Indian Motorcycle Scout - Service Manual

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Table of Contents1
Features6
Product Overview6
Component and System Descriptions8
Chassis8
Engine and Related Systems8
Engine Component Locations9
Transmission and Drive9
Motorcycle Identification10
Chassis VIN10
Maintenance Service, Repairs and Safety11
Engine, Transmission Serial Number11
Maintenance12
Primary/Interval Service12
Renewal Service13
Chassis Troubleshooting14
Brakes Weak or Do Not Hold Normally14
Handling Irregulations14
Engine Troubleshooting15
Basic Engine Tests16
Lubrication System Troubleshooting16
Engine Compression Test16
Cylinder Leakage Test16
Emission Control System Troubleshooting17
Ignition System Troubleshooting17
Evaporative System Checks17
Spark Plug Condition, Electrical Ignition Diagnostics17
Ignition Cover (Trigger Plate), Speed Sensor Check18
Ignition Coil, Wires and Sprak Plugs Operational Check18
Ignition Module Operational Check19
Carburetor Troubleshooting21
Overflow or Flooding21
Poor Fuel Economy21
Poor Idle22
Poor Part Throttle Performance22
Poor Full Throttle Performance23
Carburetor and Exhaust Backfire23
Transmission and Drive Troubleshooting24
Shifts Hard24
Jumps out of Gear24
Clutch Chatters24
Clutch Drags or Does Not Release25
Clutch Slips25
Electrical Troubleshooting Charts26
Alternator Does Not Charge/Alternator Charge Rate below Normal26
Starter Motor Does Not Operate or Does Not Turn Engine over26
Battery Charging27
Battery Voltmeter/Load Testing27
Using Battery Charging28
Battery Charging Rate28
Ground Path Tests28
Battery Ground Cable28
Current Draw/Leak Test29
Battery to Starter29
Rectifier/Regulator Current Leak Test30
Charging System Tests30
System Output Test30
Measuring Current Output at Specified Voltage30
Stator Resistance Test31
Alternator Output Test31
Short-To-Ground Check31
Starting System Tests32
Starter Current-Draw Test32
Wiring Circuit Tests33
Electrical Harness Controller33
Diagnostic Strip33
Coil33
Horn34
Resistance Tests34
Power-Side Voltage Drop Test34
Voltage Drop Test for Slow Cranking Starter35
Starter Solenoid Test (Starter Removed)36
Front Suspension Service37
Fork Oil Replacement37
Fork Tube Procedures, Removal37
Fork Tube Disassembly39
Fork Tube Cleaning and Inspection/Assembly40
Fork Tube Installation41
Fork Seating42
Steering Component Service43
Steering Stem Inspection and Adjustment43
Inspection and Fall-Away Test43
Bearing Preload Adjustment44
Steering Stem Disassembly and Assembly46
Triple Clamp Removal46
Stem Bearing Replacement48
Bearing Race Removal/Installation48
Triple Clamp Installation48
Handlebar Replacement/Removal49
Handlebar Installation51
Rear Suspension Service52
Shock Absorbers Removal, Assembly52
Shock Absorber Installation53
Swingarm Removal53
Swingarm Pivot Bearing Replacement54
Swingarm Cleaning and Inspection54
Swingarm Installation55
Wheel and Tire Service56
Front Wheel Removal and Installation56
Checking and Adjusting Wheel Bearing End Play58
Installing Front Axle58
Rear Wheel Removal and Installation59
Dial Indicator Setup59
Removing Caliper59
Axle Nut Removal60
Hub Bearing Cleaning and Inspection61
Seal and Bearing Removal61
Installing Caliper61
Removing Seal61
Bearing and Seal Installation62
Repacking Wheel Bearing62
Wheel Sprocket and Brake Rotor Removal and Installation63
Front/Rear Wheel Brake Rotor63
Wheel Rim, Hub and Spokes Inspection64
Rear Wheel Sprocket64
Tightening Loose Spokes (Front and Rear Wheels)64
Tire Inspection and Pressure Check65
Tire Inspection66
Tire and Tube Replacement67
Tire Removal/Installation67
Wheel Lacing Procedure68
Lacing 19-Inch, 40-Spoke Wheel68
Measuring Wheel Rim Offset69
Wheel Lacing Setup69
Lacing 16-Inch 40-Spoke Wheels70
Cup-Shaped Hub Flange70
Staggered Offset Rim Hole Arrangement70
Lacing 16-Inch, 60-Spoke Wheels73
Proper Cross of Inner-To-Outer Spokes74
Aligning the Hub and Rim (Truing)75
Checking and Adjusting Lateral Alignment75
Checking and Adjusting Radial Alignment76
Adjusting Lateral Alignment76
Spoke Group Centers76
Wheel Alignment Check77
Brake System Service78
Brake Fluid Level and Condition78
Front/Rear Brake Master Cylinders78
Brake Pad Replacement79
Checking Brake Pad Thickness79
Brake Pad Comparison79
Front and Rear Brake Pad Removal and Installation80
Brake Caliper Service81
Front Caliper Removal and Installation81
Disconnecting Caliper Brake Line81
Front Brake Caliper Assembly82
Front Brake Caliper Installation83
Rear Caliper Removal and Installation83
Rear Caliper Brake Line Removal at Bonjo Fitting83
Rear Brake Caliper Assembly84
Brake Caliper Shimming Inspection85
Rear Brake Caliper Installation85
Shim Placement on Mounting Screws between Caliper and Mounting Bracket85
Brake Rotor Service86
Rotor Inspection86
Master Cylinder Service86
Front Master Cylinder Removal and Installation86
Front Master Cylinder Assembly87
Rear Master Cylinder Removal and Installation88
Rear Master Cylinder Location88
Rear Master Cylinder Pushrod Free Play89
Front and Rear Master Cylinder Disassembly and Assembly89
Front Master Cylinder Cleaning and Inspection89
Hydraulic Brake Line Replacement90
Front Brake Line Removal and Installation90
Opening Brake Bleeder Screw90
Rear Brake Line Removal and Installation91
Disconnecting Brake Line91
Disconnecting Brake Line at Rear Caliper/Junction Block92
Replacing Brake Fluid and Bleeding the Hydraulic System93
Frame and Accessories Service95
Seat Removal and Installation95
Seat Front Retainer Bracket95
Removing Seat Mounting Screw95
Fender Removal and Installation96
Unplugging Fender Light Connector96
Tightening Retainer Clip97
Removing Rear Fender Bracket Mounting Screws97
Unplugging Rear Fender Light Harness97
Dash Removal and Installation98
Front Turn Signal and Headlight Procedures98
Removing Dash Rear Retaining Screw98
Removing Lens98
Headlight Assembly/Bulb Replacement99
Housing Removal and Installation99
Removing Damp and Light Assembly99
Removing Headlight Turn Rug Screws99
Headlight Housing Replacement100
Front Fender Light100
Fender-Mounted Light Procedures100
Bulb Replacement100
Floorboard and Buddy Peg Removal and Installation101
Integral Taillight and Turn Signal Assembly101
Floorboard Overview101
Kickstarter Removal and Installation102
Mirror Assembly Removal, Installation and Adjustment102
Buddy Ped Procedure102
Removing Kickstand Assembly102
Chassis Frame Inspection and Repair103
Air Cleaner and Filter Element Service105
Air Filter Replacement105
Removing Air Cleaner Cover105
Filter Element Seated over Web and against Base105
Air Cleaner Assembly Removal and Installation106
Installing Base-To-Cylinder Head Breather Rent Fitting Screws107
Filter Element Seated over Base and against Base107
Installing Air Cleaner Cover107
Fuel System Service108
Fuel Filtration Maintenance108
Cleaning the Petcock Filter Screen108
Cleaning the In-Line Fuel Filter109
Fuel Line Inspection and Replacement110
Throttle Control Inspection and Maintenance110
Throttle Cable Lubrication110
Removing Mounting Screws, Removing Front Brake Control110
Removing Throttle/Switch Housing Screws111
Installing Front Brake Control111
Lubricating Throttle Cable111
Throttle Cable Adjustment112
Fuel Tank Removal and Installation112
Installing Clamp Screws112
Adjusting Front Cable Jam Nut112
Tank Removal113
Fuel Crossover Lube113
Removing Dash Panel113
Center Mounting Screws114
Removing Left Fuel Tank114
Installing Upper Mounting Screws115
Installing Left Fuel Tank115
Speedometer and Warning Light Wiring Connections116
Installing Dash Panel Rear Retaining Screw116
Installing Seat/Dash Panel116
Carburetor Service117
S&S Type E Carburetor117
Air Leaks117
Carburetor Removal and Installation118
Removing Air Cleaner Base/Cover118
Disconnecting Throttle-Control Cables118
Carburetor Maintenance119
Idle Speed and Mixture Adjustment119
Accelerator Pump Adjustment120
Idle Mixture Adjustment Screw120
Carburetor Rebuild121
Carburetor Disassembly and Assembly121
Accelerator Pump121
Directing Compressed Air through Accelerator Pump Discharge Tube121
Diaphragm Removed from Accelerator Pump Cap122
Float Brass Needle/Float Pin Retaining Screw122
Accelerator Pump Discharge Tube with O-Ring122
Setting Float Height123
Low Speed Port/Main Jet Port123
Bleed Hole and Port Check123
Main Jet Discharge Tube124
Enrichener/Fast Idle Port124
Throttle Shaft/Spool125
Accelerator Pump Actuator Assembly125
Idle Mixture, Idle Stop and Accelerator Pump Adjustment Screws126
Bowl Gasket, Drain Plug and Body O-Rings126
Cabruretor Installation, Exploded View127
Cabruretor Exploded View Legend128
Ignition System Service129
Spark Plug Replacement129
Ignition Coil and Spark Plug Wire Replacement129
Coil Removal and Installation129
Ignition Trigger Plate/Rotor Removal and Installation130
Spark Plug Wire Removal and Installation130
Ignition Module Replacement131
Installing Ignition Rotor131
Access to Ignition Module131
Ignition Timing Check and Adjustment132
Static Timing Procedure132
Timing Mark Inspection Plug132
Dynamic Timing133
T:F Mark Centered in Inspection Hole133
Trigger Plate and Screws133
Flywheel with Indicated Timing Marks Shown134
Lubrication System Service135
Engine Oil and Oil Filter Replacement135
Opening the Oil Drain Tube135
Proper Engine Oil Level135
Cleaning the Tappet Screen136
Oil Line Inspection and Replacement136
Inspection at Oil Tank136
Removing the Tappet Screen136
Oil Pump Removal and Installation137
Inspection at the Oil Filter Adapter137
Oil Line Connections at Tank137
Removing Oil Pump Cover/Tappet Screw138
Oil Tank Removal and Installation139
Oil Pump Gear Arrangement139
Installing Tappet Screen139
Oil Tank Assembly140
Removing Retaining Nut at Rear Isolator Mount141
Removing Oil Tank/Rear Mounting Bracket141
Installing Seat142
Emission Control System Service143
Evaporative System143
Carbon Canister Removal and Installation144
Air Valve Removal and Installation144
Removing Air Valve and Diaphragm145
Air Valve and Vent Tube145
Exhaust System Service146
Muffler, Heat Shields and Exhaust Header146
Heat Shield, Muffler, Exhaust Removal and Installation146
Engine Removal and Installation148
Removing Chassis Components and Engine Accessories148
Removing Seat Bolt148
Dash Rear Retaining Screw148
Removing Dash, Air Cleaner Cover149
Remounting Carburetor150
Removing Upper Support Bracket-To-Frame Bolt150
Engine Removal151
Exhaust Manifold Retaining Nuts151
Removing Air Filter Adapter151
Muffler Retaining Bolt151
Compensator Sprocket and Chain Adjuster152
Primary Housing Mounting Screws152
Engine Installation153
Breather Hoses and Oil Lines153
Installing O-Ring on Crankcase153
Removing Front Engine Mounting Bolts153
Positioning Engine on Frame154
Installing Chassis Components and Engine Accessories155
Engine Disassembly and Assembly156
Rocker Box Procedures Removal156
Removing Cover Screws156
Rocker Shaft Disassembly and Inspection157
Removing Rocker Shaft157
Rocker Shaft Assembly158
Rocker Shaft Assembly Installation159
Installing Rocker Base159
Installing Covergasket, Rocker Cover160
Pushrod and Tube Removal and Installation161
Removing Pushrod Tube Clip162
Pushrod Adjustment163
Adjustment End of Pushrod163
Adjusting Pushrod164
Cylinder Head Procedures165
Cylinder Head Removal, Disassembly166
Removing Intake Manifold Screws, Cylinder Head Bolts166
Cylinder Head Cleaning and Inspection, Assembly167
Installing Valve Springs167
Cylinder Head Installation168
Valve Spring Compressor Tool Setup168
Installing Cylinder Head168
Cylinder Head Torque Sequence168
Cylinder and Piston Assembly Procedures169
Installing Intake Manifold Gasket169
Cylinder Inspection170
Piston Inspection and Ring Replacement170
Checking Cylinder Bore Dimensions170
Piston and Cylinder Installation171
Positioning Ring Gaps171
Installing Piston and Wrist Pin171
Alternator Rotor/Stator Removal and Installation172
Removing Stator Mounting Screws172
Installing Cylinder172
Installing Stator Plug Setscrew173
Lifter Block Removal and Installation, Cleaning and Inspection174
Removing Lifter Block Assembly174
Remounting Ignition Rotor175
Cam, Breather Valve and Pinion Gear Removal and Installation176
Installing Flageless Cover176
Removing Cam Cover176
Timin Gmarks Aligued177
Removing Pinion Gear Nut177
Remounting Cam Assembly177
Pinion Shaft, Cam and Breather Valve Assemblies178
Remounting Spacer and Oil Pump Drive Gear178
Installing Shim and Thrust Washer179
Timing Mark Properly Aligned179
Measuring Camshaft End Play179
Crankcase Disassembly and Assembly180
Sprocket Shaft Bolder Mounted180
Driving out Locator Bolts180
Driving and Locator Bolts181
Cleaning and Inspection of Crankcase183
Flywheel and Crank Assembly Mounted in Jig184
Seating Bearing in Case with Locket Wrench184
Placing Left Case Half on Sprocket Shaft184
Placing Sprocket Shaft Seal in Position on Case185
Sprocket Shaft Holder Mounted in Vise185
Seating Seal in Case185
Installing Right Case185
Driving in Locator Bolts186
Primary Drive Service187
Primary Chain Inspection187
Chain Adjustment Inspection Cover187
Chain/Tensioner Visible through Inspection Cover187
Primary Drive Removal, Installation, Adjustment188
Removing Primary Drive Housing Screws188
Inspecting Primary Drive Components188
Chain Tensioner Assembly189
Remounting Chain Tensioner Inlock Nut189
Sliding Tensioner down to Loosen Chain189
Compensator Spring Cup Inspection190
Removing Compensator Assembly/Pressure Plate Screws and Springs190
Remove Pressure Plate and Discs190
Measuring Spring Cup Height190
Remove Clutch Hub Retaining Nut191
Removing Starter Motor Drive Pinout Assembly191
Removing Primary Drive Chain and Sprockets191
Bending Tabs to Unlock191
Removing Inner Primary Drive Housing192
Positioning Inner Primary Drive Housing192
Installing O-Ring192
Installing Starter Motor Drive Pinion Assembly, Drive Chain and Sprockets193
Installing Clutch Hub Retaining Nut193
Installing Pressure Plate and Discs, Compensator Assembly194
Primary Drive Chain Adjustment195
Checking Primary Chain Slack Adjustment195
Tightening Chain Adjuster Inlock Nut195
Engine/Transmission Alignment196
Tightening Primary Drive Housing Screws196
Housing Screw Tightening Sequence196
Upper Engine Mount Bolt Torque Sequence197
Engine/Transmission Mounting Bolt Torque Sequence197
Rear Drive Service198
Rear Drive Belt Inspection, Removal and Installation198
Removing Primary Drive Components, Rear Wheel and Swing Arm198
Slip Rear Drive Belt from Transmission Sprocket198
Rear Wheel Alignment and Drive Belt Tension Adjustment199
Installing Rear Drive Belt, Primary Drive Components199
Rear Wheel Alignment200
Drive Belt Tension Adjustment200
Loosening Rear Asle200
Rear Drive Belt Tracking201
Measuring Belt Tension201
Rotating Axle Adjusting Nut201
Checking Belt Tracking201
Drive Belt Handling and Storage202
Clutch Service203
Clutch Lever and Cable, Cable Inspection203
Lever Removal and Cable Lubrication203
Snap Ring Removal203
Clutch Lever Bracket Removal and Installation204
Clutch Cable Adjustment, Clutch Cover Installation205
Clutch Adjusting Screw and Jam Nut205
Clutch Removal and Installation206
Chain Adjuster Access Cover Removal206
Removing Pressure Plate Retaining Screws206
Removing Pressure Plate207
Friction and Steel Disc Orientation207
Installing Pressure Plate208
Disc Orientation208
Clutch Disassembly and Assembly209
Clutch Cover Installation209
Check Tab Slots for Wear209
Hub/Sprocket Case Disassembly/Assembly210
Check Splines for Wear210
Clutch Assembly211
Transmission Maintenance212
Transmission Shift Control Linkage Maintenance and Adjustment212
Shift Rod Rear Pivot Bolt Clearance Check212
Pivot Bolt Bear-To-Primary Housing Clearance212
Shift Rod Pivot Bolt Lubrication/Adjustment213
Loosening Jam Nut213
Shift Pawl Adjustment214
Equal Lash between Pin and Pawl214
Removing Shift Drum Cover214
Loosen Locknut214
Transmission Oil Change215
Tighten Locknut215
Drain Plug Removal215
Checking Transmission Oil Level216
Fill Plug Dipstick216
Transmission Removal and Installation217
Disconnecting Clutch Cable at Handlebar Control217
Removing Shift Rod Pivot Bolt/Starter Motor218
Loosening Rear Axle218
Transmission Installation219
Loosening Axle Adjusting Nuts219
Removing Transmission Mounting Nuts, Transmission219
Installing Transmission, Primary Drive Chain and Sprockets220
Installing Starter Motor220
Adjusting Drive Belt Tension220
Installing Oil Tank221
Transmission Overhaul, Disassembly222
Removing Six Clutch Cover Bolts222
Removing Shift Drum Cover, Drum and End Supports from Housing, Locking Plate223
Remounting Shift Drum Supports223
Removing Drive Sprocket Nut from Shaft224
Loosening Mainshaft and Countershaft Nuts224
Remove Set Screw from Left Side of Transmission/The Trapdoor Bolts224
Main Gear (5Th Gear) Removal from Case225
Removing Mainshaft, Countershaft and Gears225
Main Gear (5Th Gear) Roller Bearing Removal and Replacement226
Removing Main Drive Gear, Main Bearing, Seal226
Setting up Tool to Install Main Bearing226
Case Needle Bearing Inspection and Replacement227
Installing New Main Seal227
Inspecting Needle Bearing at Left of Case227
Main Gear (5Th Gear) Needle Bearing Inspection and Replacement228
Countershaft and Mainshaft Disassembly228
Installing Main Gear into Case228
Removing 5Th Gear228
Removing 2Nd Gear and Thrust Masher229
Remounting the 3Rd Gear Relating Ring229
Removing Shift Cage Roller Bearing229
Removing 2Nd Gear from Mainshaft, Split Cage Roller Bearing230
Pressing Countershaft from Trap Door Bearing230
Bearing Removal and Installation in Trapdoor231
Pressing Mainshaft from Trapdoor Bearing231
Remove and Inspect Split Cage Roller Bearing231
Shaft Assembly232
Install Thrust Washer232
Trapdoor End of Mainshaft232
Countershaft233
Installing Thrust Washer Onto Countershaft/Split Bearing Onto Countershaft233
Installation of Shafts into Trapdoor234
Mainshaft234
Stepped Spacer and Spacer Without Step234
Seating Shafts to Bearings234
Gear Stacking235
Installing 3Rd Gear Retaining Ring on Mainshaft235
Groove in Gear for Shift Fork235
Installing 3Rd Gear into Countershaft236
Installing Gearset into Transmission Case237
Square Cut Seal238
Installing Spacer Onto Main Drive Gear238
Seal Location on Main Drive Gear238
Sprocket Spacer238
Driving Seal into Transmission Case239
Drive Seal in until Fully Seated239
Installing Seal over Sleeve Tool on Mainshaft239
Slip the Rod into the Mainshaft239
Shift Fork Inspection and Installation240
Shift Drum Installation240
Lift Shift Pawl Upward240
Align Shift Fork Pins to Grooves in Shift Drum241
Installing Support Block Bolts241
Seat Shift Drum Support Blocks Onto Split Pins241
Sprocket Installation243
Placing Ramp Back into Housing243
Snap Ring Ends Captured by Groove243
Starting System Service244
Starter Motor and Drive Pinion Assembly244
Starter Drive Pinion Assembly245
Drive Pinion Removal245
Outer Primary Housing Removal245
Transmission Shift Rod245
Drive Pinion Installation246
Starter Motor/Starter Removal246
Starter Installation, Disassembly and Assembly247
Starter Mounting Bolt Removal247
Starter Relay Replacement, Removal248
Speedometer and Warning Light Wiring Connectors248
Charging System Service249
Battery and Cables Cleaning and Inspection249
Disconnecting Battery Cables249
Alternator Replacement250
Rotor/Stator Removal250
Battery Replacement250
Compensator Sprocket Removal251
Loosening the Cabin Tensioner251
Rotor/Stator Inspection, Installation252
Stator Electrical Connector and Lead Position252
Positioning the Chain Adjuster252
Measuring Primary Chain Deflection Slack252
Voltage Regulator Replacement, Removal and Installation253
Power Distribution, Lighting and Instrument Service254
Electrical Equipment Check254
Warning Lights, Left/Right Handlebar Switches254
Circuit Breakers254
Speedometer and Warning Light Replacement255
Dash Panel Removal255
Remounting Threaded Collar from Housing255
Electronic Control Module, Access And/Or Replacement256
Dash Panel Installation256
Warning Lights256
Road Light Replacement257
Handlebar Switch Replacement257
Replacing the Module257
Remounting Electronic Control Module257
Right Handlebar Switch258
Installing/Removing Front Brake Control258
Remove/Install Throttle258
Replacing a Switch and Harness Assembly259
Disconnecting Switch Harness259
Removing Front Brake Control260
Harness Routing through Upper Fork Bracket260
Circuit Wiring Repair261
Installing the Left/Right Handlebar Switches261
Completing the Installation261
Chassis Specifications and Torque Values262
Dimensions and Weight262
Brakes262
Wheels and Tires263
Front Fork and Suspension264
Rear Swingarm and Suspension264
Frame and Accessories265
Engine Specifications and Torque Values266
Fits and Tolerances266
Valve Rocker Box Assembly266
Cylinder Head and Valves/Cylinder and Piston Assembly267
Oil Pump Assembly267
Crankcase268
Cam Cover268
Flywheel and Crank Assembly268
Ignition System268
Engine Fastener Torque Values269
Drivetrain Specifications and Torque Values271
Primary, Clutch and Final Drive271
Transmission272
Electrical Component Fastener Torque Values273
Lubricants and Fluids273
Sealants and Threadlock Compounds274
Engine Assembly274
Chassis Assembly275
Chassis Wiring Diagrams277
Ignition System Diagram279
Lubrication Flow Diagram280
Transmission Power Flow Diagrams281
Indian 5-Speed Transmission281
Engine Part and Assembly Drawings283
Camshaft Gear Case Cover283
Crankcase Overview and Parts284
Crankcase Bolts286
Ignition Timing Plate287
Front/Rear Cylinders, Camshaft and Breather Valve288
Flywheel Assembly290
Pistons and Front/Rear Cylinder Beads292
Front/Rear Lifter Block Assembly295
Front/Rear Cylinder Rocker Assembly297
Oil Pump299
Special Tools301
Index303
Shock Absorber Inspection and Adjustment309
Removing Shock Absorber Swingarm Mounting Screw309
Rotating Adjustment Collar with Spanner Wrench309

Indian Motorcycle Scout - Service Manual

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