Polaris 2016 INDIAN Chief Classic- Manuals

5 Introduction Identification Number Records Record important identification numbers below. Vehicle Identification Number (VIN) (see page 20) Engine Identification Number (see page 6) Master PIN Rider PIN Key Fob #1 Serial Number Key Fob #2 Serial Number Key Fob #3 Serial Number Key Fob #4 Serial Nu...

6 Introduction Ser vice and Warranty Information Some procedures are beyond the scope of this manual. See your dealer to purchase an INDIAN MOTORCYCLE Service Manual . Some procedures provided in the service manual require specialized knowledge, equipment, and training. Be sure you have the required...

7 Safety About the Rider's Manual Failure to follow all recommended precautions and procedures could result in severe injury or death. Always heed all safety precautions and follow all operation, inspection and maintenance procedures outlined in this manual. All references to RIGHT, LEFT, FRONT or R...

8 Safety Safe Riding Practices Improper use of a motorcycle can result in serious injury or death to you, your passenger and others. To minimize the risk of injury, read and understand the information contained in this section before operating the motorcycle. This section contains safety information...

9 Safety Safe Riding Practices Follow these general safe riding practices: • Before each ride, perform the pre-ride inspections as outlined beginning on page 65. Failure to do so may result in damage to the motorcycle or an accident. • Until you're thoroughly familiar with the motorcycle and all of ...

10 Safety Safe Riding Practices • Reduce speed when: - The road has potholes or is otherwise rough or uneven.- The road contains sand, dirt, gravel or other loose sub- stances. - The road is wet, icy or oily.- The road contains painted surfaces, manhole covers, metal grating, railway crossings or ot...

11 Safety Safe Riding Practices Carr ying a Passenger Do not carry a passenger unless the motorcycle is equipped with passenger seat and passenger footrests. To carry a passenger safely: • Do not exceed the gross vehicle weight rating (GVWR) for your motorcycle. Refer to the Specifications section o...

12 Safety Safe Riding Practices Protective Apparel Wear protective apparel to decrease the risk of injury and increase riding comfort. • Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) labe...

13 Safety Use of Accessories Because INDIAN MOTORCYCLE cannot test and make specific recommendations concerning every accessory or combination of accessories sold, the operator is responsible for determining that the motorcycle can be safely operated with any accessories or additional weight. Use th...

14 Safety Modifications Modifying the motorcycle by removing any equipment or by adding equipment not approved by the manufacturer may void your warranty. Such modifications could make the motorcycle unsafe to ride and could result in severe injury to operator or passenger, as well as damage to the ...

15 Safety Carr ying Cargo Use the following guidelines when attaching cargo or accessories to the motorcycle. Where applicable, these guidelines also refer to the contents of any accessories.• Keep cargo and accessory weight to a minimum, and keep items as close to the motorcycle as possible to mini...

16 Safety Transporting the Motorcycle If you must transport the motorcycle:• Use a truck or trailer. Do not tow the motorcycle with another vehicle, as towing will impair the motorcycle's steering and handling. • Position and restrain the motorcycle in an upright position. If the motorcycle leans to...

17 Safety Safety Maintenance Failure to perform safety maintenance as recommended can result in difficult handling and loss of control, which could result in serious injury or death. Always perform the safety maintenance procedures as recommended in this manual. Perform maintenance and repairs promp...

18 Safety Electromagnetic Interference This vehicle complies with UN ECE Regulation 10 requirements and Canadian ICES-002. Key Fob and Vehicle Control Module FCC/IC Compliance Statement FCC: W99PI01, W99PI02IC: 8296A-PI01; 8296A-PI02This device complies with Part 15 of the FCC Rules and Canada licen...

19 Safety Gross Vehicle Weight Rating (GVWR) WARNING! Exceeding the gross vehicle weight rating of your motorcycle can reduce stability and handling and could cause loss of control. NEVER exceed the GVWR of your motorcycle. The maximum load capacity of your motorcycle is the maximum weight you may a...

20 Safety Safety and Information Labels Labels are model-specific and market-specific. Some of the following labels will be present only if your motorcyle is equipped with the feature. 1. Vehicle Identification Number (VIN) (side of steering head) 2. Vehicle Emission Control Information (VECI) 3. No...

21 Component Identification Console 1. Clutch Lever 2. Auxiliary Light Switch (CHIEF VINTAGE/CHIEFTAIN/ ROADMASTER) 3. Fuel Gauge (CHIEF VINTAGE) 4. Instrument Cluster 5. Power Switch/Security Light 6. Front Brake Master Cylinder 7. Throttle Control Grip 8. Front Brake Lever 9. 12-Volt Outlet (CHIEF...

23 Component Identification 24. Front Fork 25. Fuel Tank 26. Air Box Cover (left) 27. Driver’s Seat 28. Battery (under seat) 29. Passenger Seat (if equipped) 30. Saddlebag (if equipped) 31. Radio Antenna (if equipped) 32. Side Cover (Left) 33. Shock Air Fill (under cover) (CHIEFTAIN/ROADMASTER) 34. ...

24 Instruments, Features and Controls Switches Flasher (Hazard) Switch High/Low Light Switch Horn Switch Turn Signal Switch Engine Starter Switch Engine Stop/Run Switch LEFT-TOGGLE Switch Audio Control Switches (if equipped) Cruise Control Switch Cruise On/Off Switch Left Control Left Control Right ...

26 Instruments, Features and Controls Switches Symbol Switch Description Emergency Flasher Switch (Hazard Switch) The hazard switch activates and cancels the emergency flashers. See page 27. High/Low Headlight Beam Switch The high/low headlight beam switch toggles the headlight between high beam and...

27 Instruments, Features and Controls Switches Power Switch The power switch is located on the center console. Press and release the power switch to enable or disable all electrical power to the vehicle. The power switch does not have to be on to start the engine. See page 28.To disable all electric...

28 Instruments, Features and Controls Switches Engine Starter Switch Read the engine starting procedures before starting the engine. See page 79.The power switch does not have to be on to start the engine. Press and hold the starter switch to engage the one-touch starting feature, which activates th...

29 Instruments, Features and Controls Switches High/Low Headlight Beam Switch The headlights automatically come on when the engine is started. See page 54.The high/low headlight beam switch toggles the headlight between high beam and low beam. To activate the high beam, press the upper portion of th...

30 Instruments, Features and Controls Switches Toggle Switches All models are equipped with toggle switches on the front side of the left and right handlebar controls. The LEFT- TOGGLE switch is active for all models. The RIGHT-TOGGLE switch is active only for CHIEFTAIN and ROADMASTER models. The po...

31 Instruments, Features and Controls Switches Saddlebag/Trunk Lock Switch (if equipped) Use the key fob or the lock switch on the console to lock and unlock the electric saddlebag and trunk locks. When using the console lock switch, the key fob must be within range. If the key fob is not detected, ...

32 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) The instrument cluster includes the speedometer, indicator lamps and Multi-Function Display (MFD). Speedometer The speedometer displays forward vehicle speed in either miles per hour or kilometers per hour. Speedometer Indic...

33 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) Indicator Lamps Lamp Indicates Condition Chassis Fault The alert symbol illuminates if a chassis fault occurs. Tire Pressure Monitoring System (TPMS) If equipped, the TPMS indicator illuminates if low tire pressure is detect...

34 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) Multi-Function Display (MFD) MFD Indicators Fuel Gauge Display (CHIEF CLASSIC/DARK HORSE) The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated....

35 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) Multi-Function Display (MFD) The power switch must be ON to access the MFD. Use the mode switches to toggle through the modes of the multi- function display and to change settings in the display. Odometer The odometer displa...

36 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) Multi-Function Display (MFD) Display Units (Standard/Metric) The display can be changed to display either standard or metric units of measurement. 1. Stop the engine.2. Wait 10 seconds.3. Press and hold the LEFT-TOGGLE switc...

37 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) Multi-Function Display (MFD) Diagnostic Functionality Certain conditions will cause an error message to display in the screen. If this occurs, please see your authorized dealer. Engine Error Codes The error screen displays o...

38 Instruments, Features and Controls Instrument Cluster (CHIEF/DARK HORSE) Multi-Function Display (MFD) Low Oil Pressure Display (CHIEF) “LO OIL” displays under the following conditions. Condition Indicates Action Required Engine oil pressure has dropped while the engine is running. Oil pressure is...

42 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Multi-Function Display (MFD) The power switch must be on or the engine must be running to view or change settings in the MFD. Use the LEFT- TOGGLE and RIGHT-TOGGLE switches to toggle through the modes of the multi-functi...

43 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Infotainment Display Settings The following items can be displayed in Zone Three on the infotainment display: • Trip 1 Hours/Distance• Trip 2 Hours/Distance• Fuel Economy• Front/Rear Tire Pressure• Engine Hours/Oil Life•...

44 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Infotainment Display Settings Fuel Economy This screen will display the current instant and average miles per gallon (MPG) or liters per 100 kilometers.1. Press and hold LEFT-TOGGLE to reset the average. 2. Press LEFT-TO...

45 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Infotainment Display Settings Average Speed/Batter y Voltage This screen displays the average motorcycle speed and current battery voltage.1. Press and hold LEFT-TOGGLE to reset the average speed. 2. Press LEFT-TOGGLE to...

46 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Infotainment Display Settings Diagnostic Trouble Codes (DTCs) If the CHECK ENGINE indicator is illuminated on the instrument cluster, this screen will display, indicating there are Diagnostic Trouble Codes (DTCs).The err...

47 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup The instrument cluster setup menus allow the following actions: • Set clock• Set units (volume, temperature, clock type, pressure) • Set bottom screen display (trip 1 distance, instant fuel econo...

48 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup Set Units Use the SET UNITS menu to set the following items: • DISTANCE: Miles or kilometers• VOLUME: Gallon, Imperial Gallon or Liter • TEMPERATURE: Fahrenheit or Celsius• CLOCK TYPE: 12-hour or...

49 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup Set Units - Volume Settings Use the VOLUME menu to change the instrument cluster volume units. Select gallon, imperial gallon or liter.1. With VOLUME highlighted in the SET UNITS menu, press LEFT...

50 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup Set Units - Clock Type Use the CLOCK TYPE menu to change the clock format. Select 12- hour or 24-hour format.1. With CLOCK TYPE highlighted in the SET UNITS menu, press LEFT-TOGGLE . 2. Press RIG...

51 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup Set Bottom Screen Menu Use the SET BOTTOM SCREEN menu to display one of the following items in ZONE FOUR of the display screen: • Trip 1 Distance• Instant Fuel• Average Fuel• Range 1. With SET BO...

52 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup Gauge Information The instrument cluster hardware and software part and serial numbers are displayed on the Gauge Information menu.1. With GAUGE INFORMATION highlighted on the setup menu, press L...

53 Instruments, Features and Controls Instrument Cluster (CHIEFTAIN/ROADMASTER) Instrument Cluster Setup Set Brightness The brightness level of the instrument cluster and display screen can be adjusted. There are two methods to enter the Set Brightness menu. METHOD 1: This method bypasses the instru...

54 Instruments, Features and Controls Headlights The headlights automatically come on when the engine is started. WARNING! Motorcycle riders must remain as visible as possible at all times. To aid in this, the headlight must be on at all times. Do not modify the ignition/headlight wiring to circumve...

55 Instruments, Features and Controls Gear Shift Lever The gear shift lever is located on the left side of the motorcycle. Operate the lever with your foot.• Press downward on the toe lever to shift to a lower gear. • Lift upward on the toe lever to shift to a higher gear.• Release the lever after e...

56 Instruments, Features and Controls Trunk (if equipped) Do not exceed the cargo capacity of a trunk, a cargo rack or a trunk/cargo rack combination. The capacity for the trunk alone, as well as for any trunk/cargo rack combination, is 30 lbs. (10 kg). The capacity for a rack alone is 5 lbs. (2.2 k...

57 Instruments, Features and Controls Saddlebags (if equipped) Do not exceed the weight limit of each saddlebag. Always distribute weight evenly in each of the saddlebags. Refer to the saddlebag/cargo warning label on or near the saddlebag for cargo capacity. Hard bag capacity is 22 lbs. (10 kg) of ...

58 Instruments, Features and Controls Saddlebags Soft Bag Removal 1. Unbuckle the saddlebag lid clasps and open the lid. 2. Flip the two quick-release latches upward. 3. Tilt the saddlebag away from the fender and lift upward to remove it from the spools. WARNING! Improper saddlebag installation can...

59 Instruments, Features and Controls Windshield (if equipped) Windshield Removal Applies to: CHIEF 1. If equipped with a quick-latch windshield, rotate the two latches upward. 2. From the front of the motorcycle, pull firmly on the upper windshield to remove the windshield from the upper mounts, th...

60 Instruments, Features and Controls Brakes Anti-Lock Brake System (ABS) The anti-lock brake system automatically reduces or increases brake pressure as needed to provide optimum braking control, reducing the chance of wheel lock-up during hard braking events or when braking on rough, uneven, slipp...

61 Instruments, Features and Controls Brakes Anti-Lock Brake System (ABS) • If the lamp continues to illuminate after vehicle speed exceeds 6 MPH (10 km/h), the ABS system is not functioning. See your INDIAN MOTORCYCLE dealer promptly for service. • Operating with non-recommended tires or improper t...

62 Instruments, Features and Controls Brakes The front brake lever activates the front brake calipers. The rear brake pedal activates the rear brake caliper. For maximum brake effectiveness, apply the front brake lever and the rear brake pedal together. Front Brake Lever The front brake lever is loc...

63 Instruments, Features and Controls Passenger Floorboard Supports (if equipped) The passenger floorboard height and angle can be adjusted.To adjust the angle, loosen both attachment screws. Rotate the floorboard to the desired position using the indicator mark on the rear- facing support as a guid...

64 Instruments, Features and Controls Fuel Cap The fuel filler cap is located on the right side of the console. An ornamental cap is located on the left side of the console. Do not attempt to remove the ornamental cap. 1. Turn the fuel cap counter-clockwise to remove it.2. See page 78 for fueling in...

66 Pre-Ride Inspections Turn the power switch on and move the stop/run switch to RUN before performing the following electrical inspections. Turn the power switch off after completing these inspections. If inspection of any electrical item reveals component failure, repair or replace the component b...

67 Pre-Ride Inspections Item Inspection Procedure General Engine Oil Check the oil level. See page 68. Fuel Check the fuel level. See page 75. Fluid Leaks Check the vehicle and the ground/floor for any fuel, oil or hydraulic fluid leaks. Tires Inspect condition, pressure and tread depth. See page 70...

68 Pre-Ride Inspections Engine Oil Level With the semi-dry sump lubrication system, the engine oil level on the dipstick will fluctuate, depending on the motorcycle’s position and engine speed when the engine is turned off. To ensure a proper reading of the engine oil level, follow all inspection pr...

69 Pre-Ride Inspections Engine Oil Level 1. Start the engine and allow it to run until it reaches normal operating temperature. 2. Stop the engine and wait one minute before checking the oil level. Tip: If the oil level is not checked within 3 minutes, repeat steps 1-2. 3. Position the motorcycle on...

70 Pre-Ride Inspections Tires WARNING! Operating the motorcycle with incorrect tires, incorrect tire pressure or excessively worn tires could cause loss of control or accident. Underinflation can cause a tire to overheat and result in a tire failure. Always use the correct size and type of tires spe...

74 Pre-Ride Inspections Fasteners 1. Inspect the entire motorcycle chassis and engine for loose, damaged or missing fasteners. 2. Tighten loose fasteners to the proper torque. See the INDIAN MOTORCYCLE Service Manual or an authorized INDIAN MOTORCYCLE dealer. Tip: Always replace stripped, damaged or...

75 Pre-Ride Inspections Rear Drive Belt 1. Check drive belt tension. See pages 96-97. Tip: The drive belt system must be cool, clean and dry to accurately measure belt tension (deflection). Do not measure belt tension when the belt or drive system is wet or when it is hot (such as immediately after ...

76 Operation The operation section of this manual describes how to ensure maximum performance and longevity through the proper care and operation of your motorcycle.Important areas covered by the operation section include: Tip: Even if you’re an experienced motorcycle operator or passenger, read all...

77 Operation Engine Break-In Operating Speeds and Gears Odometer Break-in Procedure Miles Km 0-90 0-145 Do not operate for extended periods above 1/3 throttle or at any one throttle position. Vary engine speed fre- quently. 91-300 146-483 Do not operate for extended periods above 1/2 throttle or at ...

78 Operation Fueling Always dismount the motorcycle and refuel on level ground with the sidestand down. Review the fuel warnings. See page 16. Use only the recommended fuel. See page 151. Hold the nozzle while filling. Do not rest the weight of the nozzle and hose on the filler neck. Do not leave th...

79 Operation Starting the Engine The starter interlock system allows the engine to be started only when the transmission is in neutral, or when the transmission is in gear with the clutch disengaged (clutch lever pulled in). The engine should NEVER start in any gear except neutral if the sidestand i...

80 Operation Starting the Engine 9. Leave the throttle closed and allow the engine to idle. Idle speed will gradually slow to normal as the engine warms to operating temperature. Tip: Do not rev the engine or put the transmission in gear immediately after starting the engine. Allow the engine to idl...

81 Operation Shifting Gears WARNING! Forced shifting (with clutch engaged) could cause damage to the engine, transmission and drive train. Such damage could cause loss of control, which could result in serious injury or death. Always pull the clutch lever fully toward the handlebars to disengage the...

82 Operation Shifting Gears Shifting Gears While Driving 1. Start the engine. See page 79.2. With the engine at idle speed, apply the front brakes.3. Disengage the clutch (pull the clutch lever fully toward the handlebar). 4. Push the toe lever downward until you feel it stop in first gear. 5. Relea...

83 Operation Shifting Gears Recommended Shift Points Upshifting (Accelerating) Downshifting (Decelerating) Gear Change Recommended Speed Gear Change Recommended Speed 1 to 2 15 MPH (24 km/h) 6 to 5 40 MPH (64 km/h) 2 to 3 25 MPH (40 km/h) 5 to 4 35 MPH (56 km/h) 3 to 4 35 MPH (56 km/h) 4 to 3 25 MPH...

84 Operation Braking Always allow sufficient stopping distance so that brakes can be applied gradually. Tip: Applying slightly more front brake than rear brake generally provides the best braking performance. 1. To slow the motorcycle with the brakes, close the throttle and apply the front and rear ...

85 Operation Using Cruise Control The cruise control switches are located on the right handlebar. Read this section and understand how to safely operate this feature before using the cruise control. WARNING! Improper operation of cruise control could cause loss of control and result in serious injur...

86 Operation Using Cruise Control Set Speed 1. Press and release the cruise on/off switch. The amber cruise control indicator will illuminate in the instrument cluster. Cruise control is enabled, but not set. 2. Accelerate to the desired speed and press the SET/DEC switch. The green cruise control i...

87 Operation Parking Choose a firm level surface to park the motorcycle.1. When fully stopped, shift into neutral.2. Stop the engine.3. Fully extend the sidestand.4. Turn the handlebars to the left and lean the motorcycle to the left until the sidestand firmly supports the motorcycle. 5. Turn the po...

88 Maintenance Safety During Ser vice Procedures Failure to follow all recommended precautions and procedures could result in severe injury or death. Always heed all safety precautions and follow all operation, inspection and maintenance procedures outlined in this manual.• Improperly installed or a...

89 Maintenance Proper maintenance assures the highest level of safety, durability and dependability for your motorcycle. Break-in maintenance is required to ensure warranty coverage and proper emissions system operation.• Perform the break-in maintenance procedures when the motorcycle’s odometer reg...

90 Maintenance Periodic Maintenance Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine INDIAN MOTORCYCLE parts available from your dealer. Record service and maintenance information in the Maintenance Log beginning on...

91 Maintenance Periodic Maintenance Table Odometer Reading in Miles (Kilometers) Component See table key below Page 50 0 (80 0) 2,50 0 (4,0 00 ) & ev er y 5, 000 (8, 000) thereafter 5, 00 0 (8, 000 ) 10 ,0 00 (1 6, 000) 15 ,0 00 (2 4, 000) 20 ,0 00 (3 2, 000) 25 ,0 00 (4 0, 000) 30 ,0 00 (4 8, 0...

93 Maintenance Engine Oil/Filter Change Change the engine oil at the intervals specified in the periodic maintenance table beginning on page 91. Change the oil more frequently if the motorcycle is subjected to severe use, especially operation in cold weather. See page 90. NOTICE: Failure to perform ...

94 Maintenance Engine Oil/Filter Change 8. Using a clean dry cloth, clean the filter sealing surface on the engine. 9. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 10. Install the new filter and rotate it clockwise by han...

95 Maintenance Air Filter The air box is located on the left side of motorcycle. Inspect the air filter often if riding in unusually wet or dusty conditions. Replace the filter at the intervals specified in the periodic maintenance table beginning on page 91.1. Remove the three air box cover screws ...

96 Maintenance Rear Drive Belt Cleaning Cleaning the drive belt will maximize belt and sprocket life and minimize drive line noise. Clean the belt at every tire change. Clean the belt more often if riding in dirty, dusty or high debris environments.1. Mix a few drops of mild dish soap with a cup of ...

97 Maintenance Rear Drive Belt Condition Inspect the rear drive belt at the intervals specified in the periodic maintenance table beginning on page 91. Replace the drive belt if it is cracked or has broken teeth or frayed edges. No matter its condition, the drive belt should be replaced at periodic ...

98 Maintenance Rear Shock Preload (Ride Height) Inspection Periodically inspect rear shock preload. For the most comfortable ride and proper ground clearance, adjust preload if ride height is out of specification.1. Verify that tire pressure is at specification. See page 114.2. Secure the motorcycle...

99 Maintenance Rear Shock Preload (Ride Height) Adjustment Applies to: CHIEF/DARK HORSE 1. Park the motorcycle with the sidestand down on a firm, level surface. Remove all riders and cargo. 2. Remove the seat. See page 117. Tip: Using the INDIAN MOTORCYCLE spanner wrench PV-46993 will make rear susp...

100 Maintenance Shock Air Pressure (Ride Height) Adjustment Applies to: CHIEFTAIN/ROADMASTER For riding comfort and to ensure proper ground clearance, adjust rear shock air pressure. Refer to the label located on the inside of the left side cover. The label shows recommended pressures based on poten...

101 Maintenance Shock Air Pressure (Ride Height) Adjustment Applies to: CHIEFTAIN/ROADMASTER 1. Park the motorcycle with the sidestand down on a firm, level surface. Remove all riders and cargo. 2. Remove the left side cover. Remove the cap from the air fitting. 3. Determine the recommended rear sho...

102 Maintenance Front Fork/Suspension Inspection 1. Place the motorcycle on the sidestand and inspect the front forks. If fork oil is present on the outer tube, do not ride the motorcycle. See your dealer for service before operating. If fork oil is present around the fork seals or inner tubes, repl...

103 Maintenance Steering Head Inspection 1. Elevate and support the motorcycle with the front tire slightly off the floor. See page 128. CAUTION! Make sure the motorcycle is stable when elevated. Injury may occur if the motorcycle tips or falls. 2. Turn the handlebars from stop to stop. The action s...

104 Maintenance Evaporative Emission Control System (California Models) 1. Inspect all evaporative emission control system hoses and connections. Make sure all connections are tight and locked. 2. The canister is located under the rear fender. Make sure it is securely fastened to the mounting bracke...

105 Maintenance Throttle Control Inspection 1. With the engine OFF, rotate the throttle control grip fully open and then release it. It should rotate smoothly from the rest position to the completely open position. It should return to the rest position quickly when released. 2. Repeat the twist and ...

106 Maintenance Mechanical Clutch Lever Lubrication 1. The clutch cable adjuster nut is located alongside the left down-tube. Slide the rubber protective cover away from the adjuster. Loosen the lock nu t. 2. Turn the cable adjuster completely inward to provide maximum lever freeplay. 3. Remove the ...

107 Maintenance Rear Brake Pedal 1. Lubricate the pivot bushing at the intervals recommended in the periodic maintenance table beginning on page 91. Also lubricate any time binding is evident. Use all-purpose grease. 2. Inspect brake pads as outlined on page 110. Brake Hoses/Connections Inspect all ...

108 Maintenance Rear Brake Fluid Change the brake fluid at the intervals recommended in the periodic maintenance table beginning on page 91. Always add brake fluid from a new, unopened container. Always use the recommended fluid. See page 151.1. Position the motorcycle on level ground in the fully u...

109 Maintenance Front Brake Lever 1. See page 62 for front brake lever reach adjustments.2. Lubricate the pivot pin and brake lever hinge points at the intervals recommended in the periodic maintenance table beginning on page 91. Also lubricate any time binding is evident. Use all-purpose grease. 3....

110 Maintenance Brake Disc Inspection/Cleaning 1. Inspect brake discs for nicks, scratches, cracks or other damage. Inspect the thickness of each brake disc at four or more locations around the disc. If any disc is worn to the minimum thickness at the thinnest point, or if a disc is damaged, see you...

111 Maintenance Brake Pads Front Brake Pad Inspection 1. Remove the two acorn nuts and one screw securing the protective caliper covers. Remove the covers. 2. Use an inspection mirror, positioned at the front side of the caliper, to view the friction material. 3. Reinstall the caliper covers. Torque...

112 Maintenance Wheel Spokes (if equipped) Inspect both wheels for loose, bent, broken or missing spokes (if equipped). To identify loose spokes, grasp each spoke and try to move it side to side or up and down. All spokes should be equally tight and have the same amount of flex. Tighten loose spokes...

113 Maintenance Tires Operating the motorcycle with incorrect tires, incorrect tire pressure or excessively worn tires could cause loss of control or accident. Underinflation can cause a tire to overheat and result in a tire failure. Always use the correct size and type of tires specified by INDIAN ...

114 Maintenance Tires Tire Pressure Always check and adjust tire pressure when tires are cold. Do not adjust tire pressure immediately after riding. Wait at least 3 hours after riding to check pressure. If pressure checked and adjusted while tires are warm, the pressure will drop as tires cool and r...

115 Maintenance Spark Plugs Inspect spark plugs after the break-in period and every 15,000 miles (24,000 km) thereafter. Replace spark plugs every 30,000 miles (48,000 km). Always replace spark plugs in pairs. 1. Make sure the engine has cooled to room temperature.2. Turn the power switch off.3. Pul...

116 Maintenance Side Covers Remove the left side cover to access the tool kit, shock air fitting (if equipped), fuse box and diagnostic connector.Remove both side covers to access the seat mounting fasteners and the electrical connections for the saddlebags (if equipped).1. Pull outward at each corn...

117 Maintenance Seat Removal Applies to: CHIEF/CHIEFTAIN/DARK HORSE Remove the seat to access the battery.1. Remove the left side cover to access the tool kit.2. Locate the seat mount brackets under the edge of the driver’s seat. Remove the seat mount bolt from each side of the seat. 3. Remove the r...

119 Maintenance Headlight Aim Inspection CHIEF/CHIEFTAIN/DARK HORSE: On HIGH beam, the center of highest intensity (appearing as a diamond shape) should be 7.5 in. (19 cm) lower than the headlamp and centered straight ahead at 25 feet (7.6 m). ROADMASTER: On LOW beam, the top of the low beam cut-off...

120 Maintenance Headlight Aim Adjustment The headlamp adjustment screws are located inside the headlamp housing.1. Remove the two headlight bezel screws ( CHIEFTAIN/ROADMASTER only) and remove the bezel from the fairing. Reinstall the bezel after adjusting the headlamp. Tool: M4 hex wrench or univer...

122 Maintenance Battery The motorcycle battery is a sealed, maintenance-free battery. Do not remove the battery cap strip for any reason. Keep the battery connections clean and tight at all times. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with...

123 Maintenance Battery Installation WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative ...

124 Maintenance Battery Charging If your motorcycle will not be used for a period of four (4) weeks or longer, a maintenance charger should be connected to the battery. A maintenance charger can be purchased through your authorized INDIAN MOTORCYCLE dealer.1. Following the charger manufacturer’s ins...

125 Maintenance Fuse Replacement NOTICE: Use fuses with the recommended amperage to avoid damage to the electrical system. Standard Fuses The standard fuse box is located under the left side cover. This fuse box houses all standard service fuses and the automatic circuit breakers. Fuse application a...

126 Maintenance Electrical Precautions Be aware of the following precautions regarding the electrical system to avoid disruption of electrical signals and possible system malfunction.• DO use ONLY genuine INDIAN MOTORCYCLE parts and accessories designed for your model, and follow the instructions pr...

127 Maintenance Changing Your Security System PIN To change your PIN, you must have either the key fob or your existing valid PIN available to gain access to the security system. If the key fob is not detected or is not available and you cannot remember your PIN, please see your INDIAN MOTORCYCLE de...

129 Maintenance Troubleshooting For your personal safety, do not attempt inspection or repairs not fully described in this rider’s manual. Contact an authorized dealer for service if you cannot determine the cause of a problem or if the inspection/repair exceeds your mechanical ability or tool resou...

130 Maintenance Troubleshooting Engine Starts But Misses or Runs Poorly Tip: Turn engine OFF before inspecting any of these items. Shifting Difficulties or Hard to Find Neutral Possible Cause Possible Remedy/Action Battery Discharged Fully charge the battery. See page 124. Battery Cables Loose or Co...

131 Maintenance Troubleshooting Battery Charging Rate Low or Battery Discharges Brake Noise/Poor Brake Performance Tip: See your dealer if brake performance does not return after these inspections. Anti-Lock Brake Light Remains Illuminated or Illuminates Intermittently Possible Cause Possible Remedy...

132 Cleaning and Storage Matte Clear Coat Finishes Matte finish products are prone to trapping dirt, oils and other contaminants. Always clean this type of finish with warm water and a mild dish-washing detergent. Use a soft sponge to gently rub the surface, then rinse with clean warm water. For stu...

133 Cleaning and Storage Washing the Motorcycle NOTICE: Do not use pressurized water to wash the motorcycle. Water may seep in and deteriorate wheel bearings, brake caliper assemblies, brake master cylinders, electrical connectors, steering head bearings, and transmission seals.Do not direct any wat...

134 Cleaning and Storage Windshield Care (if equipped) Clean the windshield with a soft cloth and plenty of warm water. Dry with a soft clean cloth. Remove minor scratches with a high-quality polishing compound designed for use on polycarbonate surfaces. NOTICE: Brake fluid and alcohol will permanen...

135 Cleaning and Storage Gloss Clear Coat Finish Care The Axalta Sports and Equipment Finish System was used to provide the original gloss finish on your motorcycle. This finish system provides superior protection against the elements. To maximize the benefits of this system, use the following guide...

136 Cleaning and Storage Leather Care Leather Facts Leather is a natural product and will exhibit qualities inherent in a natural material. Fading, wrinkles, grain changes, creases and small marks are assurance that this material is not man-made. As the product is used, each leather product will exh...

137 Cleaning and Storage Leather Care Leather Care Dressing INDIAN MOTORCYCLE Leather Care Dressing is a leather conditioner formulated to restore many of the oils that are lost from leather due to exposure to environmental elements. This conditioner is suitable for all oil-tanned leather on your IN...

138 Cleaning and Storage Leather Care Tan Leather Restore Kit This kit helps restore color to a tan leather seat, saddlebags and other leather accessories. The kit allows for an incremental color change, depending on the number of coats applied. As with any natural leather, the appearance, shade and...

139 Cleaning and Storage Leather Care Frequently Asked Questions Q. Can I use shoe polish to restore leather color? A. Shoe polish should not be used on the leather items on your INDIAN motorcycle. Shoe polish contains a dye that can damage the leather and may leave residue on clothing. Q. What shou...

140 Cleaning and Storage Storage Area Preparation If you will not operate the motorcycle for more than 60 days, store the motorcycle to prevent damage to the fuel system and the battery and to protect components from corrosion or deterioration. During storage preparation you might use products that ...

142 Cleaning and Storage Rodents Mice and other rodents are often the worst enemy of a stored motorcycle. If the motorcycle will be stored in an area where mice are a concern (particularly in rural areas, barns, sheds, etc.) be sure to take extra measures to deter their infestation. This may include...

143 Specifications Model Year 2016 CHIEF CHIEFTAIN ROADMASTER Dimensions (Dimensions and specifications may vary with features, options and accessories) Overall Length 103.5 in. (2630 mm) Classic 103.7 in. (2634 mm) Vintage 101.2 in. (2571 mm) 104.6 in. (2656 mm) Overall Width 39.4 in. (1000 mm) 39....

144 Specifications Model Year 2016 CHIEF CHIEFTAIN / ROADMASTER Capacities Engine Oil 5.5 qts. (5.2 l) with filter at oil change 5.5 qts. (5.2 l) with filter at oil change Fuel 5.5 gal. (20.8 l) 5.5 gal. (20.8 l) Fuel Reserve (fuel light on) 1.0 gal. (3.8 l) 1.0 gal. (3.8 l) Fork Oil 20.3 oz. (599 c...

145 Specifications Model Year 2016 CHIEF / CHIEFTAIN / ROADMASTER Drive System Primary Drive Gear Drive Wet Clutch Crank Gear 55 Teeth Clutch Gear 86 Teeth Clutch Type Wet, Multi-Plate Primary Reduction Ratio 1.564:1 Transmission Type 6 Speed/Constant Mesh/Foot Shift 1st Gear Ratio 2.733:1 2nd Gear ...

146 Specifications Model Year 2016 CHIEF CHIEFTAIN / ROADMASTER Wheels And Tires Front Wheel Size/Type 3.5 in. x 16 in. 40 Spoke 3.5 in. x 16 in. Cast Aluminum Rear Wheel Size/Type 5 in. x 16 in. 40 Spoke 5 in. x 16 in. Cast Aluminum Front Tire Type/Size White 130/90-B16 67H American Elite Black 130...

147 Specifications Model Year 2016 DARK HORSE Dimensions (Dimensions and specifications may vary with features, options and accessories) Overall Length 103.5 in. (2630 mm) Overall Width 39.4 in. (1000 mm) Overall Height 46.3 in. (1176 mm) Seat Height 26 in. (660 mm) Wheelbase 68.1 in. (1730 mm) Grou...

151 Specifications Fuel Recommendation For best performance, use only unleaded gasoline with a 91 pump octane minimum (R+M/2 Method). DO NOT USE E-85 GASOLINE OR GASOLINE CONTAINING METHANOL. Using E85 or gasoline/methanol blends can result in poor starting and driveability, engine damage and damage...

152 Warranty INDIAN MOTORCYCLE Warranty Policy LIMITED WARRANTY INDIAN MOTORCYCLE COMPANY, 2100 Highway 55, Medina, MN 55340 (INDIAN MOTORCYCLE) gives a TWO YEAR LIMITED WARRANTY on all components of your INDIAN motorcycle against defects in material or workmanship. This warranty covers parts and la...

153 Warranty INDIAN MOTORCYCLE Warranty Policy WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This INDIAN MOTORCYCLE limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. T...

154 Warranty INDIAN MOTORCYCLE Warranty Policy LUBRICANTS AND FLUIDS 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of INDIAN MOTORCYCLE engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by ...

155 Warranty INDIAN MOTORCYCLE Warranty Policy HOW TO OBTAIN WARRANTY SERVICE If your motorcycle requires warranty service, you must take it to an INDIAN MOTORCYCLE Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COS...

156 Warranty INDIAN MOTORCYCLE Warranty Policy EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that hav...

157 Warranty INDIAN MOTORCYCLE Warranty Policy Motorcycle Noise Regulation Tampering with noise control systems is prohibited. Federal law prohibits the following acts or causing thereof: • The removal or rendering inoperative by any person other than for the purposes of maintenance, repair, or repl...

158 Warranty Emissions Control System Warranty INDIAN MOTORCYCLE COMPANY - Emission Control System Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and INDIAN MOTORCYCLE COMPANY (hereinafter INDIAN MOTORCYCLE) are pleased to explain the emission control syst...

159 Warranty Emission Control System Warranty Owner’s Warranty Responsibilities As the motorcycle owner, you are responsible for the performance of the required maintenance listed in your Rider’s manual. INDIAN MOTORCYCLE recommends that you retain all receipts covering maintenance on your motorcycl...

162 Warranty Emission Control System Warranty III. Limited Liability A. The liability of INDIAN MOTORCYCLE under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized INDIAN MOTORCYCLE dealer at its place of business during cu...

163 Maintenance Log Maintenance Performed Miles/Km Notes Performed by

165 Audio System Audio System Introduction Not all motorcycles are equipped with an audio system. Motorcycles equipped with an audio system may not be equipped with all components discussed in the audio section of this manual. Components not installed at the factory can be purchased from and install...

166 Audio System Audio System Introduction Radio Frequencies North America • AM 520 to 1720 kHz • FM 87.9 to 107.9 MHz • WX 7 NOAA Channels (162.400 to 162.550 MHz) Europe • FM 87.5 to 108.00 MHz (100 kHz steps) • MW 531 to 1602 kHz • LW 153 to 279 kHz Europe 50 • FM 87.5 to 108.00 MHz (50 kHz steps...

167 Audio System Audio System Introduction Audio Menu Options • Audio Output• Bass• Mid• Treble• Fader• Automatic Volume Control (AVC)• Bluetooth Setup• Driver Device• NAV Audio• AM/FM Clear Preset• Radio Broadcast Data System (RBDS)

168 Audio System Audio System Introduction Audio Controls The audio controls are located on the left handlebar. 1. Radio On/Off Volume +/- Menu Scroll 2. Tuner Music Track Select Menu Navigation 3. Preset Button (Select/Enter Menus) 4. Mute Push-to-Talk (PTT) Voice Recognition 5. Mode Button Tip: So...

169 Audio System Audio System Introduction Instrument Cluster Audio Display The audio system information is displayed in the center display on the instrument cluster. All audio system information is displayed in zones two (2) and three (3). USB Connector A USB connector cord is located on the right ...

170 Audio System Power and Volume Controls Audio System Power Turn the power switch ON to use the audio system. The screen will display “RADIO OFF”. Tip: To prevent battery drain when the engine is not running, power will automatically turn off after 5 minutes. To turn the audio system on, press and...

171 Audio System Mute/Push-To-Talk (PTT) Press once to mute the audio system volume. Press or or to un-mute the audio system volume.Double press to activate voice recognition feature on a paired phone. Low Voltage Mute If the battery voltage drops to 10.5 +/- 0.5 volts, the radio will mute to reduce...

172 Audio System Selecting Audio Sources Press repeatedly to choose the desired audio source. Each press changes the audio source as follows:• FM• AM• MW (Europe only)• LW (Europe only)• WX (Weather) (North America only)• USB• NAV (If enabled)• Bluetooth Driver (if enabled) FM source: All models (sh...

173 Audio System Selecting Audio Sources NAV source: All models (skipped if not enabled) Bluetooth Driver source: All models (skipped if not enabled) Tip: Pandora ® is available on some Bluetooth devices. FM/AM/MW/LW Tuning MW and LW radio sources are in Europe only.1. Press repeatedly to choose the...

174 Audio System Selecting Audio Sources FM/AM/MW/LW Tuning Memor y Presets The audio system features 15 user-defined presets for each tuner source for storing favorite stations.1. To set a preset, press repeatedly until the desired source is active (FM, AM, MW, LW). 2. Use or to tune a radio statio...

176 Audio System Selecting Audio Sources USB Audio Source - iPod / iPhone Connected 1. Connect a compatible iPod or iPhone device to the USB connector cable. 2. Press and release until iPod is the active source. When iPod is active, the console screen will display “iPod” as the active source. Tuning...

177 Audio System Selecting Audio Sources USB Audio Source - iPod/iPhone with Pandora ® When using the Pandora app on an iPod or iPhone , connect the device to the USB connector. Using the USB connection will enable Pandora functions like: skip track, thumbs up, and thumbs down, through the left-hand...

178 Audio System Selecting Audio Sources NAV Source Please read this manual and the GARMIN ZUMO 660 NAV MP3 information provided with your player to become familiar with all unit features and operation.The audio integration kit must be installed to enable outputs from the NAV MP3 (such as navigation...

179 Audio System Selecting Audio Sources Bluetooth Sources Press and release until “DRIVE DEVICE” is displayed on the screen. Tip: If a Bluetooth compatible device is paired to the DRIVE DEVICE. the radio will automatically turn on the DRIVE DEVICE in the audio source loop. Make sure the Bluetooth v...

180 Audio System Selecting Audio Sources Bluetooth Device Music Mode Settings The DRIVE DEVICE source will play the music source that is active on the connected device. Some Bluetooth devices allow the radio to access additional features and controls when using the Pandora ® app. The MUSIC MODE menu...

181 Audio System Voice Recognition Mode The radio features voice recognition when a driver headset is connected and turned on. Radio Bluetooth functionality is dependent on the capabilities of the device. Please see your device’s user manual. Tip: Make sure the Bluetooth volume on your device is tur...

182 Audio System Voice Recognition Mode Error Messages If your phone receives an incoming call, but you do not have your headsets connected, the incoming call information and “CANNOT ANSWER” displays.Press or to send the incoming call to voice mail. If you attempt to initiate a phone call, but you d...

183 Audio System Audio Mode Menus Entering Mode Menu 1. Press and hold until the system enters the audio system mode menus. 2. Press and release to cycle through the following menu items, shown in order of display: • Audio Output Select• Bass• Mid• Treble• Fader• Automatic Volume Control (AVC)• Blue...

184 Audio System Audio Mode Menus Treble Setting Press or to adjust. Press and release to move to next selection. Fader Setting 1. Press or to adjust speaker fader balance. 2. Use the fader adjustment menu to control audio sound balance between front and rear speakers. Tip: Fader setting menu not sh...

185 Audio System Audio Mode Menus Bluetooth Setup Bluetooth Setup allows the user to pair and unpair the headset and devices.1. To access Bluetooth Setup, Press and hold to access the audio menu. 2. Press and release until “BLUETOOTH SETUP” is displayed. 3. Press and release to access the Bluetooth ...

186 Audio System Audio Mode Menus Bluetooth Setup Menu Bluetooth Setup Notes • The Bluetooth Setup Menu will display “C” next to each position when there is either a headset or device connected. • Each Bluetooth position can have a maximum of three devices paired to that location. To add another dev...

187 Audio System Audio Mode Menus Bluetooth Setup Menu Driver Headset Pairing Tip: Incoming phone calls cannot be answered if driver headset is not connected. Press and release or to send the calls to voice mail. 1. Press and hold to access the audio menu. 2. Press and release until “BLUETOOTH SETUP...

188 Audio System Audio Mode Menus Bluetooth Setup Menu Driver Device Pairing The radio can be paired with Bluetooth devices such as smart phones. 1. In the Bluetooth Setup Menu, press or to scroll. 2. Set device to “Discoverable Mode” before starting the pairing procedure. 3. Select DRIVE DEVICE.4. ...

189 Audio System Audio Mode Menus Bluetooth Setup Menu Unpairing/Reconnecting Devices Tip: The following steps reference the DRIVE H-SET as an example. Unpairing other devices follows the same procedures. 1. In the Bluetooth Setup Menu, use or to make a selection. Select DRIVE H-SET. 2. Press and re...

190 Audio System Audio Mode Menus Bluetooth Driver Device 1. Press or to turn the DRIVER Bluetooth device source ON or OFF. • SOURCE ON• SOURCE OFF 2. Press and release to move to the next selection. NAV Audio 1. Press or to turn the NAV AUDIO source ON or OFF. 2. Press and release to move to the ne...

191 Audio System Audio System Diagnostics The audio system diagnostic menu allows the following actions for you or your INDIAN MOTORCYCLE dealer: • View radio software version• Perform left hand audio control key pad tests• Set radio tuner location• View vehicle speed Diagnostic Menu To access the d...

192 Audio System Audio System Diagnostics Tuner Location Settings Tip: Partial screen shown. Full list will appear on screen if DTC display mode is inactive. The radio tuner can be set to the geographical location where the motorcycle will be driven.The following settings can be chosen under the Tun...

193 Audio System Audio Compliance Information FCC and Industr y Canada Compliance Statement This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance of 20 cm between the radiator and yo...

194 Index A About the Rider’s Manual . . . . . . . . . . . . . . . . 7 ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61 ABS Tone Ring/Sensor Inspection . . . . . . . 111 ABS, How to Respond . . . . . . . . . . . . . . . . . . 10 Accelerating . . . . . . . . . . . . . . . . . . ....