLEANER SERVICE

Overview of the air cleaner assembly.

ENGINE REMOVAL; INSTALL

Procedures for removing and installing the engine.

LUBRICATION; COOLING

Information on the lubrication and cooling systems.

CYLINDER HEAD; VALVES

Information on cylinder head and valve train service.

CAM CHAIN SERVICE

Procedures for servicing the cam chain.

CYLINDER; PISTON

Information on cylinder and piston service.

EXHAUST

Information on servicing the exhaust system.

CHAPTER 4 FUEL DELIVERY; EFI

FUEL SYSTEM ASSEMBLY VIEW

Labeled diagram of the fuel system components.

EVAP SYSTEM OVERVIEW

Explanation of EVAP system components and function.

CARBON CANISTER REPLACEMENT

Procedure to replace the carbon canister.

PURGE VALVE REPLACEMENT

Steps to replace the purge valve.

THROTTLE BODY ASSEMBLY REMOVAL; INSTALLATION

Steps to remove and install the throttle body assembly.

FUEL PUMP PRESSURE INSPECTION

How to inspect fuel pump pressure.

FUEL SYSTEM DEPRESSURIZATION

Procedure to depressurize the fuel system before service.

FUEL TANK REMOVAL

Steps to remove the fuel tank.

FUEL PUMP REMOVAL

Steps to remove the fuel pump.

FUEL PUMP INSTALLATION

Steps to install the fuel pump.

FUEL LEVEL SENSOR RESISTANCE TEST

How to test the fuel level sensor resistance.

FUEL PUMP SUPPLY VOLTAGE TEST

How to test the fuel pump supply voltage.

FUEL PUMP CURRENT DRAW TEST

Procedure to test fuel pump current draw.

PRIMING THE FUEL SYSTEM

Procedure for priming the fuel system after service.

EFI SERVICE

Overview of the Electronic Fuel Injection system.

DIAGNOSTIC TROUBLE CODES

List of diagnostic trouble codes (DTCs) and their conditions.

SENSOR DIAGNOSTICS

General approach to diagnosing sensor issues.

ECM REMOVAL; INSTALLATION

Procedure to remove and install the ECM.

CRANKSHAFT POSITION SENSOR, TEST; REPLACE

Testing and replacing the crankshaft position sensor.

CYLINDER MISFIRE DETECTION

How the ECU detects misfires and troubleshooting steps.

ENGINE CONTROLLER REPROGRAMMING (REFLASH)

Process overview for reprogramming the engine controller (ECM).

TROUBLESHOOTING

Troubleshooting guide for fuel system problems.

CHAPTER 5 CLUTCH; PRIMARY; SHIFT

SERVICE SPECIFICATIONS - CLUTCH

Specifications for clutch type, ratios, and lever play.

PRIMARY COVER REMOVAL

Steps to remove the primary cover.

CLUTCH PINION SHAFT REMOVAL

Steps to remove the clutch pinion shaft.

SHIFT RATCHET REMOVAL; INSPECTION

How to remove and inspect the shift ratchet mechanism.

CLUTCH SERVICE

Procedures for clutch service.

FLYWHEEL SERVICE

Procedures for servicing the flywheel.

TROUBLESHOOTING CLUTCH; PRIMARY; SHIFT

Troubleshooting common clutch and shift problems.

Indian Motorcycle FTR 1200 2019 Specifications