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Indian Motorcycle 2015-2017 Scout & Scout Sixty Service Manual
Indian Motorcycle 2015-2017 Scout & Scout Sixty Service Manual
Indian Motorcycle 2015-2017 Scout & Scout Sixty Service Manual
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates ·a potential hazard that may result in minor personal injury or damage to the
vehicle. ·
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
INDIAN MOTORCYCLE ACKI.\JOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Some Indian Motorcycle factory publications can be downloaded from www. polarisindustries. com, purchased
from www.purepolaris.com or by contacting the nearest Indian Motorcycle dealer.
REVISION INDEX
REV DATE CHANGE.$
ROI 7/22/2016 Initial release
Add Master Torque Table, Add Vehicle Model Conversion Process (INT'L
R02 1/18/2017 bikes)
l -l
Service Manual
Chapter Summary
1:
2:
3:
4: FUEL-............... I
5: CLUTCH/ PRIMARY/
CHAPTER 6: TRANSMISSION/ CRANKSHAFT
7: FRAME/
CHAPTER 8: , STEERING/ SUSPENSION
9: BRAKES
10:
GENERAL I SPECIFICATIONS
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- GENERAL/ SPECIFICATIONS
VEHICLE INFORMATION
MODEL NUMBER DESIGNATION
Example: NlSMSAOOAA
l 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
5 6 K C .C A A A 0 E 3 0 0 0 0 0 0
* Model Year: E = 2014; F= 2015; G = 2016; H = 2017
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GENERAL I SPECIFICATIONS
MANUFACTURER LABEL
The manufacturer label CD located on the left side of
the steering head contains the following information:
Vehicle Identification Number (V1N)
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating (GAWR)
Tire Type and Load Information.
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- GENERAL I SPECIFICATIONS
GENERAL SPECIFICATIONS
2015 - 2017 SCOUT SPECIFICATIONS.
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GENERAL I SPECIFICATIONS
Chassis
Dry Weight 516 lbs '(236 kg) Engine Number 1204691
I
Wet Weight 560 lbs (255 kg) Engine V-Twin
Gross Vehicle Engine
988 lbs ( 449 kg) Liquid Cooled V-Twin 60°
Weight Rating Configuration
Gross Axle Weight Engine Wet Weight 205 lbs (93 kg)
337 lbs (153 kg)
Rating, Front
Engine 69 cid (1133 cc); Sixty- 61 cid
Gross Axle Weight Displacement (999 cc)
661 lbs (296 kg)
Rating, Rear
Engine Cooling Liquid
Maximum Load 428 lbs (194 kg)
Compression Ratio 10.7:1, (Sixty)- 11.0:1
Overall Length 91.0 in (2311 mm)
Compression 210 - 230 psi (1448 - 1586 k:Pa)
Overall Width 34.6 in (880 mm) Pressure
Overall Height 47.5 in (1207 mm) DOHC, 4 Valves Per Cylinder,
Valve Train
Graded Buckets
Seat Height 25.3 in (643 mm)
3.898 in x 2.898 in (99 mm x 73.6
Ground Clearance 5.3 in (136 mm) Bore x Stroke mm); (Sixty) - 3.661 in x 2.898 in
Total Storage (93 mm x 73.6 mm)
N/A
Volume Idle Speed 1100 RPM ± 50 RPM (fully warm)
Passenger
1 Oil Capacity 4.5 qts (4.3 L) Dry engine
Capacity
Oil Type SAE Synthetic l 5W60
Wheelbase 61.5 in (1562 mm)
Lubrication System Semi-Dry Sump
Rake/ Trail 29° / 4.7 in (119.9 mm)
Spark Plug Type /
NGK MR7F / 0.030 in (0.8 mm)
Gap
Fuel System
Two 02 Sensors / Single three-
Exhaust System
Fuel System Electronic Fuel Injection (MEI 7) way catalyst in each muffler
Fuel Delivery Electronic Fuel Pump (in tank)
58 psi (400 k:Pa)
Electrical
Fuel Pressure
Throttle Body Bore 2.362 in (60 mm) Stator Rated Output 460 W @ 3000 RPM
Fuel Capacity 3.5 gal (13.2 L) Battery 12V / 12 AH/ 210 CCA,
Maintenance Free AGM
Fuel Reserve
0.5 gal (1.9 L) Headlights Osram HB2 12V 60/55W
Capacity
Recommended Tail / Brake / LED (non-serviceable)
91 Octane License
Fuel
Turn Signals RYlOW
Starting System Electric Start
Ignition System BoschME-17
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GENERAL/ SPECIFICATIONS
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GENERAL I SPECIFICATIONS
1
Exceeding the gross vehicle weight rating of your
motorcycle can reduce stability and handling and
could cause loss of control. NEVER exceed the gross
vehicle weight rating of your motorcycle.
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- GENERAL I SPECIFICATIONS
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GENERAL / SPECIFICATIONS
1
2015 Scout 2016 Scout Sixty
2016 Scout
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-GENERAL I SPECIFICATIONS
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GENERAL I SPECIFICATIONS
The U. S. Environmental Protection Agency and Tampering with Noise Control Systems is Prohibited.
I
California Air Resources Board (CARB) require Federal law prohibits the following acts or causing
manufacturers to certify that their motorcycles comply thereof:
with applicable exhaust emissions standards during
1. The removal or rendering inoperative by any
their useful life, and that motorcycles built after
person other than for purposes of maintenance,
January 1, 1983 comply with applicable noise emission
repair or replacement, any device or element of
standards for one year or 6,000 km (3,730 mi) after the
design incorporated into the motorcycle for the
time of sale to the ultimate purchaser, when operated
purpose of noise control prior to its sale or
and maintained according to the instructions
delivery to the ultimate purchaser or while it is in
provided.
use, or
2. The use of the motorcycle after such device or
EMISSION element of design has been removed or rendered
An internal combustion engine produces carbon inoperative.
monoxide and hydrocarbons during operation.
Hydrocarbons must be controlled because under Among those acts presumed to constitute
some conditions hydrocarbons react with sunlight to tampering are the acts listed below:
produce photochemical smog. Carbon monoxide must 3. Removal of, or puncturing the muffler, baffles,
be controlled because it is toxic. header pipes or any other component which
conducts exhaust gases.
EXHAUST EMISSION CONTROL 4. Removal or puncturing of any part of the intake
Indian Motorcycles have an electronic engine system.
management system which controls fuel delivery and
ignition timing to control hydrocarbon and carbon 5. Lack of proper maintenance.
monoxide emissions. If components are replaced that 6. Replacing any moving part of the motorcycle or
affect idle speed, no adjustments should be made to parts of the exhaust / intake system with parts
· the system. The Electronic Fuel Injection (EFI) and other than those specified by the manufacturer.
Electronic Throttle Control (ETC) systems control idle
speed.
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- GENERAL I SPECIFICATIONS
COLOR DESCRIPTION
Green Engine Oil (liquid)
Red Engine Oil (mist)
Blue Engine Vapors
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GENERAL / SPECIFICATIONS
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GENERAL I SPECIFICATIONS
Welcome
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GENERAL I SPECIFICATIONS
Fuel Tank Fitting Plug 12mm Fork Spring Compressor Fuel Pressure Adapter
PV-50567 PV-49463 PV-48656
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GENERAL I SPECIFICATIONS
Fuel Pressure Gauge Oil Pressure Gauge Output Shaft Seal Tool
PU-43506A PV-43531 PF-51243
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GENERAL I SPECIFICATIONS
Fork Socket Adapter / Cartridge Engine Case Assembly Cup Mainshaft / Crankcase Installer
Tool
PF-51664-2
PF-51663 PV-45030 l
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- GENERAL / SPECIFICATIONS
REFERENCE
SCOUT MASTER TORQUE TABLE
ITEM TORQUE ITEM TORQUE
Air Filter Fasteners 24 in-lbs (3 Nm.) Brake Line P-Clamp 19 ft-lbs (26 Nm.)
Fastener (rear)
Axle (front fork) 52 ft-lbs (70 Nm.)
Brake Pedal Spring 84 in-lbs (9.5 Nm.)
Axle Nut (rear) 65 ft-lbs (88 Nm.) Fastener
ABS Sensor Fastener Brake Pushrod Fastener 84 in-lbs (9.5 Nm.)
84 in-lbs (9.5 Nm.)
(Both)
Bearing Retainer 88 in~lbs (10 Nm.)
Axle Pinch Fasteners 18 ft-lbs (24 Nm.) Fastener
Backbone Bracket to Bearing Support Plate 15 ft-lbs (20 Nm.)
19 ft-lbs (26 Nm.)
Front Frame Fasteners Fasteners
Balance Shaft Gear Bearing Support Plate 52 ft-lbs (70 Nm.)
83 ft-lbs (112 Nm.)
Fastener Center Fastener
Banjo Fastener (Front 16 ft-lbs (22 Nm.) Caliper Mounting 35 ft-lbs (47 Nm.)
Caliper, M/C) Fasteners (front)
Banjo Fastener (Rear 16 ft-lbs (22 Nm.) Caliper Mounting 30 ft-lbs (41 Nm.)
Caliper, M/C) Fasteners (rear)
Battery Box Mount Caliper Slide Fastener 20 ft-lbs (27 Nm.)
8 ft-lbs (11 Nm.)
Fastener (rear)
Battery Box Shoulder 8 ft-lbs (11 Nm.) Caliper Slide Pin (front, 18 ft-lbs (24 Nm.)
Fasteners upper and lower)
Battery Cable to Starter 62 in-lbs (7 Nm.) Camshaft Carrier
Motor Nut 88 in-lbs (10 Nm.)
Fasteners (short & long)
Battery Bracket Hold 12 ft-lbs (16 Nm.) Cam Chain Gallery 88 in-lbs (10 Nm.)
Down Fastener
Fasteners
Battery Terminal 45 in-lbs (5 Nm.) Cam Chain Guide
Fasteners 88 in-lbs (10 Nm.)
Fasteners (lower)
Belt Guard Fasteners 85 in-lbs (9.6 Nm.)
(lower) Cam Chain Guide
88 in-lbs (10 Nm.)
Fasteners (upper)
Bleeder Fastener (All) 60 in-lbs (6.8 Nm.)
Cam Chain Guide
88 in-lbs (10 Nm.)
Brake Disc Fasteners 19 ft-lbs (26 Nm.) Fasteners (side)
Brake Lever Perch Cam Chain Tensioner 15 ft-lbs (20 Nm.)
12 ft-lbs (16 Nm.)
Fasteners
Cam Drive Sprocket 52 ft-lbs (70 Nm.)
Brake Lever Pivot 48 in-lbs (6 Nm.) Fastener
Fastener
Cam Driven Sprocket 88 in-lbs (10 Nm.)
Brake Lever Nut 60 in-lbs (7 Nm.) Fasteners
Brake Line Bracket 60 in-lbs (7 Nm.) Clutch Cable Guide Jam 48 in-lbs (5. 4 Nm.)
Fasteners (rear) Nut
Brake Lever Clamp 12 ft-lbs (16 Nm.) Clutch Lever Pivot 60 in-lbs (6. 8 Nm.)
Fastener Fastener
Brake Line P-Clamp 84 in-lbs (9.5 Nm.). Clutch Lever Pivot Nut 84 in-lbs (9.5 Nm.)
Fastener (front)
Clutch Perch Clamp 12 ft-lbs (16 Nm.)
Fastener
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GENERAL I SPECIFICATIONS
Exhaust Studs 15 ft-lbs (20 Nm) Head Light Mount Pivot 35 ft-lbs (47 Nm)
Fastener
Frame Tube Bracket to 19 ft lbs (26 Nm)
Frame Fastener Head Light to Lower
18 ft-lbs (24 Nm)
Triple Mount Fastener
Frame Tube to Mid-Cast/ 35 ft-lbs (47 Nm)
Frame Fasteners Head Pipe Nuts 12 ft-lbs (16 Nm)
Frame Backbone to Front 35 ft-lbs (47 Nm) Head Pipe Hanger (rear) 19 ft-lbs (26 Nm)
Frame Fastener
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1.19
GENERAL I SPECIFICATIONS
Ignition Cover Fasteners 96 in-lbs (11 Nm) Oil Pump Fasteners 88 in-lbs (10 Nm)
Ignition Cover Bracket 12 ft-lbs ( 16 Nm) Oil Pump to Crankcase 88 in-lbs (10 Nm)
Fasteners Fasteners
Instrument Panel 22 ft-lbs (30 Nm) Oil Pump Gear Fastener 88 in-lbs (10 Nm)
Fasteners
Oxygen Sensors 14 ft-lbs (19 Nm)
Instrument Cluster 22 ft-lbs (30 Nm)
Fasteners Pad Retaining Pin (front 80 in-lbs (9 Nm)
and rear)
Intake Manifold Clamps 20 in-lbs (2.3 Nm)
Piston Cooling Jet 62 in-lbs (7 Nm)
Intake Manifold Boot 22 ft-lbs (30 Nm) Fastener
Fasteners
Pressure Plate Fasteners 88 in-lbs (10 Nm)
License Plate Light Nuts 18 in-lbs (2 Nm)
Primary Cover Fasteners 9 ft-lbs (12 Nm)
Load/ Tipover Module
96 in-lbs (11 Nm)
Mounting Fasteners Radiator Cover Fasteners 8 ft-lbs (11 Nm)
Main Plate Mounting 88 in-lbs (10 Nm) Radiator Mount 18 ft-lbs (24 Nm)
Fasteners Fasteners
Master Cylinder Cover 13 in-lbs (1.5 Nm) Regulator/Rectifier to
Fasteners (front) 84 in-lbs (9. 5 Nm)
Bracket Nuts
Master Cylinder Cover 13 in-lbs (1.5 Nm) Regulator/Rectifier
Fasteners (rear) Bracket to Frame 19 ft-lbs (26 Nm)
Fasteners
Master Cylinder Clevis 84 in-lbs (9.5 Nm)
Fastener (rear) Scavenge Inlet Tube 88 in-lbs (10 Nm)
Fastener
Master Cylinder Clevis 80 in-lbs (9 Nm)
Nut (rear) Scavenge Oil Return 88 in-lbs (10 Nm)
Tube Fastener
Master Cylinder 84 in-lbs (9.5 Nm) Scavenge Oil Pump
Mounting Fasteners 88 in-lbs (10 Nm)
Fasteners
(rear)
Shift Rod Fastener 84 in-lbs (9.5 Nm)
Mid Cast Frame to
35 ft-lbs (47 Nm)
Backbone Fasteners Shift Star Fastener 88 in-lbs (10 Nm)
Mid Frame to Engine 51 ft-lbs (69 Nm) Shift Rod Jam Nuts 8 ft-lbs (11 Nm)
Fasteners
Shock Fasteners (upper 65 ft-lbs (88 Nm)
Muffler Hanger & lower)
19 ft-lbs (26.Nm)
Fasteners
Side-Stand Pivot 35 ft-lbs (47 Nm)
Oil Cooler Spigot 22 ft-lbs (30 Nm)
Fastener
Oil Filter 115 in-lbs (13 Nm) or Side Stand Mounting
approximately 3/4 to 1 19 ft-lbs (26 Nm)
Fasteners
full turn after seal
contacts the filter Side Stand Switch 60 in-lbs (7 Nm)
mount sealing surface.
Spark Plug 10 ft-lbs (14 Nm)
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1.20 " Polaris Industries Inc.
GENERAL I SPECIFICATIONS
Speed Sensor Fastener 84 in~lbs (9.5 Nm) Water Pump Impeller 30 in-lbs (3 Nm) 1
Speedometer Cover Water Pump Shaft Nut 13 ft-lbs (18 Nm)
36 in-lbs (4 Nm)
Fastener
Wind Fairing Mount 15 ft-lbs (20 Nm)
Stake Nuts 125 ft-lbs (170 Nm) Fastener (side)
Stator Clip Fasteners 71 in-lbs (8 Nm) Wind Fairing Mount 36 in-lbs ( 4 Nm)
Fastener (rear)
Stator Cover Fasteners 88 in-lbs (10 Nm)
Worm Drive Clamp 24 in-lbs (3 Nm)
Stator Mounting 88 in-lbs (10 Nm)
Fasteners to Cover
Starter Clutch Fasteners 88 in-lbs (l ONm)
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GENERAL I SPECIFICATIONS
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1.22 · · Polaris Industries Inc.
GENERAL / SPECIFICATIONS
1/64 in= .0156 in 47/64 in= .7344 in [19 mm= .74~0 in]
3/4 in= .75 in
I
1/32 in= .0312 in [l mm= .0394 in]
3/64 in = .0469 in 49/64 in = . 7656 in
1/16 in= .0625 in 25/32 in= .7813 in [20 mm= .7874 in]
5/64 in= .0781 in [2 mm= .0787 in] 51/64 in= .7969 in
3/32 in = .0938 in 13/16 in= .8126 in [21 mm=. 8268 in]
7/64fa = .1094 in [3 mm= .1181 in] 53/64 in = .8281 in
1/8 in= .1250 in 27/32 in= .8438 in
9/64 in= .1406 in 66/64 in= .8594 in [22 mm= .8661 in]
5/32 in= .1563 in [4 mm= .1575 in] 7/8 in= .876 in
11/64 in= .1719 in 57/64 in= .8906 in [23 mm= .9065 in]
3/16 in= .1875 in [5 mm= .1969 in] 29/32 in = .9063 in
13/64 in= .2031 in 59/64 in= .9219 in
7/32 in= .2188 in 15/16 in= .9375 in [24 mm= .9449 in]
15/64 in= .2344 in [6 mm= .2362 in] 61/64 in= .9531 in
1/4 in= .25 in 31/32 in= .9688 in [26 mm= .9843 in]
17/64 in= .2656 in [7 mm= .2756 in] 63/64 in= .9844 in
9/32 in= .2813 in 1 in= 1.0 in
1.9/64 in = .2969 in
5/16 in= .3125 in [8mm= .3150 in]
21/64 in = .3281 in
11/32 in = .3438 in [9 mm =-·.3543 in]
23/64 in = .3594 in
3/8 in = .376 in
26/64 in= .3906 in [10 mm= .3937 in]
13/32 in= .4063 in
27/64 in= .4219 in [11 mm =.4331 in] · ·
7/16 in= .4376 in
29/64 in = .4531 in
15/32 in= .4688 in [12 mm= .4724 in]
31/64 in = .4844 in
. 1/2 in= .6 in [13mm = .5118 in]
33/64 in= .5156 in
17/32 in= .6313 in
36/64 in= .6469 in [14 mm= .5512 in]
9/16 in = .5625 in
37/64 in= .6781 in [16 mm= .5906 in]
19/32 in = .6938 in
39/64 in = .6094 in
5/8 in= .625 in [16mm=. 6299 in]
41/64 in = .6406 in
21/32 in= .6663 in [17 mm= .6693 in]
43/64 in= .6719 in
11/16 in= .6875 in
45/64 in= .7031 in [18 mm= .7087 in]
23/32 in= .7188 in
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-GENERAL/ SPECIFICATIONS
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1.24 Polaris Industries Inc.
MAINTENANCE
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Polaris Industries Inc. 2.1
MJUNTENANCE
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2.2 Polaris Industries Inc.
MAINTENANCE
General Specifications
ITEM STANDARD SERVICE LIMIT
Battery Type / CCA 12 Volt/ 12 AH/ 210 CCA - 2
Brake Pad Thickness, Front .16 in (4.0 mm) .04 in (1.0 mm)
Brake Disc Thickness, Front .20 in (5.0 mm) .18 in (4.5 mm)
Brake Pad Thickness, Rear .25 in (6.5 mm) .04 in. (1.0 mm)
Brake Disc Thickness, Rear .20 in (5.0 mm) .18 in (4.5 mm)
Clutch Lever Freeplay .019 - .059" (0.5-1.5 mm) -
Compression Pressure 210 - 230 psi (1448 -1586 kPa) Below 190 psi (1310 kPa)
(Cylinder)
Drive Belt Deflection (with 10 .472" (12 mm) or 45 - 50 Hz with Sonic Tension -
lbs force) Meter
Fuel Pressure (KOEO) 58 psi (400 kPa) 51 psi (350 kPa)
Idle Speed / Fast Idle Speed 1100RPM ±50RPM
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Polaris Industries Inc. 2.3
MAINTENANCE
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
2.4 · · Polaris Industries Inc.
MAINTENAJ.\ICE
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Polaris Industries Inc.
2.5
MAINTENANCE
s0 s0 s0 s0 s0 s0 s0 s0 s s0 s0
s0 0
-
0 0 0 0 0 0 0 0 0
0 0 c.c ,;i< N 0 CX) c.c ,;i< N 0
e0 ~ e e e ~ ~ !:2, e ~ e0
0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0
- -
If) If) 0 0 0 0 0 0 0 0 0 0
N If) 0 If) 0 If) 0 If) 0 If) 0
N N M M ,;i< ,;i< If)
.:
Air Filter I r I . R I R ·.
I R . I R ..·
•· I R
' .
.. ..
Crankcase Ventilation System I I I 1 ..•
I . I I I I I I I
:. : .. . •. .'· .. .,
: :· .. .. .
Cooling System / Radiator I I I I I . .
I I .. :;. I
:·
.·· I I ···•
I
. ·.
Drive Belt I
...
I I . I . I I I .. R .. I .
I . .
I .• .
I
··· .. ·. :·:··
Engine Compression I I I ... I I I
< .·. : /';•; ·'.. ·
.
. . : • .
.
1·. :: ..... ·. ·· ... .. . .·
Engine Mount Fasteners I ....
1 ..
. . · . .·.·:.
..
·······., :: .. ___ .;:·- : ·'.•.:'·,
Engine Oil* R R R .• : R .·
..
R ; ··.
R
··.
.
. ·,, ..
' ·. ·.
.
Engine Oil Filter* R ·. R R R
..
R R
. .• . ... . >
.. .
Evaporative Emission Control .:. :i : ,.
I : .. I I I I I I .
I : I I I
System (CA. Only) ....
' I··
!···· ·.·..:. .. : . · ...
.• ·.·
: .•
.. .
Exhaust System .. .. I• .
I I I I I I ·:., I ,·. ·. I .
I •.
I ..
I I I
I•'
. ..
.. ·.
Fuel Filter .::: . R .... R
.. . . ,· ·•. ·.
.•
Fuel System I I I
.
I I .
I .··· I I I . I , .. I . I
.
.
. . .
.. •
,.·:··.·. .
Oil Lines / Oil System ,. ·.
. .
.
!> '
Inspection I I I I I . I I I I I I
I• I··
. .· .. · .. .. . .·
. .
Spark Plugs I .... I R
..
.. • .. .. I
.. ' . '• : ..
Engine Coolant I I .. I I I
1·•.
. I
•. ,:.·,
I I 1····.··· I .. ..
I R
.• / ..
.. .. : ..
..
Valve Lash Clearance .. . . · I .• ': I 1·· ..
'
Operation Codes:
I - Inspect (tighten, clean, adjust, correct or replace if
necessary)
R - Replace/Rebuild
L - Lubricate with proper lubricant as directed
P-Perform
* - Replace at specified interval or annually. If driven
in extreme conditions.
** - Replace at specified interval or every 2 years
9927619 R02 - 2016 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
2.6 Polaris Industries Inc.
MAINTENANCE
6'
0
-
0
0
0
6'
0
0
6'
0
0
I.I:)
6'
0
0
<::I'
6'
0
0
C\3
6'
0
0
0
6'
0
0
co
6'
0
0
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6'
0
0
~
6'
0
0
C\3
6'
0
0
0
e ~ e :::, ~ C. ~ ~ !!!, !::, ~ e
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0
-
I.I') I.I') 0 0 0 0 0 0 0 0 0 0
0 I.I') 0 I.I') 0 I.I') 0
0
~
C\3 I.I')
C\3 C\3 (") (") '<:f' '<:f' I.I')
Battery I I I I I I I I I I• I I I
Brake Fluid** I I I R I R I
-_
R I R I R
Brake Pads I I I I I I I I I I I I
--
.
Clutch Lever L I L I L I L I L I ---- L
I I I I I I I I I I I I
Fasteners . .
Head Light I I I I I I I
-
p p p p . p p p p •• p p p p
Road Test
Sidestand / Sidestand Safety L I L I I
-
I I I I I I I
Switch . .
I I .-. I I I
Steering Bearings I I I I I I I
-._
Shock Bushings and Fasteners I I I I I I I I I I I I
Tires / Wheels I I I I I I I I I I I I
Operation Codes:
I - Inspect (tighten, clean, adjust, correct or replace if
necessary)
R - Replace/Rebuild
L - Lubricate with proper lubricant as directed
P-Perform
* - Replace at specified interval or annually. If driven
in extreme conditions.
** - Replace at specified interval or every 2 years
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GENERAL INFORMATION
SERVICE NOTES BREAK-IN PROCEDURE
Periodic Maintenance Overview Engine break-in for Indian Motorcycles occurs in the
Inspection, adjustment and lubrication of important first 500 miles (800 km) of operation. Indian
components are explained in the periodic Motorcycles are manufactured using the best possible
maintenance chart. materials and manufacturing techniques, but the final
machining process is the break-in. During this break-
Inspect, clean, lubricate, adjust and replace parts as in period, critical engine parts wear and polish to
necessary. When inspection reveals the need for correct operating clearances. Read, understand and
replacement parts, use genuine Indian Motorcycle follow all break-in procedures to ensure the long-term
parts available from your Indian Motorcycle dealer. performance and durability of the engine.
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MAINTENANCE
ENGINE OIL LEVEL CHECK 7. Oil level should be between the ADD and FULL
With the semi-dry sump lubrication system, the lines on dipstick. If oil level is low, add Indian
engine oil level on the dipstick will fluctuate, Motorcycle 15W60 Full Synthetic engine oil and
depending on the motorcycle's position and engine repeat steps 3 - 6 until the reading is within the safe
speed when the engine is turned off. To ensure a operation range.
proper reading of the engine oil level, follow all
inspection procedures closely.
Oil level will NOT be accurate if checked on a cold
engine. DO NOT ADD oil to bring to FULL mark on a
Engine MUST BE AT FULL OPERATING cold engine, as this can result in overfilling.
TEMPERATURE when checking oil level.
Do not overfill! The approximate volume between
the FULL CD and ADD CD marks on the dipstick is 16
1. With the motorcycle in an upright (vertical) oz. (.45 L).
position, run the engine for 30 seconds.
2. Stop engine.
3. Place the machine on a level area and hold it in an
upright (centered) position.
4. Remove the engine oil dipstick G) and clean off the
engine oil.
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MAlNTENANCE
1. Run engine until warm, then turn engine off. 3 US quarts will bring the engine oil level at or near
2. Securely support the motorcycle in a vertical the "FULL" mark on the dipstick. For a new or rebuilt
"centered" position. (dry) engine add an additional .5 US quart (.47
Liters).
Total engine oil fill volume with oil filter change will
be approximately 3.0 - 4.0 US quarts (2.8 - 3.8 Liters).
Total engine oil fill volume with a new or rebuilt (dry)
engine will be approximately 4.5 quarts (4.25 Liters).
Oil Filter:
115 in-lbs (13 Nm) or approximately 3/4 to l full
turn after seal contacts the filter mount sealing
surface.
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MAJNTENANCE
1. The pressure cap G) is located under the fuel tank. 1. Remove the seat. See Seat Removal / Installation,
page 7.8.
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 4.14.
2
Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and
serious burns may result. Allow the engine and
cooling system to cool };)efore servicing.
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COOLING
NUMBER DESCRIPTION
G) Radiator Inlet Hose
CD Bypass Hose
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Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators
effectiveness. Use of a high-pressure washer is not recommended.
NUMBER DESCRIPTION
CD Radiator Cover
CD Radiator
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COOLANT I 3.
• 2015-16 Models
Remove the coolant return hose G) from the oil
Never remove pressure cap when engine is warm or cooler assembly to drain the coolant.
hot.
The cooling system is under pressure and serious
burns may result. 2
Allow the engine and cooling system to cool before
servicing.
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installation.
{\ __1j '-\
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INSPECTION
1. Pull and release the front brak~ lever. It should 1. Remove the nut G) and pivot fastener(D.
move freely and smoothly and return to its rest
position quickly when released. Lubricate brake
lever if binding, or if it does not return quickly and
completely when released. See Front Brake Lever
Lubrication, page 2.21. 2
2. Measure brake lever free play G). You should feel
a firm resistance in the lever within the specified
length of lever travel. If brake lever travels too far
before beginning to apply the brake, inspect for
brake fluid leaks and bleed air from the system.
See Brake Bleeding.
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MAINTENANCE
Lubricate brake pedal at intervals listed on periodic 4. Remove brake pedal return spring ®· Remove
maintenance table. See Periodic Mai:p.tenance Interval brake pushrod pivot bushing ®· Remove the brake
Table, page 2.6. pedal bushing (J) and washer®·
1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.
2. Working on the RH side of the motorcycle, remove 2
brake line p clamp bolt CD and foot peg mount
bolts (D. Move foot peg mount/master cylinder
assembly so the brake pedal pivot shoulder bolt
can be accessed.
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1. Turn handlebars or adjust the motorcycle until top 8. Fluid level is checked at the rear brake master
of reservoir is level. cylinder reservoir.
9. View fluid level through reservoir sight glass ®·
The fluid should be clear and at or above the
middle of the sight glass.
,::
'······--.: ...................... .. ..·
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14. Install diaphragm and cover. Tighten cover screws FRONT BRAKE PAD INSPECTION
to specification.
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MAINTENANCE
FUEL TANK VENT INSPECTION (49 STATE) EVAPORATIVE EMISSION CONTROL SYSTEM
• Inspect fuel tank vent hose G) in accordance with (CALIFORNIA MODELS)
periodic maintenance schedule and any time fuel
tank has been removed and installed. Be sure the
hose is clear and not pinched or kinked, and that all The fuel tank vent line is routed to a vapor canister
connections are tight. where the fuel vapor is stored until specific operating
parameters are met and the ECM opens the purge
valve. Fuel vapor is then routed out of the vapor
canister, through the purge valve and into the throttle
body for combustion. Inspect all EVAP lines for
abrasion or wear. Check that all connections for both
vent and canister purge systems are securely
attached.
NUMBER DESCRIPTION
G) Fuel Tank Vent Hose
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MAJNTENAN"CE
FUEL I RAIL
1. The fuel supply hose and fuel. rail are located
behind the engine cover on the RH side of the
motorcycle. HOT COMPONENTS Wear insulated gloves and/
2. Inspect fuel supply line G) and fuel rail CD for or allow engine and exhaust to cool before
deterioration, damage, leakage, or kinked areas. handling these parts.
Inspect fuel supply line-to-fuel rail connection G)
2
for signs of leakage.
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MA1NTENANCE
1. Remove spark plug (s). See Spark Plug Removal, Spark Plug Gap: 0.030 in (0.80 mm)
page 2.29.
2. Inspect electrodes for wear and carbon buildup. 2. Apply anti-seize compound sparingly to spark
Look for a sharp outer edge with no rounding or plug threads, avoiding the bott'?m. 2 - 3 threads.
erosion 9f the electrodes. 3. Torque spark plugs to specification.
3. Clean with electrical contact cleaner or a glass
bead spark plug cleaner only.
4. Measure electrode gap with a wire gauge G). Do not over tighten spark plugs. Damage to the
Adjust gap if necessary by carefully bending the cylinder head or spark plug may result.
grounding electrode until the specified gap is
achieved. 4. Install ignition coil(s). See Ignition Coil Removal/
Installation, page 10.35.
5. Install air box assembly. See Air Box Installation,
page 3.5
6. Install fuel tank assembly. See Fuel Tank
Installation, page 4.19
7. Install seat assembly. See Seat Removal /
Installation, page 7 .8
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..;~~:'ff
.......:... ./
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Battery terminals and connections s11,ould be kept free CHARGING NEW BATTERY
of corrosion. If cleaning is necessary, remove the
corrosion with a stiff wire brush. Wash with a solution 1. Charge the battery at J. 8 amps for S to IO hours. use
a straight rate charger (not load sensing or battery
of one tablespoon baking soda to one cup water. Rinse
tender type) for the initial charge of a new battery.
well with tap water and dry off with clean rags. Coat
terminals with dielectric grease. 2
1. Visually inspect the exterior of the battery. Do not attempt to quick charge the battery at any
Replace battery if housing is damaged, case is time.
deformed, or if electrolyte is leaking.
2. To remove corrosion, remove battery from 2. Remove battery from charger and let battery stand
motorcycle and wash terminals with water and for 30 minutes or longer.
baking soda solution. Clean terminals, bolts, and
3. Measure voltage with a digital multi-meter. If lower
cable ends with a brass wire brush and apply a
than 12.5 Vdc, battery must be recharged again in
thin film of dielectric grease.
accordance with step 1 and 2 above.
3. Measure battery voltage. 4. After charging battery and letting it sit for 30
minutes or more, check battery voltage again. If
battery voltage is still below 12.5 Vdc, replace the
battery.
CHARGING BATTERY IN SERVICE
1. Measure battery voltage with a digital multi-meter.
The reading should be above 12.5 Vdc. If battery
voltage is lower than 12.
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INSTALLATION
1. Install battery into battery box.
2. Install battery hold down bracket and torque
Inspect drive belt in accordance with Periodic
fastener to specification. Maintenance Interval Chart and replace at specified
intervals regardless of belt condition. See Periodic
Maintenance Interval Table, page 2.6. 2
Battery Bracket Fastener:
12 ft-lbs (16 Nm)
DRIVE BELT CONDITION SERVICE
WEAR RECOMMEN-
3. Connect the positive battery terminal and torque
EXA.MPLES DATION
fastener to specification.
External Tooth Replace Belt
I~ Serious) monitor
condition
l~I replaced if
damage is on
the edge of the
belt
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3. If the drive belt or sprocket is being replaced due DRIVE BELT TENSION
to damage, replace belt and both sprockets as a Special Tool: Belt Tension Gauge PV-43532
set if drive system has more than 5000 miles (8000
Km) of use.
Do not adjust the belt when wet, or immediately after
DRIVE BELT SPECIFICATIONS riding. Belt must be dry and the drive system must be
at ambient temperature (60-80° F). This is extremely
DRIVE BELT DEFLECTION DATA important for accuracy.
DRIVE BELT FREQUENCY TENSION DATA A drive belt that is not properly tensioned can cause
drive line noise and damage the drive belt, causing
possible belt failure and loss of control of the
motorcycle.
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MAJNTENANCE
4. Use the tire valve stem as a reference and perform 8. If belt deflects more than the specified distance
the following Steps: with IO lbs. of force, tighten the belt. If deflection
is less than specified loosen the belt. See Drive
• Check / record belt deflection at 4 different points,
Belt Adjustment, page 2.38.
90 degrees apart. Rotate wheel in a COUNTER-
CLOCKWISE rotation as viewed from belt side of
motorcycle.
• Place a mark on rear wheel at the tightest point New drive systems (new vehicle or when belt and 2
(least deflection) to use as a reference. sprockets are replaced) should be set to the tight
• Continue to rotate the wheel in normal drive side of the specification and inspected after the first
direction (COUNTER-CLOCKWISE) 1-2 revolutions 500 miles (800 km).
until your reference mark (the tightest point) is lined
up with the tension setting window CD in the lower
belt guard. BELT
Specifications: Drive Belt
. -
' --
BELT DEFLECTION
Model Deflection @ 10 lbs force
6. Slide 0-ring on belt tension gauge to the 10 lb. Tension 48 Hz(± 2 Hz)
mark. Scout / Scout Sixty
• Place belt tension gauge squarely against belt at
center and keep it at a 90° angle to the belt surface.
Belt
~~-
' I
~
~
0 t~
OK
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Belt Tension
t\
\ . \
I
\
ij
.11
l'
1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Make note of adjuster locations G) and Q). ;J
f Ii
I
Il ···.
!l)
3. Raise the rear of the motorcycle so the rear tire can
be freely rotated. 6. When belt tension is correct, check and adjust final
belt alignment as follows.
Belt Alignment
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MAJNTENANCE
(2.,)
\~...• ·'
.L.
3. Closely inspect drive belt condition.
Ci
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MAfNTENANCE
Adjust headlight aim when there i!:1 a change in load (rider, cargo, accessories, etc.) or after suspension
adjustment.
With the headlight switched to HIGH beam, the center of highest intensity (appears as a diamond shape) should
be 7.5 in (19 cm) below the height of the headlight bulb when centered straight ahead at 25 feet (7.62 m).
Follow all steps below to ensure accurate aim inspection.
2
1. Check and adjust the tire pressure. See Tire Pressure / Specifications, page 2.18.
2. Verify suspension ride height is set correctly. See Rear Shock Preload Inspection, page 2.45.
3. Move the motorcycle to a clear area with a level floor and dim lighting, and place it so the top front edge of the
headlight housing is 25 ft. (7.6 m) from the wall.
4. Have the rider (and passenger if normally present) straddle the motorcycle in an upright position and sit in
the seat(s). Center the handlebars in a straight ahead position.
5. Turn ignition switch ON.
6. Set headlight to HIGH beam.
7. Compare the position of headlight beam on the wall to the illustration below and adjust if necessary.
NUMBER DESCRIPTION
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MAfNrENANCE
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© Copyright Polaris Industries Inc.
MAINTENANCE
Care should be taken to be sure the motorcycle will Care should be taken to be sure the motorcycle will
not tip or fall while elevated. Severe personal injury not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls. or death may occur if the motorcycle tips or falls.
1. Secure motorcycle with front wheel off the floor. 3. Inspect for worn swing arm bearings by grasping
the rear wheel and attempting to move wheel side-
2. Turn handlebars from full left to full right and to-side G) . Inspect for worn bearings and linkages
inspect for smooth, free movement. Point front by moving the wheel side-to-side Q).
wheel straight ahead, grasp fork tubes and pull/
push fork tubes back and forth. If steering binds,
feels rough or uneven, or if movement is detected
at steering stem, adjust or replace steering head
bearings as necessary.
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Intake Valve Clearance (cold): 0.006 in (0.152 mm) Camshaft Carrier Bolts:
Exhaust Valve Clearance (cold): 0.008 in (0.203 mm) 88 in-lbs (10 Nm)
2. Remove the valve tappet from a valve that was out 9. Measure and confirm that valve clearance is now
of specification. within specification for each valve.
10. If valve clearance is not within specification, repeat
this procedure.
Keep mated parts together and in order with respect
to their location in the cylinder head for assembly
purposes. Mark each component or place them in an
organized rack as you remove them.
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N TES
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLING / EXHAUST
Installation, page 7 .8
3. Remove fuel tank. See Fuel Tank Removal. Fuel
Tank Removal, page 4.14
4. Remove frame tube to mid-casting bolts G), two
nuts ® and bolt CD retaining the right frame tube
©.
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3.5
ENGINE I COOLING / EXHAUST
REQUIRES ENGINE REMOVAL FOR SERVICE CAN BE SERVICED WITH ENGINE IN FRAME
Camshaft(s) / Bearings Airbox Removal
Crankshaft & Crankshaft Component Service Camshaft Chain/ Guide / Tensioner Assembly
Cylinder Heads Fuel Injectors/ Throttle Body/ Fuel Rail
Cylinders Voltage Regulator, Stator, Rotor (Flywheel)
Lifters Clutch
Oil Pump Gearshift Linkage (External)
Balance Shaft Ignition System
Piston/Cylinder Oil Pump Drive
Pushrods Output Shaft Seal
Transmission/All Internal Transmission Parts Torque Compensator Assembly
Valve Covers
Starter, Starter One-Way Clutch, Starter Torque Limit
Clutch
Crankshaft Position Sensor Timing Wheel
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ENGINE I COOLING I EXHAUST
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Engine Stand Adapter PF-51240
Motorcycle Table Lift / Wheel Vise Commercially Available
12"xl2" Platform Jack Commercially Available
Engine Hoist (Cherry Picker) Commercially Available
Engine Stand Commercially Available
SERVICE SPECIFICATIONS
ITEM SPECIFICATIONS
Engine Dry Weight Approximately 200 lbs (91 kg)
Oil Capacity (Dry Fill) Approximately 4.6 Quarts (4.3 Liters)
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ENGINE / COOLING / EXHAUST
ASSEMBLY VIEWS
ENGINE BRACKET/ FASTENER COMPONENTS
ENGINE MOUNTING BRACKETS/ FASTENERS
CD Nut -
© Spacer -
® Side Stand Fastener 19 ft-lbs (26 Nm)
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ENGINE / COOLING / EXHAUST
22. Disconnect the overflow reservoir hose @) and 28. Disconnect the starter motor battery cable at the
remove the thermostat housing ®· terminal@.
23. Disconnect the TMAP sensor connector @. 29. Disconnect the oil pressure switch connector ®·
See Sensors - Powertrain Management, page 4.11.
30. Disconnect the crankshaft position sensor
connector ®·
31. Disconnect the vehicle speed sensor connector @).
32. Disconnect the gear position switch connector@.
See Sensors - Powertrain Management, page 4.11.
33. Disconnect the side stand switch connector®·
34. Disconnect the stator connector.
35. Proceed to engine removal. See Removing Engine
From Frame, page 3.11.
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ENGINE / COOLING / EXHAUST
ENGINE INSTALLATION 6. Install the two engine mounting bolts (I) into the
The following procedure is written assuming the en- RH frame panel with side stand assembly and
gine has been assembled and is resting on an engine tighten until the engine is fully drawn into the
stand, ready for installation. frame panel. Do not torque bolts at this time.
Refer toEngine Brackets/ Fasteners, page 3.8 in this
chapter for torque values and assembly views.
1. Clean mating surfaces of frame and engine Be sure engine is aligned at the proper height and
crankcase. Install alignment spacer dowels CD angle with the dowel pins. DO NOT force engine
between right side engine case and mid frame. alignment using the mounting bolts, or the dowel
pins may be damaged! Adjust engine height and
angle continuously as required while drawing up
the bolts.
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ENGINE I COOLING I EXHAUST
8. Install the two front motor mount bolts ®, nuts ©, 17. Connect the electronic throttle body connector@).
and spacer (J) through frame into the engine case.
Torque to specification. ·
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24. Install the thermostat cover bracket fasteners ® 32. Install the exhaust head pipe assembly. See Head
and bracket@. Torque fasteners to specification. Pipe Installation, page 3.95.
33. Install the mufflers. See Muffler Installation, page
3.93.
34. Install the radiator assembly. SeeRadiator Removal
/ Installation, page 3.35.
35. Fill and bleed the cooling system. SeeCoolant
Drain/ Fill, page 2.17.
36. Install the fuel tank. SeeFuel Tank Installation,
page 4.19.
37. Install the battery. SeeBattery Installation, page
10.12.
38. Install the seat. SeeSeat Removal / Installation,
page 7.8.
39. Install ignition side cover. Seeignition Cover
Thermostat Cover Bracket Fasteners: Removal/ Installation, page 7.11.
96 in-lbs (11 Nm) 40. Install thermostat housing cover. SeeThermostat
Cover Removal / Installation, page 7 .11.
25. Install the ignition switch cover bracket fasteners~
ID and bracket®· Torque fasteners to specification.
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ENGINE / COOLING / EXHAUST
NG TROUBLESHOOTING
LOW OIL PRESSURE HIGH OIL PRESSURE
SERVICE NOTES Incorrect oil being used Incorrect oil being used
The Scout uses a semi-dry sump lubrication system.
or low oil level
The engine oil is housed in a separate chamber within Additives added to oil to
Engine temp above test
the engine cases CD as shown in the image below. temperature range increase viscosity
Damaged 0-rings or Engine temp below test
leaks at pipes or fittings temperature range
Damaged or worn oil Restricted oil passages
pump or oil pump drive
Pressure relief valve Incorrect oil filter
stuck open
Damaged engine Pressure relief valve stuck
bearings/excessive closed
engine wear.
Restricted oil filter, oil
filter screen or
passages
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
The engine has two separate oil pumps, a scavenge Oil Pressure Gauge PV-43531
pump CD and pressure (lubrication) pump CD. The
scavenge pump has two sets of internal gerotors. One Bosch Automotive Service Solutions: 1-800-345-
set scavenges oil from the right side of the engine 2233 or https://polaris.service-solutions.com/
crankcase and the second set from the left side. The
scavenge pump supplies oil to fill the oil tank area CD
of the engine. The oiling system pressure relief valve
is located inside the pressure oil pump.
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ENGINE / COOLING / EXHAUST
SERVICE SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Engine Oil Fill Capacity (for DRY 4.5 U.S. qts (4.3 Liters) Not Applicable
rebuilt engine)
Engine Oil Capacity (for Change with 3.0 - 3.5 U.S. qts (2.8 - 3.3 Liters) Not Applicable
Filter) Follow the oil change procedure
outlined in the Maintenance Chapter.
Engine Oil Capacity (for Change 2.9 - 3.2 U.S. qts (2.7 - 3.0 Liters) Not Applicable
without Filter) Follow the oil change
procedure outlined in the
Maintenance Chapter.
Recommended Engine Oil if Indian Indian Motorcycle Synthetic Not Applicable
Motorcycle 15W60 is not available, 15W60
use motorcycle oil with same
specifications.
Oil Pressure @ 3000 rpm (supply side) 40 psi (275 kPa) Readings should MINIMUM PRESSURE: 32 psi (220
Measurements must be taken with be within 20% of the kPa)
engine at operating temperature specification.
and specified Indian Motorcycle
Engine Oil
9927619 R02 - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
3.16 · · Polaris Industries Inc.
ENGINE I COOLING / EXHAUST
Pump Gerotor OD to Oil Pump Body .003"-.007" (0.100 mm - 0.200 .011" (.300 mm)
mm)
Oil Pump End Clearance .0019"-.003" (.050 mm - 0.100 .007'' (.200 mm)
mm)
Gerotor Tip Clearance .0031 "-.007" (.080 mm -.200 mm) .0098" (.250 mm)
..
Pump Gerotor OD to Oil Pump Body .003"-.007" (0.100 mm - 0.200 .011" (.300 mm)
mm)
Oil Pump End Clearance .0019"-.003" (.050 mm - 0.100 .007'' (.200 mm)
mm)
.. .. ..
COOLING FAN OPERATION . . ... ,
Coolant Hot Lamp (On Solid) 1400 233.6 Degrees F (112 Degrees C)
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ENGINE / COOLING / EXHAUST
ASSEMBLY VIEWS
COOLING SYSTEM COMPONENTS
NUMBER DESCRIPTION
CD Funnel Coolant Filler
Q) Coolant Surge Tank
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ENGINE / COOLING / EXHAUST
NUMBER TORQUE(IF
DESCRIPTION
APPLICABLE)
CD SCREW -
CD WATER PUMP DRIVEN GEAR -
CD WATER PUMP DRIVEN GEAR PIN -
© NEEDLE BEARING -
® WATER PUMP SHAFT -
® ROLLER BEARING -
(I) WATER PUMP SHAFT NUT 13 ft-lbs (18 Nm)
® SHAFT SEAL -
® SHAFT WATER SEAL -
@) WATER PUMP IMPELLER 30 in-lbs (3 Nm)
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___ ,b~·'.;:::i)
_,,.-------~--:--------·
--·-,
( 11
\......./
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ENGINE / COOLING / EXHAUST
•. - . - - - - - - - - ~ , - - - - - - - - - - , , - - - - - - - - - -•. - - - - - ~ ['----ii>
LEGEND
Supply f~t
Drainback Return
Rear Cylinder
lntake/Exhaus t
Camshafts
Left Connecting
Rod Bearing
l~ ~l
'f
·p-
' 7
Right Connecting
Rod Bearing
~
Front Cylinder
Intake/Exhaust
Camshafts
' "
!!
Lubrication Oil
Pump Pickup · r···.,·.·\····..,. . ·..· ··>.······ .,,i
Screen/Tube
I Il f(;== Drilled Crankcase _,._ Right Side
"- Crankcase Oil Inlet k:==
RIGHT SIDE
....---
1 Scavenge Pump (Front) ENGINE
1 Right Gerotor l Oil Passage Scavenge Screen OIL SUMP
I
:. ··1
t
I
Crankcase Oil Scavenge Oil
.L----------1.
Reservior Return Tube FL }if~~~~~ifeulll~
r·r----------,
I'ii Scavenge Pump rI
Left Side LEFT SIDE (Rear)
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OIL
Oil PRESSURE
·.···cAUTION
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ENGINE / COOLING / EXHAUST
OIL PUMP SERVICE 7. Remove the stator cover fasteners ® and stator
SCAVENGE OIL PUMP REMOVAL cover assembly ®·
1. Drain cooling system. Coolant Drain / Fill, page
2.17
2. Remove the left ~ide ignition cover fasteners G)
and cover CD.
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ENGINE / COOLING / EXHAUST
Oil COOLER SERVICE 6. Hold the oil cooler assembly CD from turning to
OIL COOLER REMOVAL prevent distorting the locating tang CD and remove
the oil cooler mounting spigot ©.
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Recommended Coolant:
Indian Motorcycle 50/50 Pre-Mixed Extended Life
Antifreeze
System Capacity:
2.77 qt (2.63 L)
2. Prevent the oil cooler assembly from spinning
Recovery Bottle Capacity:
when installing the oil cooler spigot ® and torque
.16 qt (.15 L)
spigot to specification.
(PN 8560214) (Quart)
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Never remove pressure cap when engine is warm or Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and hot. The cooling system is under pressure and
serious burns may result. Allow the engine and serious burns may result. Allow the engine and
cooling system to cool before servicing. cooling system to cool before servicing.
3. Remove the cooling system pressure cap and test 3. Remove the cooling system pressure cap and test
using a cooling system pressure tester. using a cooling system pressure tester.
(Commercially available). (Commercially available).
4. The system must retain 11-14 psi (75-95 kPa) for 4. The cooling system pressure cap relief pressure is
five minutes or longer. If pressure loss is evident 16 psi ( 110 kPa). Replace cap if it does not hold the
within five minutes, check the radiator, all cooling required specification pressure.
system hoses, hose clamps and water pump for
leakage.
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ENGINE I COOLING I EXHAUST
• 2017 Models
Remove the coolant drain plug CD from the
radiator.
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9. Remove the water pump seal assembly® with a 12. Use the wrench flats® to hold the water pump seal
hooked tool or equivalent tak.ing care to not installation tool @) from turning while turning the
damage the water pump shaft or engine case. tool wrench hex ® to seat the seal in the bore.
10. Clean the water pump seal bore and inspect the Water Pump Impeller:
seal bore surfaces for scoring or damage. 30 in-lbs (3 Nm)
11. Install new water pump seal ® in engine case by
hand. Thread water pump seal installation tool PF-
51608 @) on the water pump shaft.
Stator Cover Fasteners:
88 in-lbs (10 Nm)
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2. Remove water pump shaft oil seal G) with a hooked 5. Use a suitable driver to install the seal so the outer
tool or equivalent taking care to not damage water face is flush with the step CD on the engine case.
pump shaft or engine case.
3. Clean the water pump oil seal bore and inspect the
seal bore surfaces for scoring or damage.
4. Align the new water pump shaft oil seal in the
engine case and insert with light pressure.
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ENGINE / COOLING / EX:H.AUST
THERMOSTAT
5. Drain the cooling system. See Coolant Drain/ Fill, 9. Reverse removal procedure for installation.
page 3.33.
10.Fill and bleed the cooling system. SeeCoolant
6. Disconnect the radiator inlet hose CD and overflow Drain / Fill, page 3.33.
reservoir hose G) from the thermostat housing.
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TROUBLESHOOTING
Overheating
• Low coolant level
• Air in cooling system SERVICE NOTES
" Wrong type/mix of coolant
• This chapter covers service of the cylinder heads,
" Faulty pressure cap or system leaks
camshafts, cam chains, tensioners and guides.
Restricted system (mud or debris in radiator fins
• Refer to Engine / Cooling/ Exhaust Chapter for
causing restriction to air flow, passages blocked in
engine removal and installation.
radiator, lines, pump, or water jacket, accident
" If cylinder heads are removed the cylinder base
damage) .
gasket must be replaced also.
• Engine running lean (fuel system restriction)
• Mark and store all mating parts for correct engme
• Fuel pump output weak assembly. ·
• Water pump failure/ Loose impeller
Use Moly Assembly Paste - PIN: 2871460 or Indian
Engine Coolant Temperature Sensor failure
Motorcycle Synthetic 15W60 Engine Oil to lubricate.
• Electrical malfunction parts where indicated.
• Cooling fan inoperative or turning too slowly Handle and store all parts in such a way that they
• Low oil level
will not be damaged or contaminated.
" Faulty hot lamp circuit • Some fasteners have a pre-applied locking agent,
Thermostat stuck closed or not opening completely and must be replaced if loosened or removed.
Temperature Too Low Always replace fasteners that have a pre-applied
locking agent or as directed in this service manual.
" Thermostat stuck open • There are some precision machining steps to be
performed in this section. If you are not sure of your
Leak at Water Pump Weep Hole
capabilities in these areas, have a competent
• Faulty water pump mechanical seal machinist perform these operations.
• Worn pump shaft or pump shaft bearing Valve guide and seat reconditioning should be
performed by a technician proficient in cylinder
head reconditioning techniques using high quality
equipment with grinding stones. Do not attempt
cylinder head repair without the proper equipment
or experience in cylinder head reconditioning
techniques.
The intake and exhaust valves cannot be re-faced.
• Cleanliness of parts is critical to engine life and
accurate parts inspection. Use clean solvent to clean
all disassembled parts. Dry parts with compressed
air and lubricate before engine inspection and
engine assembly.
SERVICE SPECIFICATIONS
Camshaft Data
DESCRIPTION SPECIFICATION
Over Head Valve / 4 valves per cyl
Valve Train
2 Intake Valve/ 2 Exhaust Valve
Intake Valve Opens At I mm Lift 9.0° BTDC
Intake Valve Closes At 1 mm Lift 221.0° ATDC
·-
Exhaust Valve Opens At I mm Lift 229° BTDC
CAMSHAFT DATA Exhaust Valve Closes At I mm Lift 3° ATDC
Max Lobe Lift
INTAKE .3976" (10.10 mm)
EXHAUST .3976" (10.10 mm)
Max Valve Lift
INTAKE .3976" (10.10 mm)
EXHAUST .3976" (10.10 mm)
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ASSEMBLY VIEWS
CAM CHAINS COMPONENTS
/.,. .. -..,....
( 20)
'"--~-
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('14'°:-·
...
---
\ ...... ....._. .//
/-- ....\
~ 15 ;,--------
·,., ___ _.,./
(3 i-----,,::.:
'~,.................
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Method 2
1. Remove cam chain tensioners and sealing washers.
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CAM CHAIN TENSIONER INSPECTION 6. Rotate the crankshaft to expose sprocket bolts CD
and loosen 1/2 turn.
1. Visually inspect inner plunger CD for damage,
scoring or burns.
2. Lubricate inner plunger with engine oil. Move Use a piece of nylon webbing or rope to create an
plunger in and out of outer plunger CD to check for interference between the crank drive gear and clutch
smooth movement without binding. gear, thus locking the crankshaft while loosening
3. Verify the oil passage opening is free from debris. sprocket bolts.
4. Replace tensioner assembly if worn or damaged.
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11. Remove sprocket(s) CD from camshaft(s) using care CAM DRIVE SPROCKET REMOVAL
not to drop the chain into the cam. chain gallery. 1. Lock the crankshaft for service. See Locking the
Crankshaft for Service, page 6.6.
2. Remove bolt and washer CD securing cam drive
gear to cam drive shaft.
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ENGINE/ COOLING / EXHAUST
4. Remov~ the cam drive carrier CD from the CAM DRIVE SHAFT REMOVAL
crankcase assembly. 1. Remove the camshaft sprockets. See Camshaft
Sprocket Removal, page 3.50.
2. Remove the cam drive sprocket. See Cam Drive
Sprocket Removal, page 3.51.
3. Remove the screw G) securing the cam chain guide
CD from the crankcase assembly.
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CAM DRIVE SHAFT INSTALLATION 3. Turn the cam drive shaft so the woodruff key is
pointing at 12 o'clock.
1. Apply a thin coat of assembly lube to the bearing
end of the cam drive shaft G).
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ENGINE / COOLING / EXHAUST
3. Starting with the rear cylinder, hand-tighten the 3. Using a small screw driver CD or equivalent,
preload the gear teeth of the cam drive sprocket.
screws CD until seated and torque to specification.
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ENGINE / COOLING / EXHAUST
4. Align the timing marks on the primary gear and 6. Install the bearing support plate center fastener®
cam drive sprocket as shown and slide the cam and washer. Torque to specification.
sprocket onto the cam drive shaft.
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CAMSHAFT SPROCKET INSTALLATION/ TIMING 4. Take up the slack on the intake side of the cam
PROCEDURE chain and lay it over the INTAKE sprocket. Verify
that the timing marks (I) line up with the chain
installed and slack removed.
Camshaft sprockets are interchangeable (identical
for all camshafts) and drilled offset so that they
cannot be installed incorrectly.
Letters/ Timing Marks on sprockets will appear
right-side up if timed correctly and the respective
cylinder is at TDC.
See Camshaft Timing Marks, page 3.47 for camshaft
timing marks. 3
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ENGINE / COOLING / EXHAUST
13. Rotate the EXHAUST camshaft until the screw holes CAM CHAIN TENSIONER INSTALLATION
line up and install one screw® .into the exposed 1. Verify that the engine is at TDC and the timing
hole and torque to specification. marks are properly aligned. SeeCamshaft Timing
Marks, page 3.47.
2. Install the tensioner (s) with new sealing washers
Cam Driven Sprocket Fasteners (All): and torque to specification.
88 in-lbs (10 Nm)
3. Install tensioner bolt and torque to specification.
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VALVE CLEARANCE ASSEMBLY 5. Install the camshaft carrier bolts G) and tighten the
bolts evenly to specification.
/-·--....
( 2 \
\, j
Jr=h,._,... \
r- \.!-;::-__., L.. ·• '\
1.~. )- -.~- -:_..,._.~_....ral. T·
)1.., .-bff~-,
t..
l r--..::--·, /.
\ ""'J1'-- '-...j !'_--:--_:-::-.....:_.
>'."~ ·.. . - ... "".· ·. ·.·.·_· 1 . ,,...---~.
0 . ;:.::-_) l
1/./· V /
~ Ji~~-·.··~.
r--- I_, \.
I1 I . ;·. !'--\1 .t :.;--·. · .. .'_ ,_. ,j . .
I
. ~ ..i/7:,
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I -7' , J. \{;y. ~1
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·.·
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t\ ~j:li~
\r .. \\·--\\'....... \--..- .J;;:-:./J_ i)_ =fi
. __ ,_.. .- .... U ..:~:..:\-·-=----~ r~/f
I 1.1r \,\\
\ ., • . /. ~ : - \, . . .7'
. 11/·1.;·\..
.1 .l .. ; \
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ENGINE/ COOLING / EXHAUST
Intake Valve Clearance (cold): 0.006" ± 0.001" 15.Repeat steps 10-14 until all necessary valves have
(0.152 mm± 0.05 mm) been adjusted.
Exhaust Valve Clearance (cold): 0.008" ± 0.001" 16. Reinstall the camshafts and camshaft carriers and
(0.203 mm± 0.05 mm) tighten the bolts evenly to specification.
If all valve clearance measurements are within 17.Measure and confirm that valve clearance is now
specification proceed to Camshaft Sprocket within specification for each valve.
Installation/ Timing Procedure, page 3.57. 18. If valve clearance is not within specification, repeat
this procedure.
10. Remove the valve tappet from a valve that was out 19. If all valve clearance measurements are now within
of specification. specification, remove the camshaft carriers and
proceed to Camshaft Sprocket Installation/ Timing
Procedure, page 3.57.
Keep mated parts together and in order with respect
to their location in the cylinder head for assembly
purposes. Mark each component or place them in an
organized rack as you remove them.
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ENGINE / COOLING / EXHAUST
CAMSHAFT INSPECTION
For the following camshaft inspec~ion procedure, refer to the camshaft service specifications section. See
Service Specifications, page 3.42.
NUMBER DESCRIPTION
CD Exhaust Camshaft
CD Intake Camshaft
G) Thrust Face
© Cam Lobes
® Bearing Journals
1. Visually inspect camshaft journal surfaces for scoring or signs of insufficient lubrication. Replace camshaft if
heavy scoring or damage is noted.
2. Inspect height of each cam lobe for INTAKE and EXHAUST camshafts.
3. Measure O.D. of each camshaft journal for INTAKE and EXHAUST camshafts.
4. Inspect the camshaft hub face for damage or surface roughness.
6. Inspect decompression device (EXHAUST camshaft only).
6. Inspect camshaft thrust face(s) for uneven wear and scoring.
7. Wash the camshaft in solvent.
8. Oil the camshaft.
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10. Alternately loosen and remove cylinder head bolts CYLINDER HEAD DISASSEMBLY
Q).
CAUTION
Wear eye protection while removing valve springs.
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3. Using valve spring compressor PV-1253 remove 5. Remove and discard the spring seat / valve stem
keepers (I), upper spring retainer CD and valve seal assembly ®·
spring © from valves.
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,,---"
( 2 -f;-,,;~i-"--',--'fr-;
;r-·
''~--/
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Damaged valve face Burnt, pitted, foreign Replace valve and reface
material damage seat
Contact area too high Wear, settling of valve seat Lower with 30° stone
Contact area too low Wear, settling of valve seat Raise with 60° stone
Contact area too wide Wear, settling of valve seat Narrow with both 30° stone
and 60° stone
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Replacement of valve guides requires an oven, Valves cannot be ground. If valve face is burned or
special equipment and experience to do the job badly worn, replace the valve.
correctly. If you are unsure of your ability to do the
repair professionally it is best to sublet the labor to a
1. Remove carbon deposits from valves and seats.
competent machinist. Valve seat reconditioning is
required when valve guides are replaced. 2. Inspect valve face for burning, pitting or uneven
contact.
1. Support cylinder head and place valve guide 3. Apply a light coating of machinist's layout fluid or
remover into valve guide from the combustion paste to valve face.
chamber side. 4. Install valve into valve guide.
2. Drive or press old valve guides out of cylinder 5. Tap valve several times to make a clear impression
head. on the valve face. Do not rotate valve.
6. Remove valve and measure contact area CD. See
Service Specifications, page 3.42.
The cylinder head can be easily damaged if the
procedure is done carelessly.
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CAUTION
Do not compress valve springs more than necessary
to install keepers.
Support cylinder head so valves will not be
damaged.
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CYLINDER HEAD INSTALLATION 5. Apply a thin coat of Indian Motorcycle engine oil to
the cylinder head bolt threads and install
fasteners® finger-tight.
Torque-to-Yield cylinder head bolts can only be
reused / re-torqued once following removal.
Attempts to reuse bolts beyond one re-torque may
result in lower sealing pressure and potential oil /
coolant leaks.
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10. Insert the spark plug seal into the cam carrier and
install carrier onto cylinder head.
11. Temporarily install the upper cam chain guide and
torque the carrier fasteners per the specified
sequence.
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.. -- :. -_ .
Existing Valv:e Lai;h Tappet Marking (3 digits ontappet)
--- -- -·
.
440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525
--_.
..
---- - -
' -
Correct Valve Iiash Tappet Iyrarking (3 digits on'fappet) -_
0.000-0.024 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512
0.025-0.049 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515
0.050-0.07 4 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518
0.075-0.099 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520
0:100-0.200 \ -- .. .. .,
---
·- ----
. - .
(Standard) ' ·. -: -·- ··:: . :-:: -, ... : ' •>-: -· .... -- .. ·-·. ----;- .: -- .. :·::i' '·"· --
0.201-0.225 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532
0.226-0.250 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535
0.261-0.276 462 465 458 460 462 466 468 470 472 475 478 480 482 485 488 490 492 496 498 500 502 605 508 510 612 615 518 620 522 525 528 530 532 636 638
Itl1
0.276-0.300 466 458 460 462 465 468 470 472 475 478 480 482 486 488 490 492 496 498 500 502 505 608 610 512 616 518 520 622 625 628 530 532 635 638 640
i:: 0.301-0.325 468 460 462 465 468 470 472 475 478 480 482 486 488 490 492 495 498 500 502 606 508 510 612 515 518 520 522 526 628 630 532 536 538 540 642
'.P
Ul
;=j
:g' 0.326-0.360 460 462 466 468 470 472 476 478 480 482 486 488 490 492 495 498 600 502 506 508 610 512 515 618 620 622 625 528 530 532 536 638 640 542 545
,::i::
0.351-0.375 462 466 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 615 518 520 522 525 628 530 532 635 638 540 542 545
~
£Q) 0.376-0.400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 600 502 506 508 510 512 515 518 520 622 525 528 530 532 535 638 640 542 546
i:r:l
Q)
0.401-0.425 468 470 472 475 478 480 482 485 488 490 492 495 498 500 602 505 508 510 512 516 518 520 522 525 528 530 532 535 538 640 542 545
§
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rd
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0 0.451-0.475 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 526 628 530 532 535 538 540 542 545
~ 0.476-0.500 475 478 480 482 485 488 490 492 495 498 600 502 505 508 510 512 515 618 520 522 525 528 530 532 535 538 540 542 545
~ Cl) 0.501-0.525 478 480 482 485 488 490 492 495 498 500 602 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
.!4
] 0.526-0.550 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 640 542 545
0.551-0.575 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.576-0.600 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.601-0.625 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.626-0.650 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 628 530 532 535 538 540 542 545
0.651-0.675 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 642 545
0.676-0.700 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.701-0.725 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.726-0.750 500 502 505 508 510 512 515 518 620 522 525 528 530 532 535 538 540 542 545
0.751-0.775 502 505 508 510 512 515 518 520 522 525 628 530 532 535 538 540 542 545
0.776-0.800 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.801-0.825 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.826-0.850 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.851-0.875 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.876-0.900 515 518 520 522 525 528 530 532 535 538 540 542 545
0.901-0.925 518 520 522 525 528 530 532 535 538 540 542 545
0.926-0.950 520 522 526 528 530 532 535 538 640 542 546
0.951-0.975 522 525 528 530 532 535 538 540 542 545
0.976-1.000 525 528 530 532 536 538 540 642 645
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ENGINE I COOLING / EXHAUST
.
Existing Valve Lash Tappet Marking .(3 digits on tappet)
440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525
.
CorrectYalveLashTappetMarldng (3 digits.on tappet)
0.000-0.024 420 422 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505
0.025-0.049 422 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508
0.050-0.074 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510
0.075-0.099 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512
0.100-0.124 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515
0.125-0.149 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518
0.150-0.250 .· ..
..
(Standard) : . .. :. .
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0.251-0.275 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530
0.276-0.300 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532
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,:i:
~ 0.351-0.375 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540
.8(!) 0.376-0.400 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542
~
(!)
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ro
~
(!)
0.426-0.450 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
[5 0.451-0.475 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
(!)
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ti 0.501-0.525 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
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0.526-0.550 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.551-0.575 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.576-0.600 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.601-0.625 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.626-0.650 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.651-0.675 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.676-0. 700 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.701-0.725 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.726-0.750 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.751-0.775 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.776-0.800 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.801-0.825 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.826-0.850 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.851-0.875 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.876-0.900 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.901-0.925 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.926-0.950 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545
0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc. 3.75
ENGINE I COOLING I EXHAUST
Cylinder head, valve train and piston/ cylinder problems are usually detected by an engine compression test.
Other problems associated with this area of the engine are external fluid leaks, excessive oil consumption or
abnormal noises.
The troubleshooting tables that follow list possible causes of engine mechanical problems. Always thoroughly
investigate before disassembling an engine.
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLING / EXHAUST
CYLINDER/ PISTON
GENERAL INFORMATION
SERVICE NOTES
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Piston Ring Compressor PV-43570-A
Engine Lock Tool - PF-51612
Transmission
Engine Lock Tool - PF-51235-A
Crankshaft
Cylinder Bore Gauge PV-3017
Engine Case Splitting Tool PF-51234-A
Straightedge, Feeler Commercially
Gauge Available
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ENGINE/ COOLING / EXHAUST
SERVICE SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
98.992 - 99.008 Check taper and
I.D. (3.8973 - 3.8979") out-of-round
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ENGINE / COOLING / EXHAUST
ASSEMBLY VIEWS
CYLINDER/ PISTON COMPONENTS
//#.... __ '-.'\
( 13 )
··,....~__ ,.,,..,/
CD Piston Circlip -
(I) Piston Wrist Pin -
CD Piston -
© Oil Control Ring/ Expander -
® Compression Ring #2 -
® Compression Ring # 1 -
(J) Cylinder Base Gasket -
® Rear Cylinder -
® Connecting Rod Bolt STEP 1: Tighten both fasteners to 22 ft-lbs (30
(Single Use Fastener) Nm)
STEP 2: Tighten both fasteners an additional
90°
@) Connecting Rod -
® Front Cylinder -
@ Sealing Washer (Front Cyl. Only) -
® Cam Chain Tensioner (Front Cyl. Only) -
I
PISTON RING PROFILE AND ORIENTATION
NUMBER DESCRIPTION
CD Arrows on piston crown indicating installation direction. Both arrows point toward the front of the engine.
CD Front piston is installed closest to the primary drive side of the engine.
® Rear piston is installed closest to the mag side of the engine.
© Wrist pin circlip. Install the circlip with the gap positioned at 12 o'clock.
® Oil Control Ring
® Compression Ring No. 2
(J) Compression Ring No. I
NUMBER DESCRIPTION
CD Lower Oil Ring Rail End Gap
CD Oil Ring Spring Expander End Gap
G) Upper Oil Ring Rail End Gap
@ Second Compression Ring End Gap
® Top Compression Ring End Gap
® Piston Marking Faces Front of Engine
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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ENGINE / COOLING / EXHAUST
CYLINDER INSPECTION
1. Visually inspect cylinder bores for scratches and
wear.
2. Inspect gasket surfaces for ·scratches or other
damage that may cause an oil leak.
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ENGINE / COOLING / EXHAUST
Compare recorded measurement to specifications. If measured value exceeds service limit replace the
appropriate part.
If the piston-to-cylinder clearance exceeds the service limit, measure a new piston and re-calculate the
clearance. If the piston-to-cylinder clearance exceeds the service limits with a new piston, the cylinder can be
replaced or serviced to accommodate oversize piston/rings by a qualified machine shop.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLING / EXHAUST
PISTON & PISTON RING INSPECTION 6. Measure installed ring end gap with a feeler
1. Visually inspect piston for crack~, excessive wear, gauge and compare to specifications. See Service
scoring, etc. Specifications, page 3.79.
2. Measure piston skirt 0. D. (90° to pin and 12 mm 7. Install rings onto a clean piston. Push rings in until
from bottom of piston skirt). Replace piston if worn they are flush with piston. Using a feeler gauge,
beyond the service limit. See Service measure side clearances for the 1st & 2nd rings.
Specifications, page 3.79.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
Polaris Industries Inc. 3.85
ENGINE I COOLING / EXHAUST
PISTON PIN/ PIN BORE INSPECTION 4. Measure connecting rod small end I. D. at two
locations.
1. Measure piston pin hole I. D. (as shown) as close to
the circlip groove as possible with a telescoping
gauge. Record the smallest measurement.
//
,./
.,,/
-">.~ -··· - - - · - - - - ~ ~
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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ENGINE I COOLING / EXHAUST
6. Locate ring end gaps as shown below in relation to 2. Install a new circlip on one side of the piston with
arrow on piston crown. See Piston Ring Profile And ·end gap facing UP (12:00 position).
Orientation, page 3.81.
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ENGINE I COOLING / EXHAUST
6. Install new cylinder base gaskets onto crankcase. 12. Slide cylinder down over piston until seated to
base gasket and crankcase surface.
13. Repeat for other cylinder.
Inspect all sealing surfaces carefully for scratches or 14. Install cylinder head (s). See Cylinder Head
imperfections. DO NOT allow oil or grease to contact Installation, page 3.72.
gaskets or sealing surfaces during the assembly
process.
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLINGI EXHAUST
EXHAUST SERVICE 3. Remove the Bottom Muffler Bolt and Nut ©. Loosen
MUFFLER REMOVAL lower muffler clamp & remove muffler.
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLING / EXHAUST
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ENGINE / COOLING / EXHAUST
9. Remove old exhaust Gaskets (J) from front and rear HEAD PIPE INSTALLATION
exhaust tube. 1. Install new exhaust Gaskets (J) on front and rear
exhaust tube.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc. 3.95
ENGINE / COOLING / EXHAUST
4. Install Rear Head Pipe to engine and secure with 7. Install head pipe to the muffler hanger fastener ®·
two Head Pipe Nuts CD.
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FUEL DELIVERY / EFI
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FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Electrical Tester Kit PV-43536
Fuel Pressure Adapter PV-48656
Fuel Pressure Gauge PU-43506-A
Relay Bypass PU-49466
Smartlink Module Kit PU-47471
USB to Serial Adapter PU-50621
SERVICE SPECIFICATIONS
ITEM SPECIFICATIONS
Fuel Pump Pressure 3.51 BAR (350 kPa) (51 psi)
Idle Speed 800 rpm ± 50 rpm
Fuel Pump Amp Draw
3-5Amps
(Normal Operation)
Recommended
91 Octane Minimum
Octane
Injector Resistance 11.4 - 12.6 Ohms
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FUEL DELIVERY/ EFI
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4.5
FUEL DELIVERY/ EFI
ASSEMBLY VIEWS
FUEL LINE ROUTING (49 STATE MODELS)
NUMBER DESCRIPTION
G) Fuel Supply Line (Pump to Fuel Rail)
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FUEL DELIVERY/ EFI
NUMBER DESCRIPTION
G) Evaporative Emissions Canister
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FUEL DELIVERY/ EFI
® Fuel Pump -
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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FUEL DELIVERY/ EFI
FUEL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
·· · Polaris Industries Inc.
4.9
FUEL DELIVERY/ EFI
/_ ..._"
: 1 '\-.-----;-
\,..............,,~/
CD Air Filter -
® Airbox Assembly -
© Breather Engine Hose -
® Worm Drive Clamp -
® Airbox Frame Seal -
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
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FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
FUEL TANK REMOVAL 4. Disconnect the fuel tank vent line CD and fuel cap
recess drain line CD at the rear of fuel tank.
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FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
4. Remove fuel pump bolts G). 5. Remove the filter element retaining ring©.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
4.16 · · •', · Polaris Industries Inc.
FUEL DELIVERY/ EFI
'·.'....,., ....:.
~ ......
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· •,; .) Polaris Industries Inc.
4.17
FUEL DELIVERY/ EFI
·······r
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FUEL DELIVERY/ EFI
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·· · Polaris Industries Inc. 4.19
FUEL DELIVERY/ EFI
7. Install the fuel tank mounting bolts CD and torque readings obtained with tank installed will be in
to specification. proportion to the amount of fuel in the tank (the
temperature of the thermistor). The sensor wires are
located in the 4-pin connector with the fuel pump
wires, at rear of fuel tank.
If fuel level readings are inaccurate when the
motorcycle is powered up, or if the fuel gauge isn't
indicating fuel level at all, perform the following test
and refer to resistance values located at the end of this
procedure.
1. Remove the fuel pump. See F~el _ Pump Removal,
page 4.15.
2. Set multimeter to measure resistance. Attach
suitable test probe adaptors to meter leads (from
kit PV-43526).
3. On the fuel pump side of the connector, measure
resistance across the sensor and compare to the
table.
ITE-
COLOR ASSIGNMENT
M
SENSOR APPROXIMATE
TEMPERATURE RESISTANCE LIMITS
The sensor is a thermistor with inverse temperature 23°c 1000 ± 1s% n
characteristics (as temperature increases, sensor
50° C 190 ± 1s% n
resistance decreases). When the fuel level falls below
the sensor, temperature increases, lowering the
resistance to provide a ground path for the Low Fuel
lamp bulb which is powered when the ignition key is
on. The lamp will start to glow dimly when the fuel
level falls below the sensor, and will brighten as the
fuel level continues to fall (low resistance).
With fuel tank empty and key ON the lamp will take
approximately 30 seconds to I minute to reach full
intensity (depending upon temperature). The sensor
can be tested using a digital multimeter. Resistance
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
4.20 · Polaris Industries Inc.
FUEL DELIVERY/ EFI
FUEL PUMP CURRENT DRAW TEST 5. Insert red meter lead in pin socket B5 (7) and
black meter lead in pin socket A4 (4) of relay
block.
Fuel pump current draw is an indicator of pump
condition. Perform draw test if fuel pump operation is
suspect, or if fuel pump fuse is found open (blown).
lo
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9927619 R02 - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service l'.'rfanual
4.22 · Polaris Industries Inc.
FUEL DELIVERY/ EFI
FUEL
Prime procedure should be perform~d:
• If a new fuel.pump is installed or if tank is run
completely dry.
• Whenever fuel system is serviced (fuel line is
disconnected).
" Whenever battery disconnected.
I . Fill the fuel tank.
2. Turn Engine Stop switch OFF.
3. Turn the ignition switch to ON.
4. Turn stop switch to RUN.
6. Allow switch to remain in RUN position until pump
stops running (about 2-3 seconds).
6. Turn stop switch OFF.
7. Turn the ignition switch to OFF.
8. WAIT approximately 10 seconds.
9 .. Repeat Steps 4-8 about 4 times to complete the
priming procedure.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc.
4.23
-FUEL DELIVERY/ EFI
EFI SERVICE
FUEL INJECTION SYSTEM - OVERVIEW .OF switch is turned ON to pressurize the system for start-
OPERATION up.
The ~lectronic Fuel Injection (EFI) system functions to The fuel injectors inject fuel when they are grounded
provide the engine with precisely metered fuel under by drivers inside the ECM. The duration of an injector
varying loads and conditions. :pulse (length of time the injector circuit is grounded)
The Engine Control Module or "ECM", is located 1s controlled by the ECM. Pulse duration determines
the amount of fuel delivered to the engine (longer
adj a cent to the battery box. It is programmed to
cycles= more fuel). The ECM selects the correct fuel
~ro:v1de the correct fuel/air mixture and ignition
timmg based on several sensor input signals (engine injector pulse by calculating the airflow from the MAP
load, temp, altitude, manifold pressure etc.). The ECM sensor measurement and referencing a three
also provides grounds or voltage to other EFI related dimensional "map" for the desired .air-to-fuel ratio
(AFR). The ECM calculates an injection time based on
circuits of the electrical and fuel delivery systems.
the measured airflow and desired AFR.
An Electronic Throttle Control (ETC) system takes the
Although TMAP and engine RPM are the most
place of a conventional, cable-operated throttle body.
influential inputs for selecting a map reference point,
The ETC controls throttle blade angle and provides
rate-of-change feedback to the ECM. the ECM also evaluates feedback from minor sensors
in the system, to obtain c;3. more accurate "picture" of
The ETC also serves as a plausibility check for the the fuel needs at any given moment.
Temperature Manifold Absolute Pressure (TMAP)
sensor. The MAP portion of the TMAP sensor is the The fuel control system is closed loop. When the
· primary air flow and load sensing device. engine is at a warm idle and typical cruising engine
speeds and loads, the ECM will operate in "closed
An electric fuel pump, mounted inside the fuel tank loop fuel control" mode. The oxygen sensors in each
supplies fuel pressure to the injectors continuously head pipe provides feedback to the ECM and the
when the engine is running or cranking. A pressure injection time will be adjusted for each cylinder to
regulator incorporated on the pump keeps fuel achieve the target AFR.
pressure steady at approximately 4 Bar (400 kPa / 58
PSI). The fuel pump cycles "ON" for 2-3 seconds when The locations of sensors and other EFI system related
components are outlined in this chapter. See Sensors -
the motorcycle is powered up and the Engine Stop
Powertrain Management, page 4.11.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
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FUEL DELIVERY/ EFI
4900000000s6 490000000056
3700000000000048 37000000 00000048
25 000000 00000036 25000000 000000 36
1300000000000024 13 000000 00000024
1 00000000000012 1 00000000000012
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
. Polaris Industries Inc. 4.25
FUEL DELIVERY/ EFI
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FUEL DELIVERY/ EFI
DIAGNOSTIC TROUBLE
SPN FMI COMPONENT CONDITION MIL CODE
3 Voltage Too High ON Pl228
29 4 Accelerator Position 2 Voltage Too Low ON Pl227
2 Not Plausible ON Pl225
3 Voltage Too High ON P0123
4 Voltage Too Low ON P0122
2 Signal Out of Range (Not Plausible) ON P0121
51 0 Throttle Position Sensor 1 Voltage Above Critical Level ON Pl 123
1 Voltage Below Critic al Level ON Pl 122
10 Abnormal Rate of Change ON P0120
13 Calibration / Adaption Failure ON Pl 120
ON POSOO
0 Vehicle Speed Too High
ON Cl057
1 Vehicle Speed Too Low ON P0502
ON P0503
2 Data Erratic or Intermittent (or Missing)
84 Vehicle Speed Signal ON Cl058
8 Sensor Frequency Outside Normal Range ON P0501
9 Abnormal Update Rate ON Pl60A
ON Cl069
19 Received Vehicle Speed has error
ON Pl06B
3 Voltage Too High ON P0228
91 4 Accelerator Position 1 Voltage Too Low ON P0227
2 Not Plausible ON P0225
3 Voltage Too High ON P0463
4 Voltage Too Low ON P0462
96 16 Fuel Level Signal Above Normal Operating Range ON Pl462
18 Below Normal Operating Range ON Pl463
2 Signal Fault ON P0461
3 Pressure Too High ON Pl527
98 4 Engine Oil Level Sensor Switch Pressure Too Low ON Pl526
17 Oil Level Low OFF P250F
3 Voltage Too High ON P0108
4 Voltage Too Low ON P0107
102 2 Manifold Absolute Pressure Sensor Signal Out of Range ON P0106
10 Abnormal Rate of Change ON P0109
7 Pneumatic Fault ON Pll06
3 Voltage Too High ON POl 13
4 Voltage Too Low ON POl 12
105 Intake Air Temperature Sensor
10 Abnormal Rate of Change ON P0114
2 Signal Out of Range ON POI 11
3 Voltage Too High ON POI 18
4 Voltage Too Low ON P0117
2 Signal Out of Range ON P0116
10 Abnormal Rate of Change ON POl 19
110 Engine Temperature Sensor
16 Temperature Too High OFF P0217
0 Engine Overheat Shutdown OFF Pl217
15 Temperature Above Normal Range OFF Pll 16
17 Temperature Too Low ON P0128
System Power (Battery Potential / Power OFF P0563
168 3 Voltage Too High
Input) ON Cl063
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · Polaris Industries Inc. 4.27
FUEL DELIVERY/ EFI
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
4.28 Polaris Industries Inc.
FUEL DELIVERY/ EFI
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc.
4.29
FUEL DELIVERY/ EFI
9927619 R02 - 2018 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
4.30 Polaris Industries Inc.
FUEL DELIVERY/ EFI
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
· · ·· Polaris Industries Inc. 4.31
FUEL DELIVERY/ EFI
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
4.32 Polaris Industries Inc.
FUEL DELIVERY/ EFI
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
-· . · , Polaris Industries Inc. 4.33
FUEL DELIVERY/ EFI
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
4.34 Polaris Industries Inc.
FUEL DELIVERY/ EFI
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4.36 Polaris Industries Inc.
FUEL DELIVERY/ EFI
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc. 4.37
FUEL DELIVERY/ EFI
Fuel Injector Resistance Specifica.tion; 3. Remove the screw ® securing the CPS sensor to
11.4 n.- 12.6 Q . the engine case and remove sensor.
CPS Replacement
1. Remove regulator / rectifier assembly and bracket.
See Rectifier/ Regulator Replacement, page 10.33.
2. Disconnect the CPS sensor from the vehicle
harness and release flying lead from plastic darts
and cable ties.
9927619 ROZ - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
4.38 Polaris Industries Inc.
FUEL DELIVERY/ EFI
I
INSTALLATION
1. Remove seat assembly. See Seat Removal /
Installation, page 7 .8.
2. Remove fuel tank. See Fuel Tank Removal, page
4.14
3. Remove air box assembly. See Air Box Removal,
page 3.4.
4. Disconnect the electronic throttle body connector.
5. Remove four electronic throttle body fasteners CD.
flf -
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· . _· Polaris Industries Inc.
4.39
FUEL DELIVERY/ EFI
DRIVE CYCLE:
A drive cycle consists of cycling the ignition from OFF to ON, then start the engine and run at idle for a period of
approximately 4 minutes. Finally, turn off the ignition for approximately 2 1/2 minutes.
TROUBLESHOOTING
Once the systems is repaired and functioning normally, connect to Digital Wrench to clear active and historic
codes. Retest to verify the condition is no longer present.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
4.40 Polaris Industries Inc.
FUEL DELIVERY/ EFI
ECM REPLACEMENT
Although the need for ECM replacement is unlikely, a
specific replacement procedure is required to ensure
that all essential data contained within the original
ECU is transferred to the replacement ECU.
Refer to procedure and carefully follow all instructions
provided in Digital Wrench.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc.
4.41
FUEL DELIVERY/ EFI
5. Select the appropriate vehicle and wait for the 2. Proceed to http://polaris. diagsys. com to see if a
status to display 'Connected' in the lower · left newer update is available.
corner of the screen.
6. Once connected, proceed with using Digital
Wrench.
I. Log on to www.polarisdealers.com.
1. Open the Digital Wrench software. Locate the
version ID shown on the lower right side of the 2. Locate the· Service · and Warranty drop-down
Digital Wrench start-up screen. menu.
3. Click on Digital Wrench Updates.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
4.42 Polaris Industries Inc.
FUEL DELIVERY/ EFI
5. Click on Digital Wrench Version Updates. 7. Click on the link shown above, save the file to your
hard disk and then double-click the icon to start
the update process.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
-. -· ' · · ·· · Polaris Industries Inc. 4.43
FUEL DELIVERY/ EFI
f
Quick Start
Current VVork Order
- Open the ASSERT
ASK Form.
Vehicle Selection
Custorne r Information
Product Utilities
r System Configuration
f Srnartlink Setup
l Software Registration
f· Sy·stem Help
t
[" Digital Wrench Home Page
t Digital Wrench Kn owl edge Base
Exit Open the Software ,
Confiqu ration Screen.
Set up data capture and record
functions
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
4.44 · Polaris Industries Inc.
FUEL DELIVERY/ EFI
ENGINE • KNOW THE PROCESS: If you are not familiar with the
(REFLASH) entire reprogramming process, review the HELP
Process Overview section of the diagnostic software before you
attempt reprogramming. Click on the ? on the tool
The reprogramming feature is in the Special Tests
bar or press F 11. The information in the on-line help
menu on the Digital Wrench screen. Start Digital
is the most current and complete information
Wrench and click on the Special Tests menu icon (red
available. This should be your first step until you are
. tool box). A technician should be familiar with the
familiar with the process.
process and with computer operation in general
• COMMUNICATION PROBLEMS: If you have had
before attempting to reprogram an ECM.
problems communicating with a vehicle while
The Digital Wrench Engine Controller performing diagnostic functions, do not attempt
Reprogramming (or "Reflash") feature allows reprogramming until the cause has been identified
reprogramming of the ECM fuel and ignition map. To and fixed. Check all connections, and be sure
successfully reprogram the ECM, an Authorization Key battery voltage is as specified.
must be obtained by entering a Request Code in the
box provided on the Reflash Authorization site. The • Proceed to http://polaris.diagsys.com for specific
Request Code is automatically generated by Digital information and FAQs on how to troubleshoot
Wrench during the reprogramming process. The communication problems.
Reflash Authorization site is located under the Service • DON'T DISTURB THE PC: While reprogramming is in
and Warranty drop down menu on the dealer website progress, don't move the mouse and don't touch the
at: www.polarisdealers.com. keyboard. The process only takes a few minutes,
and is best left alqne until complete.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· - Polaris Industries Inc. 4.46
FUEL DELIVERY/ EFI
9927619 ROZ - 2016 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
4.46 · Polaris Industries Inc.
FUEL DELIVERY/ EFI
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · · ·· · Polaris Industries Inc. 4.47
FUEL DELIVERY/ EFI
12. Select the same file type from the list that you
selected previously while in Digital Wrench. Enter
the VIN along with the customer's name and
address. When completed, click the Authorize
button once to proceed.
13.An "Authorization Key" will appear in the upper
left corner of the screen. Copy (CTRL +C) this key
exactly as it appears.
14. Enter or paste (CTRL + V) the Authorization Key in
the box located on the Digital Wrench screen.
15. Click the "Continue" button.
16.At this point the reflash process will begin. Do not
touch the vehicle or PC during the process.
17. Once the ECU reprogramming procedure is
complete, select the "Finish" button.
18. Select the "Return" button.
19. Login to www. polarisdealers. com and click on
"Certificate of Conformity" from the "Dealer
Management" drop-down menu.
1/.~1.f~·~i~
(,;·ctt:C¢'Z:
:.n,:~(ti:tc*
fJi.{.H:H.
~.1t1:.:1~
t~/i4.:·.:ei,
t1/:;·~}.t¢tt
~i::: !f;c-}~~ it.:,t:n~
i1.n.:·~v,-;5
J:.{7;'}:Jt~
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
4.48 · Polaris Industries Inc.
FUEL DELIVERY/ EFI
Engine turns over with Compression too low See engine section
electric starter, but won't
start No spark at spark See ignition system
plugs
No fuel reaching intake Out of fuel Add Fuel
tract Blown Fuse Replace
Plugged fuel filters I Clean/Replace
lines Test / Replace
Fuel pump not working Test / Replace
Fuel pressure regulator Test / Replace
Faulty fuel pump relay Inspect / Repair
Open wiring / connec:tor Inspect / Repair
Faulty connection at ECM
Excessively rich or Fuel pump Test / Replace
lean fuel mixture Fuel pressure regulator Test / Replace
Crank Position Sensor Test / Replace
Low Battery Test / Replace
TMAP sensor Test / Replace
CHTsensor Test / Replace
Fuel Injector Test / Replace
Spark at wrong time or Timing Wheel or CPS Install correctly, inspect for
no spark. installed incorrectly, proper air gap (gap is preset
Fuel delivery timing damaged, or dirty; faulty but cover, sensor, and timing
incorrect. CPS wheel must be clean and in
good condition).
Poor idle Excessively rich or Air Leaks Inspect IAC system
lean fuel mixture Air restriction in IAC Inspect IAC hoses and
Fuel Pump fittings
Fuel injector/ Fuel Rail Inspect fuel pressure
obstructed or leaking Replace
Air Filter Replace
Wrong Fuel/ Old Fuel Inspect / Replace
Crank Position Sensor Inspect / Replace
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc. 4.49
FUEL DELIVERY/ EFI
9927619 R02 - 2018 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
4.50 ·· Polaris Industries Inc. ·
FUEL DELIVERY/ EFI
FUEL 3
PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
·· Polaris Industries Inc. 4.51
FUEL DELIVERY/ EFI
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
4.52 Polaris Industries Inc.
CLUTCH/ PRlMARY I SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
··· Polaris Industries Inc. 5. 1
CLUTCH/ PRIMARY/ SHIFT
GENERAL INFORMATION
SERVICE INFORMATION • Corroded or sticking shift linkage pivot points can
• Clutch and external transmission shift linkage cause abnormal shifting. Replace any linkage
service can be accomplished with the engine in the components that are damaged or do not move
frame. freely, and lubricate at regular intervals.
• Internal transmission or internal shifting mechanism
service requires engine removal and crankcase
separation. SPECIAL TOOLS
a Oil additives of any kind are not recommended by TOOL DESCRIPTION PART NUMBER
Indian Motorcycle. Using oil additives or oil of the
wrong viscosity can have a detrimental affect on Case Splitting / Assembly Tool PF-51234-A
clutch performance, operation, and service life.
0
Burnt clutch plates are not an indication of defective Engine Lock Tool - Transmission PF-51612
clutch plates. Burnt clutch plates indicate that a Engine Lock Tool - Crankshaft PF-51235-A
problem exists within the clutch system, the clutch
has been used improperly, or plates were Engine Stand Adapter PF-51609
contaminated by improper oil or additives.
• Indian Motorcycle 15W/60 motorcycle oil is Moly Assembly Paste 2871460
recommended for all operating temperatures. If
Indian Motorcycle 15W/60 oil is not available, a high Bosch Automotive Service Solutions: 1- 800- 328-
quality 15W/60 motorcycle oil suitable for use in wet 6657 or https://polaris.service-solutions.com/
clutch transmissions can be used.
• Lubricate parts during assembly as described in the
procedures.
SERVICE SPECIFICATIONS
ITEM SPECIFICATIONS
Clutch Type Wet, Multi-Disk
Clutch Operating Mechanism Manual / Cable Operated
Primary Reduction Ratio 1.674: 1
Transmission Shift Mechanism Manually Operated, Spring
Clutch / Gear Shift / Linkage Centered
Gearshift Pattern l-N-2-3-4-5-6
Clutch Spring (Coil Type, QTY.6) Spring Height - Free: 55.3 mm/
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
5.2 Polaris Industries Inc.
CLUTCH / PRlMARY I SHIFT
,.;i:;::.:;,
ti:.r:::::.:r
/----"
2 4 5 6 ( 7 \ 8
\ ____,../
CD Primary Cover -
© Primary Cover Gasket -
® Primary Gear Cover Fasteners 9 ft-lbs (12 Nm)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
- ' Polaris Industries Inc. 5.3
CLUTCH / PRIMARY/ SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
5.4 ·· Polaris Industries Inc.
CLUTCH/ PRIMARY/ SHIFT
CLUTCH
NUMBER DESCRIPTION
CD Primary Cover
CD External E-Clip
G) Washer
® Shaft Seal
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · · .' · Polaris Industries Inc. 5.5
CLUTCH/ PRIMARY I SHIFT
CLUTCH COMPONENTS
.,---~"
( 13)
"~~ .....,,..·
/!
( 16 )
'·, __,/
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
5.6 Polaris Industries Inc.
CLUTCH/ PRIMARY/ SHIFT
1. Place motorcycle in an upright position with the 1. Clean gasket surfaces of crankcase and cover.
front wheel clamped in a wheel vise.
2. Install a new primary cover gasket CD with flat side
2. Drain oil from engine. See Engine Oil / Filter towards primary cover CD.
Change, page 2.11.
3. Remove the exhaust system. See Head Pipe
Removal, page 3.94.
4. Disconnect clutch cable from engine clutch lever.
See Clutch Cable Removal / Installation, page
8.13Clutch Cable Removal.
5. Remove clutch cover fasteners CD and cover
assembly CD.
5
3. Torque the primary cover fasteners CD to
specification following the torque sequence.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
Polaris Industries Inc. 5.7
CLUTCH / PRIM.ARY I SHIFT
5. Install new clutch cover gasket with flat side facing CLUTCH PINION SHAFT REMOVAL
clutch cover®· 1. Remove the Primary Cover CD. See Primary Drive
Cover Removal, page 5. 7.
2. Remove the E-clip CD and washer from the end of
the clutch pinion shaft as shown.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
5.8 Polaris Industries Inc.
CLUTCH / PRIMARY I SHIFT
4. Drive seal into place with a suitable driver. 4. Gently pry oil seal out of shift shaft bore and
remove external circlip as shown.
CLUTCH PINION SHAFT INSTALLATION
1. Lubricate and install clutch pinion shaft G) until
fully seated in bearings.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
"· · · · Polaris Industries Inc. 5.9
CLUTCH/ PRIMARY/ SHIFT
8. Using a 4 mm hex wrench, remove the screw (D 11. Inspect shift shaft return spring @) for cracks or
securing the shift star CD to the shift drum and loss of tension. The spring should have enough
remove shift star G). Secure locating pin © for tension to keep the shift shaft centered.
reassembly.
10. Pull the shift shaft and spring assembly ® out of 13. Inspect ratchet arm return spring @ for tension.
the bore. The spring should apply enough tension on the
shift ratchet mechanism to keep it engaged with
the shift star.
14. Inspect fit of rivet ® on shift ratchet assembly. It
should ·allow for free movement, but not be
excessively loose.
/
.-,
·'-7 -
,/'
.
~~t) )
'//
0 0
//~'\
i-------1, 13 J
\.~_./
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
5.10 · · Polaris Industries Inc.
CLUTCH/ PRIMARY/ SHIFT
9927619 R02 - 201 S - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc. 5.11
CLUTCH / PRIMARY/ SHIFT
7. Remove locking pin ® to release the detent roller SHIFT SHAFT SEAL REPLACEMENT
arm. 1. Remove shift shaft assembly. See Shift Ratchet
Removal I Inspection, page 5.9.
2.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
5.12 · Polaris Industries Inc.
CLUTCH / PRIMARY/ SHIFT
I CLUTCH
Remove the clutch cover. See Primary Drive Cover 1. Remove primary cover. See Primary Drive Cover
Removal, page 5. 7. Removal, page 5.7.
2. Remove the six pressure plate screws CD and coil 2. Remove bolts CD, springs CD and pressure plate G).
springs CD.
5
3. Remove all friction and separator plates.
4. Prevent input shaft from turning by placing Engine
3. Lift the pressure plate off of the clutch basket Transmission Lock Tool PF-51612 inside clutch and
assembly to access the clutch rack from the back securing handle.
side of the plate.
®T
('4"'\ ( 3 )
\,.-// \,...... -/
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
·· · · ' · Polaris Industries Inc. 5.13
CLUTCH / PRIMARY/ SHIFT
,,... .........
(51
\ ; /
, .. _/
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
5.14 Polaris Industries Inc.
CLUTCH / PRIMARY/ SHIFT
4. Remove the inner hub CD and thrust washer©. 6. Then alternately remove Friction Plates B ® and
Separator Plates C (J).
® Friction Plate A 1
,,--~\
® Friction Plate B 6 .il-----( 9 )
, _._........
.... ~
@) Friction Plate C 1
/~-·---..,
(5
\'-.........,/'
/...--......,
~----{\_~_)
9927619 R02 - 201 S - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
,;,...,~- ··· , .. Polaris Industries Inc. 5.15
CLUTCH / PRIMARY/ SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
5.16 · · Polaris Industries Inc.
CLUTCH / PRIMARY I SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc. 5.17
CLUTCH/ PRlMARY / SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
5.18 · Polaris Industries Inc.
CLUTCH / PRIMARY/ SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
.. Polaris Industries Inc.
5.19
CLUTCH / PRIMARY I SHIFT
9927619 ROZ - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
5.20 : Polaris Industries Inc.
CLUTCH / PRlMARY I SHIFT
STATOR INSTALLATION
1. Assemble new gasket G) on stator cover Q) with the 5
gasket flat surface facing the engine.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
· Polaris Industries Inc.
5.21
CLUTCH/ PRIMARY/ SHIFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
5.22 Polaris Industries Inc.
CLUTCH/ PRIMARY I SHIFT
Flywheel Fastener:
5
STEP 1: Tighten fastener to 133 ft-lbs (180 Nm)
STEP 2: Back out fastener 180° and :re-torque to
spec.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
Polaris Industries Inc.
5.23
CLUTCH/ PRIMARY/ SHIFT
Dragging clutch (doesn't Oil level too high Oil level Correct oil level
disengage completely,
Oil viscosity too high Oil quality Replace oil & filter
creeping)
Pressure plate worn, Pressure plate Replace
warped or distorted
Clutch plate(s) worn, Driven plates and / or Replace
warped or distorted drive plates
Weak clutch springs Clutch springs Replace
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
5.24 · Polaris Industries Inc.
CLUTCH / PRIMARY / SHIFT
Worn gear shift pawl ratchet Shift pawl mechanism Replace parts that fail
mechanism inspection
Broken or dislodged shift shaft Shift shaft return spring Repair or replace
return spring
Roller detent arm stuck Roller detent arm Repair or replace parts
Sticking pivot point, bent external External shift linkage Repair or replace
shift linkage
Transmission Jumps Out of Broken I loose stop pin Shift stop pin Replace
Gear
Worn shift drum or shift drum Shift drum or shift linkage Replace
ratchet
Broken shift return spring Shift return spring Replace
Transmission Noise Drive belt tension incorrect Drive belt Adjust or replace
Clutch plates bind or drag when Clutch plates / hubs Adjust / repair / replace
clutch is disengaged
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual 5.25
·· · . : Polaris Industries Inc.
CLUTCH/ PRIMARY/ SHIFT
NOTES
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
5.26 Polaris Industries Inc.
TRANSMISSION / CRANKSHAFT
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · ·· · Polaris Industries Inc. 6.1
TRANSMISSION/ CRANKSHAFT
9927619 R02 - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
6.2 · ·· Polaris Industries Inc.
TRANSMISSION / CRANKSHAFT
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Case Splitting / Assembly PF-51234-A
Tool
Clutch Holding Tool PF-51612
Crankshaft Locking Pin PF-52135-A
Drive Sprocket Seal Installer PF-51243
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
,- Polaris Industries Inc. 6.3
TRANSMISSION/ CRANKSHAFT
SERVICE SPECIFICATIONS
Connecting Rod / Crankshaft Specifications
ITEM PART SPECIFIC STANDARD SERVICE LIMIT
Connecting Rod Connecting Rod to .22 - .42 mm .66 mm (.026")
Crankshaft Side Clearance (.0087 - .0166")
Connecting Rod Bearing to .0264 - .0635 mm .11 mm (.0043")
Crankshaft Oil Clearance (.00 I - .0025")
Connecting Rod Small End 22.01 - 22.02 mm 22.09 mm (.8694")
I.D. (.8665 - .8670")
.. '
Right Main Bearing Journal 64.9523 - 64.9703 mm 64.9273 mm (2.5 561 ")
0.D. (2.5571 - 2.5578")
.05- .30 mm
Crankshaft End Play
(.0019 - .0118") ·-
Balance Shaft Journal 0.D., Left (Primary 24.980 - 24.992 mm/
Side)/ Journal 0.D., Right 24.969 - 24.979 mm -
(Cam Side)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
6.4 Polaris Industries Inc.
TRANSMISSION/ CRANKSHAFT
Transmission Specifications
ITEM PART SPECIFIC STANDARD SERVICE LIMIT
Shift Fork 12.00 - 12.026 mm 12.05 mm (.47 44")
Shift Fork I.D. (Rail)
(.4725 - .4732")
6.036 - 6.136 mm 6.02 mm (.2370")
Shift Fork Pin O.D. (.2376 - .2416")
ITEM SPECIFICATIONS
Drive Train (General) Transmission 6 Speed / Sliding Mesh
Primary Reduction Ratio 1.674: 1
Final Reduction Ratio 2.357: 1
Drive Train (Gear Ratios) Gear Ratio: 1st Gear 2.769: 1
Gear Ratio: 2nd Gear 1.882: 1
Gear Ratio: 3rd Gear 1.500: 1 6
Gear Ratio: 4th Gear 1.273: 1
Gear Ratio: 5th Gear 1.125: 1
Gear Ratio: 6th Gear (Overdrive) 1.036: 1
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · . Polaris Industries Inc.
6.5
TRANSMISSION/ CRANKSHAFT
LOCKING THE CRANKSHAFT FOR SERVICE 5. Lock the crankshaft by inserting the Crankshaft
This procedure describes how to lock the crankshaft in Locking tool (PF-51235-A) or equivalent into the
the Top Dead Center (TDC) position for the front or desired locking hole.
rear pistons using the Crankshaft Locking Tool: PF-
51235-A or equivalent (5/16" punch).
1. Remove the spark plugs. See Spark Plug Removal,
page 2.29.
2. Remove the clutch and primary drive covers. See
Primary Drive Cover Removal, page 5.7.
3. Using a 32mm wrench or socket, rotate the
crankshaft clockwise (primary side) until the front
piston is at TDC. See the Camshaft Timing Marks,
page 3.47 illustration for details.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
6.6 · Polaris Industries Inc.
TRANSMISSION/ CRANKSHAFT
;.•'
® Bearing Retainer Fastener 88 in-lbs (10 Nm) @ Ball Shift Drum Bearing -
Ball Transmission Output Shaft Ball Balance Shaft Right
® Bearing
- @ Bearing -
@) Needle Shift Drum Bearing - @ Bearing Retainer Fastener 88 in-lbs (10 Nm)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
' -· ' · Polaris Industries Inc. · 6.7
- TRANSMISSION/ CRANKSHAFT
Left crankcase bolts CD, G) and ® in tightening sequence are M8 x 1.25 x 40 all other bolts are M8 x 1.25 x 75.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
6.8 , Polaris Industries Inc.
TRANSMISSION/ CRANKSHAFT
,-, ···.,.
('-) i'
I •
..\
C) 6
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
· ·· ·· · Polaris Industries Inc. 6.9
-TR.A:NSMISSION / CRANKSHAFT
CRANKSHAFT COMPONENTS
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
6.10 ' Polaris Industries Inc.
TRANSMISSION / CRANKSHAFT
6
Input Shaft
r;'\)
\J· \
/-· -,
( 11 ')
(~) \,_.,/
NUMBER DESCRIPTION
G) Input Shaft Plug
© Flat Washer
® Retaining Ring
(J) Washer
® Plain Bushing
@) Washer
® Retaining Ring
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc.
6.11
- TRANSMISSION/ CRANKSHAFT
Output Shaft
......... -,
.....
( 20)
'·---~ /
11 \
9927619 R02 - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
6.12 Polaris Industries Inc.
TRANSMISSION/ CRANKSHAFT
s
Input Shaft
Ii
\ 1.. / J
"-.
6
NUMBER DESCRIPTION
G) Input Shaft Plug
© Flat Washer
(J) Washer
® Plain Bushing
@ Washer
® Retaining Ring
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
·· .- · ·. Polaris Industries Inc. 6.13
TRANSMISSION/ CRANKSHAFT
Output Shaft
( 13) ( 15 )
\ _,/ '-., ,/
~
.~\\,
.~t1/~'i t 14.'1
/'\,~,)
(\ / 1~L'"\)
"'~.-r/
NUMBER DESCRIPTION
CD 0-ring
Q) Flat Washer
© Flat Washer
® Retaining Ring
® Splined Bushing
® Retaining Ring
® Plain Bushing
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6.14 Polaris Industries Inc.
TRANSMISSION / CRANKSHAFT
SHIFT
NUMBER DESCRIPTION
G) Bearing, Shift Drum - Drive Sprocket Side
G) Shift Rail
© Shift Rail
® Shift Drum
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Polaris Industries Inc. 6.15
-TRANSMISSION/ CRANKSHAFT
BALANCE SHAFT
Balance shaft service requires engine remov~ and crankcase separation.
CD Washer -
Q) Balance Shaft Bearings -
© Bearing Retainer Plate Washer -
® Bearing Retainer Plate Screws (QTY.3) -
® Balance shaft Snap-Ring (Inner) - Non-Serviceable -
(J) Balance Shaft Gear (Inner) - Non-Servicable -
® Pre-Load Springs -Non-Serviceable -
® Balance Shaft Gear (Outer) - Non-Serviceable -
@) Balance Shaft -
® Balance Shaft Retaining Key -
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TRANSMISSION / CRANKSHAFT
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TRANSMISSION / CRANKSHAFT
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TRANSMISSION / CRANKSHAFT
4. Fit the crankshaft assembly into the. engine case 5. Install the balance shaft washer © and bolt ®·
and align the timing marks G) c;m the crank and Torque to specification.
balance shaft gears as shown.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
· · Polaris Industries Inc. 6.19
- TRANSMISSION/ CRANKSHAFT
~~~a
/---~~~3,~,) -{D
trnc: [IQ D D D JD JJ JJJ~ ,.,·-,
~<~:_·;;.,;:.::.:.:.::.:~··· ... ·;;::::::;;i0;:,J--(_~)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
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TRANSMISSION I CRANKSHAFT
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Polaris Industries Inc. 6.21
- TRANSMISSION/ CRANKSfIAFT
CRANKSHAFT SERVICE
CRANKCASE SEPARATION 20. Remove three (Qty 3) M8xl.26x40 engine case
1. Drain engine oil. See Engine Oil / Filter Change, bolts G).
page 2.11.
2. Drain cooling system. See Coolant Drain / Fill,
page 3.33.
3. Remove engine from frame. SeePreparation For
Engine Removal, page 3.9.
4. Mount engine securely on an engine stand using
Engine Stand Adapter tool PF-51609.
6. Remove the cam chains/chain guides. See Cam
Chain Removal, page 3.63.
6. Remove cylinder heads. See Cylinder Head
Removal, page 3.64.
7. Remove cylinders. See Cylinder Removal, page
3.82.
8. Remove primary cover. See Primary Drive Cover 21. Remove nine (Qty 9) M8xl.26x76 engine case
Removal, page 6.7. bolts CD.
9. Remove clutch assembly. See Clutch Removal, 22. Remove one (Qty 1) M8xl.26x60 engine case bolt
page 6.13. Q) from primary drive side of engine case.
10. Remove flywheel. See Flywheel Removal, page 23. Place the Engine Case Splitting / Assembly tool
6.22. PF-51234-A on a flat surface and assemble the M6
· 11. Remove stator cover. See Stator Cover Removal, threaded spacers© and Ml2 threaded spacers®
page 6.21. into the main plate ® as shown. Use only holes
marked with the letter B.
12. Remove the starter drive. See Starter Drive
Removal, page 6.20.
13. Remove the balance shaft driven gear and drive
gear. See Balance Shaft Removal, page 6.18.
14, Remove the drive sprocket. See Drive Sprocket
Removal, page 8.39.
16. Remove the oil filter. See Engine Oil & Filter
Change, page 2.1 lEngine Oil & Filter Change,
page 2.11.
16. Remove the oil cooler adapter assembly.
17. Remove the shifter shaft assembly. See Shift Shaft
Removal.
Severe damage to the engine cases and shift shaft 24. Rotate the engine stand so the engine is lying flat
assembly may occur if attempting to separate cases with the output shaft pointing UP.
with shift shaft installed.
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TRANSMISSION / CRANKSHAFT
25. Position the main plate assembly ® onto the 28. Install MS bolts ® and Ml2 bolt ® into threaded
engine case as shown. Note: The threaded spacers spacers and torque to specification.
should line up with the corresponding engine case
bolt holes.
26. Install the case splitting adapter (j) through the Main Plate Mounting Fasteners (All):
· center hole in the main plate and thread into nut 88 in-lbs (10 Nm)
and washer until 1-2 threads are exposed on the
other side.
29. Holding nut @) stationary with an open ended 6
wrench, turn the case splitting adapter (j)
clockwise until the engine cases begin to part.
STOP.
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-TRANSMISSION/ CRANKSHAFT
31. Alternately turn the case splitting tool in until 4. Lift the shift drum CD out of the bearing.
resistance is felt, then work around the t:J.pper case
with a mallet until the cases are completely apart.
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TRANSMISSION/ CRANKSHAFT
Input Shaft
(5···-.. \
' )
0) 6
® Shim - 25 x 34 x 2 -
(j) Gear, 3rd & 4th - Input -
® Retaining Ring, External -
® Washer, Flat - 28 x 35 -
@) Gear, 5th - Input -
® Bushing 28.016 -28.035 mm
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· · .. ... ,.-. Polaris Industries Inc. 6.25
TRANSMISSION/ CRANKSHAFT
Output Shaft
.,··~\
(~;',; /~·""\ /-~) ,...F-·.......,,. /.,,--.., \
(s'\ /,···-\ //.,.-,.,
,,,...........
./ r\,...12,./X''-10, /) '' ) ( 2 ·,)
( 17) ('\,,...
6 ,,,,J ( 4 ..)
'-, / ,....__ / (7)("13
...._-~/ /
\,
................ ,...._~/
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TRANSMISSION/ CRANKSHAFT
Shift Drum
Refer to the Assembly View section in this chapter 10. Inspect shift drum grooves for wear. Pay close
for component locations and exploded diagrams. attention to corners of grooves where forks change
See Transmission 6 Speed , page 6 .11. direction.
Refer to the Service Specifications section in this 11. Inspect surface of shift drum star for excessive
chapter for complete transmission specifications. wear or damage.
See Service Specifications, page 6.4. 12. Inspect right side shift drum bearing.
13. Temporarily install shift drum in right hand case
Shafts bearing and inspect fit. Spin drum to check for
1. Measure outside diameter of shafts and bearing smooth bearing operation.
areas for wear and concentricity. Look closely at
splines for wear. Inspect ends of shafts for signs of
wear: 1. Separate RH crankcase from LH case. See
• Dull finish Crankcase Separation, page 6.22.
• Discoloration
• Rough or uneven surface 2. Lift crankshaft assembly CD straight up until clear
" Measurement outside of specification of right side engine case.
Gears
2. Visually inspect:
" Gear internal splines
• Gear teeth
" Gear dogs for rounding, cracks, chips
• Gear dog slots for rounding
• Bearing surfaces
" Shift fork grooves
Check each gear for damage, cracks, wear
(rounding of dogs or surfaces), or discoloration.
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- TRANSMISSION/ CRANKSHAFT
CONNECTING ROD SIDE CLEARANCE 2. Mark the outside of both connecting rods prior to
INSPECTION removal so they can be assembled in the same
1. Move connecting rods to one side of crankshaft. direction in relation to the crankshaft.
Insert a feeler gauge G) between one connecting
rod and the crankshaft. Compare measurement to
specification outlined in this chapter. See Service
Specifications, page 6.4.
Mark outside I
·of both rods I
2. If clearance recorded exceeds service limit, the It may be necessary to lightly tap the caps with a
crankshaft, connecting rod or both must be plastic mallet to loosen them.
inspected and worn parts replaced. See
Crankshaft Inspection, page 6.34.
CONNECTING ROD REMOVAL/ IDENTIFICATION The mating surface of connecting rod and cap is
rough in appearance, which is a normal condition
due to the manufacturing process. If rod caps are
installed incorrectly and tightened, the precision
The connecting rod caps are marked with paint from mating surfaces will be damaged. Replace the
the factory, however it is recommended that an connecting rod assembly if mating surfaces are
additional reference mark be added for clarity. Caps damaged.
are matched to rods and MUST be installed with
the proper orientation left to right and front to
back. DO NOT strike or stamp the connecting rod,
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TRANSMISSION I CRANKSHAf'T
EXAMPLE:
• 1st Torque: Manufacturer installation of connecting
rod bolts.
• 2nd Torque: Torque for inspection per this
procedure.
• 3rd Torque: Reinstallation following inspection.
Discard bolts the next time they a:re :removed.
1. Refer to Piston Pin/ Pin Bore Inspection, page 3.86
for connecting rod small end inspection.
Be sure to match connecting rod caps with their Connecting Rod Fasteners:
respective rod and orient the cap properly before STEP 1: Tighten both fasteners to 22 ft-lbs (30 Nm)
installing the cap. Secure the big end of rods in a vise STEP 2: Tighten both fasteners an additional 90° 6
equipped with soft, protective jaws before torquing
rod bolts. 4. Measure I. b. of connecting rod big end for size
and out of round and compare to specification. See
Service Specifications, page 6.4.
2. Remove bearings and install caps on connecting 5. Visually inspect connecting rod upper and lower
rods. Be sure mating surfaces CD of rod and cap are ends for scoring, damage, or excessive wear.
clean.
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TRANSMISSION/ CRANKSHAFT
1. Two different dimension crankshafts were used. Identify the crankshaft by part number and use the
corresponding chart for bearing selection.
·Date Code
PartNwnber
Engineering Data.
2. There are 3 sizes of connecting rod bearings available: Black, Orange and Blue (see chart below).
3. To determine which bearing to use, look at the color code on the left crankshaft .counterweight "R" for Red or
"W" for White. The letter will be etched onto the outer surface of the counterweight.
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- TRANSMISSION/ CRANKSHAFT
4. The color code on the connecting rod is laser etched onto the big end side of the connecting rod. There will
be an "R" for Red or "W" for White.
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- TRANSMISSION/ CRANKSHAFT
CRANKSHAFT INSPECTION
Record all measurements and compare to 4. Crankshaft and connecting rods are identified by
specifications. Replace crankshaft if any measurement color. Be sure to compare measurements to
·is worn beyond the service limit. See Service specifications for the proper color (or non-marked)
Specifications, page 6.4. connecting rod or crankshaft.
1. Measure the width of the rod bearing journal. Measure 0. D. of crankshaft rod journal in four
places and compare to specifications.
r----·-
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TRANSMISSION / CRANKSHAFT
1. Make sure proper bearing clearance is achieved 1. Pass cleaning solvent through the oil passages to
by using the correct colored bearing insert for a ensure that passages are clear.
given color combination of connecting rod and
crankshaft.
2. Clean all oil off connecting rod, connecting rod
cap and bearing inserts.
3. Install bearing inserts into connecting rods and
caps. First, install bearing tab into groove, then
press the rest of the bearing into place.
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TRANSMISSION/ CRANKSHAFT
RIGHT
Prepare RIGHT crankcase for asse~bly:
Refer to crankcase assembly view for locations and
torque specification. See Crankcase Components,
page 6.7.
1. Insert a punch or other suitable object into the
1. Clean crankcase oil passages G) thoroughly. Rinse opening G) to align the balan~e shaft split gear
and dry with compressed air. teeth.
2. Install new bearings in crankcase as required. 2. Rotate the balance shaft so the timing marks CD are 6
• Apply a film of lithium grease to outer race of facing the main bearing bore.
bearings to prevent galling upon installation.
• Press on outer race of bearings using an arbor press
and a suitable arbor that is slightly smaller than
bearing outside diameter.
• DO NOT press on inner race of ball bearings.
3. Install bearing retainers as required and torque to
specification.
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"I
TRANSMISSION / CRANKSHAFT
CRANKCASE SPL1TLJNB
SEALANT PATH
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TRANSMISSION/ CRANKSHAFT
7. Lower the LH case onto the RH case and install 12. Install the o-ring and drive sprocket spacer
mainshaft / crankcase installer PV-45030 ® and removed in STEP 4 with tapered edge toward the
engine case assembly cup PF-51663 © onto the a-ring.
transmission output shaft.
13. Install the gear position switch. See Sensors -
Powertrain Management, page 4.11.
14. Install the drive sprocket. See Drive Sprocket
Installation, page 8.42.
15. Install the balance shaft driven gear and drive
gear. See Balance Shaft Installation, page 6.18.
16. Install the scavenge oil pump. S.~eScavenge Oil
Pump Installation, page 3.27
17. Install the pressure lubrication oil pump.
SeePressure Oil Pump Installation , page 3.28
18. Install the starter drive. See Starter Drive
Installation, page 6 .21.
19. Install the cam chains. See Cam Chain Installation,
page 3.53.
8. Pull crankcase together by tightening nut ® and 20. Install the flywheel. See Flywheel Installation,
holding tool ® tapping on crankcase with a soft page 5.23.
mallet.
21. Install the clutch assembly. See Clutch Installation,
page 5.19.
22. Install cylinders. See Cylinder Installation, page
3.88.
23. Install cylinder heads. See Cylinder Head
Installation, page 3. 72.
24. Install the primary cover. See Primary Drive Cover
Installation, page 5.7.
25. Install the stator cover. SeeStator Cover
Installation, page 5.21
26. Install engine in frame. See Engine Installation,
page 3.12 ..
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TRANSMISSION/ CRANKSHAFT
TROUBLESHOOTING
TROUBLESHOOTING TRANISMISSUlNI / CRANKSHAFT
PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR
RECOMMENDED
Transmission Will Not Broken Shift Cam Shift Cam Replace shift cam
Shift
Bent Shift Forks Shift Fork Replace shift fork(s)
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TRANSMISSION / CRANKSHAFT
Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails
Fork Rails
Transmission Jumps Out Broken Shift Stop Pin Shift Stop Pin Replace stop pin
6
of Gear
Worn Shift Drum Pawls or Shift Drum or Shift Replace damaged shift
Shifter Ratchet Linkage drum or shifter ratchet
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NOTES
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6.44 Polaris Industries Inc.
FRAME/BODY
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·- · · · · Polaris Industries Inc.
FRAME/BODY
GENERAL INFORMATION
SERVICE NOTES
This section covers the removal and installation of
frame and body components, assemblies and systems.
Pay close attention to assembly procedures and torque
specifications.
Cables, hoses and tie straps that have been removed
during disassembly must be replaced per factory
standards during assembly. Caution should be used
when tightening body panels. Any deformation on the
panel around the fastener is an indication that the
fastener is too tight. Do not over tighten body
components in order to avoid damage.
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
PV-49955 Body Panel Tool Kit
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FRAME/BODY
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"· ,- · ·. " ' Polaris Industries Inc.
FRAME/BODY
FRAME COMPONENTS
-
® Air Box Frame Foam - -
@) Swingarm Pivot Bolt - -
® Subframe to Mid.frame Fastener (rear) 35 ft-lbs (47 Nm) 4th
Backbone Bracket to Front Frame 13th (Right)
@ 19 ft-lbs (26 Nm)
Fastener 14th (Left)
1st (Lower)
® Mid Frame to Engine Fasteners 51 ft-lbs (69 Nm)
2nd (Upper)
Frame Backbone to Front Frame
® Fastener
35 ft-lbs (47 Nm) -
5th (Left)
® Frame to Engine Fastener (front) 51 ft,-lbs (69 Nm)
6th (Right)
7th (Left Front)
8th (Left Rear)
@ Mid Cast Frame to Backbone Fastener 35 ft-lbs (47 Nm)
9th (Right Front)
10th (Right Rear)
11th (Right Front)
® Backbone to Front Frame Nut - 12th (Right Rear)
® Nut (QTY.3) - -
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FRAME/BODY
FOOT
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- FRAME I BODY
·/ - (s;
,_ '----~tr
3; INSTALLATION is performed by reversing the
rexnovalprocedure. 3. Remove two bolts © securing foot peg bracket to
frame.
4. Torque driver foot peg bracket bolts to
specification.
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FRAME/BODY
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FRAME/BODY
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7.8 · Polaris Industries Inc.
FRAME/BODY
NT
Motorcycle should be parked on a l~vel surface rest- Motorcycle should be parked on a level surface rest-
ing on the side stand. ing on the side stand.
CAUTION CAUTION
Use care not to scratch or damage painted surfaces Use care not to scratch or damage painted surfaces
during fender removal and/ or installation. during fender removal and / or installation.
1. Remove two fender mount bolts from each fork 1. Gently squeeze the sides of the front fender and
slider leg. "roll" the fender into position between the fork
legs so the bolt holes line up.
3. Turn the handlebar all the way to the left and right
to verify proper operation and freedom of
movement. ·
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FRAME/BODY
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FRAME/BODY
I N I
1. Remove four handle bar screws securing the 1. Remove ignition side cover fasteners G).
instrument panel to the handle bars .
....... ···.
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·· ~ ·:, · Polaris Industries Inc. 7 .11
FRAME/BODY
FRAME REMOVAL/ INSTALLATION 13. Remove the rear subframe fasteners G) and
subframe assembly.
REMOVAL
1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Remove the seat assembly. See Seat Removal /
Installation, page 7 .8.
3. Disconnect the negative cable from the battery.
4. Remove the fuel tank. See Fuel Tank Removal, page
4.14.
14. Remove the RH and LH mid cast frame fasteners CD.
5. Remove the battery box. See Battery Box Remov;il,
page 10.13.
6. Remove the driver foot controls. SeeDriver Foot
Peg Removal/ Installation, page 7.6.
7. Remove passenger foot pegs (if equipped.). See
Foot Pegs Passenger Removal / Installation, page
7.7.
8. Remove the head pipe assembly. See Head Pipe
Removal, page 3.94.
9. Support the engine with a platform jack.
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FRAME/BODY
18. Remove the lower fasteners ® holding the front 2. Assemble RH mid frame ®, LH midframe (J),
frame to the vehicle and remove front frame. spacers ® on the engine with mounting bolts ® to
hand tightness.
INSTALLATION
Frame fasteners must be torqued in sequence. See 3. Assemble the rear subframe @) to the midcast
Torque Specifications, page frames.
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- FRAME I BODY
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FRAME/BODY
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FRAME/BODY
NOTES
-----·--- ,--------~------·-----------..---
·------·-··-----~---~---------- -
--·-·--·--·------------~-------
----------=-------,----
---~-------------~-----,
--------
________________ _____________________
, ,.
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STEERING / SUSPENSION
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- STEERING / SUSPENSION
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STEERING / SUSPENSION
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
SERVICE NOTES Fork Spring Compressor PV-49463
Fork Spring Compressor
Adapter / Cartridge Tool PF-51664-2
Indian Motorcycles are produced using the
designated tires listed as original equipment. This
includes field testing to ensure stability and superior Fork Oil Seal Driver PF-51610
handling. The use of tires other than original Fork Seal Installation
equipment may cause instability which could lead to PF-51611
Tool
a crash, resulting in serious injury or death. Use only
the recommended tires inflated to the recommended Wheel / Stem Bearing
PF-51324
tire pressures based on load conditions as listed on Removal I Installation Kit
the tire information label. Tubeless tires are used on Spanner Socket
certain Indian Motorcycle models. Operating the (Steering Stem) PV-43508
motorcycle with damaged rims creates a safety
hazard including air pressure loss, steering
imbalance and/ or reduced steering control. Do not
attempt to repair or straighten damaged rims.
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8.3
- STEERING / SUSPENSION
SERVICE SPECIFICATIONS
ITEM STANDARD SERVICE
Axle Runout - .20 mm (.008 in.)
Front Wheel Runout Axial .50 mm (.020 in.) 2.0 mm (.080 in.)
(Cast and Spoked Type)
3.5" X 16" Radial .50 mm (.020 in.) 2.0 mm (.080 in.)
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STEERING / SUSPENSION
CONTROLS
,.....----"'
------------
;;::-..----i 2 )
\.._j
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STEERING I SUSPENSION
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8.6 - Polaris Industries Inc.
STEERING / SUSPENSION
HANDLEBAR COMPONENTS
CD Ball Bearing -
29 ft-lbs (40 Nm)
CD Steering Head Nut See Tightening Procedure Outlined in this
Chapter 8
18 ft-lbs (24 Nm)
® Fork Triple Clamp Fasteners (Upper) See Tightening Procedure Outlined in this
Chapter
@ Washer -
72 ft-lbs (97 Nm)
® Steering Stem Nut (top) See Tightening Procedure Outlined in this
Chapter
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Polaris Industries Inc.
STEERING / SUSPENSION
CD Washer -
18 ft-lbs (24 Nm)
Q) Fork Triple Clamp Fasteners (Upper) See Tightening Procedure Outlined in this
Chapter
® Ball Bearing -
(J) Lower Bracket ASM -
® Sealed Bearing -
® Steering Lock -
@) Steering Lock Fastener 77 in-lbs (9 Nm)
18 ft-lbs (24 Nm)
® Fork Triple Clamp Fasteners (Lower) See Tightening Procedure Outlined in this
Chapter
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STEERING / SUSPENSION
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·· "', . Polaris Industries Inc.
- STEERING / SUSPENSION
® Spacer -
® Washer -
@) Spring -
® Cylinder Assembly -
@ Oil Lock -
® Inner Fork Tube -
@ Bushing -
® Packing -
® Fork Cartridge Fastener 17 ft-lbs (23 Nm)
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STEERING / SUSPENSION
-.,_
( 2 \
~--
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STEERING / SUSPENSION
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STEERING / SUSPENSION
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STEERING I SUSPENSION
Removal
2. Remove the front fender. See Front Fender
Removal, page 7.9.
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STEERING I SUSPENSION
3. Loosen axle pinch bolts G) on lower right fork leg. FRONT AXLE INSPECTION
1. Place axle in V-blocks and inspect runout.
\
Compare to specifications in this chapter. See
Service Specifications, page 8.4.
6. Installation is performed by reversing the 2. Check bearings by turning inner race by hand.
removal procedure. Use new brake disc • Look for signs of discoloration, scoring, galling, or
fasteners for installation contamination from moisture or dirt. Replace
bearings if any of the above are present.
6. Torque new brake disc fasteners to specification in
• Turn the inner race of the bearings. The bearings
a star pattern.
should turn smoothly and quietly. The inner race
should be firm with minimal side to side movement
and no detectable up and down movement.
3. Discard bearings that fail any of the above
inspections.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
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STEERING / SUSPENSION
j I .· }'~·'·l.'·.
beneath the engine cases.
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8
4. Refer to special tool manufacturer instructions to '
5. Remove bearing.
6. Remove spacer.
7. Extract or drive bearing from RH side of hub.
8. Installation: Use the Wheel Bearing Removal /
Installation Kit PF-51324) to install new wheel
bearings. Refer to special tool manufacturer
instructions for proper use of tool.
9. Install new wheel bearing into the RH side of hub
followed by the inner bearing spacer. Do not operate the front brake lever with the calipers
or wheel removed.
10. Install new wheel bearing into the LH side of hub.
11. Install new seals and existing outer bearing 3. Remove front brake calipers and support them so
spacers into each side of the wheel hub. they do not hang by brake hoses. See Front
Caliper Service (2015-16), page 9.31.
12. Install the brake discs. See Brake Disc Removal/
Installation, page 8.16.
13. Install the front wheel. See Front Wheel Removal/
Installation, page 8.14.
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4. Remove front wheel. See Front Wheel Removal I 8. Slide fork leg down and remove.
Installation, page 8.14.
5. Remove turn signal assembly by removing bolt CD
and nut CD.
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FRONT FORK DISASSEMBLY 2. Place fork in soft jawed vise and loosen fork cap
approximately 1 turn. Do not remove the cap.
Remove fork from vise.
The following procedure requires the use of Fork
Spring Compressor (PV-49463) and Fork Spring
Compressor Adapter/Cartridge Tool (PF-51664-2).
8
I
I
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/
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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4. Place fork tube in spring compressor tool with 8. Remove Spacer ® and Washer ® from top of
hole in bottom of fork slider over peg on bottom of spring.
tool.
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12. Prevent Fork Cartridge Tool (PF-51664-2) from 15. Remove seal retaining ring. Use care not to scratch
turning and remove cylinder screw ® from bottom the surface of the inner fork tube.
of fork. Using a pick tool, remove· crush washer®·
16. Push inner and outer tube together, then pull apart
quickly to produce a slide hammer motion to
13. Tip fork upside down and slide Cylinder remove the inner tube.
Assembly @) out of fork tube along with Oil Lock
17. Remove Oil Seal.
®·
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,...........
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9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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I,
5. Visually inspect the damper rod piston ring @. FRONT FORK ASSEMBLY
Replace component if scoring, deep scratches
and/or excessive wear is noted. ·
6. Place fork tube in V-blocks and measure runout.
Replace the tube if runout exceeds service limit
listed at Service Specifications, page 8.4. 1. Lubricate and install new bushing ® into fork
slider.
,/ .,.,
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3. Apply a light film of fork oil to outside edge and 7. Use the Fork Seal Tool (PF-51610) ® to install oil
inside seal lips of new oil seal. seal until seated. Be sure top edge of seal is past
(below) retaining ring groove.
Cylinder Installation
10. Be sure screw threads in bottom of Cylinder
Assembly are clean and not damaged.
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11. Place Cylinder Assembly@) along with Oil Lock® 14. Torque cylinder screw to specification.
into fork slider. Carefully align ~ottom of Oil Lock
with recess in bottom of fork.
Fork Cartridge Fastener:
17 ft-lbs (23 Nm)
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21. Place Washer ® and Spacer ® on top ·of spring. 25. After cap thread is started, continue to turn tube
Place Fork Cap on Spacer. and adjust spring compressor pressure as
required until cap is fully seated against top of
outer tube.
26. Tighten fork cap to outer tube. Torque to
specification.
(4'',)----
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.
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3. Torque the bottom bolt on the lower triple clamp 12. Inspect all bolts for proper torque. Inspect hoses
G). and wiring for proper routing.
4. Torque the top bolt on the lower triple clamp CD. 13. Lower front end of motorcycle to the ground and
test front suspension / fork operation.
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3. Remove front wheel. See Front Wheel Removal / 11. Remove stem adjuster nut CD with a suitable
Installation, page 8.14. spanner socket.
4. Remove Speedometer assembly. /'-·~,,
7.
Handlebar Removal/ Installation, page 8.12.
Remove fork tubes. See Front Fork Removal, page
J<'',~d/6 \\ )\
8.17.
8. Remove brake line guides from upper and lower
triple clamp.
>rw'1l~
;; ~·'~_·'
'\
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TRIPLE CLAMP INSTALLATION/ STEERING HEAD 4. Screw adjuster nut G) (shoulder side down) onto
BEARING ADJUSTMENT the steering stem until it is finger tight.
1. Inspect both top and bottom bearing races for
pitting, dents, or worn surface. Replace bearings
and races as a set if they are worn or damaged.
2. Be sure lower stem bearing CD is seated against
step on lower triple clamp. Apply all purpose
grease to bearing and install lower triple clamp /
stem to frame.
•. (1''1
'
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6.
Turn triple clamp assembly fully to the right.
Torque steering head nut to specification using
suitable spanner wrench .
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• :
2
Polaris Industries Inc.
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TROUBLESHOOTING I
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED
Heavy Steering Steering Stem Nut Over Tightened Torque to specification
Damaged Steering Stem Bearings Replace
or Races
Bent Steering Stem Replace
Front Tire Damaged or Worn Replace
Low Tire Pressure Inflate to specification
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SERVICE NOTES
8
SPECIAL TOOLS
SPECIAL TOOL PARTNUMBER
Swing-arm Bushing Tool PF-51237
Shock Spanner Wrench PV-46993
Bearing Removal / PU-51324
Installation Kit
Platform Jack Commercially Available
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SERVICE SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Axle Runout - .20 mm (.008")
RearVVheelRunout Axial / Radial .80 mm (.030 inch) 2.0 mm (.080")
Rear VVheel Size / Type All Models 16" x 3.5" Cast -
Rear VVheel Travel All Models 3.0" (76.2 mm) -
Shock Spring Free
Length All Models 8.0" (203.2 mm) -
Shock Spring Installed All Models
Length (Standard)
Perform Ride Height Adjustment -
Refer to Maintenance Chapter for
Suspension Ride Height All Models Ride Height Measurement -
procedure
Spring Rate All Models 400 lbs/ in -
Swing Arm Pivot Shaft Runout Not Applicable .20 mm (.008")
LH Ball Bearing Journal: 19.965-
Swing Arm Pivot Shaft O.D. 19.99 mm/ RH Needle Bearing -
Journal: 24.95-25.00 mm
Swing Arm Needle Bearing Bore 0.D. (RH) 31.946-31.972 mm -
Swing Arm Ball Bearing Bore 0.D. (LH) 41.967-41.992 mm -
VVheel bearing O.D. (approx) 51.987-52.00 mm -
VVheel bearing I.D. ( approx) 19.998-20.00 mm -
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- @
@
Indicator Plate
Axle Adjustment Nuts
-
-
.
® Axle Adjuster -
® Swing Arm ASM -
® Axle Nut (rear) 65 ft-lbs (88 Nm)
-
@ E-Clip Ring -
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G) Axle Spacer -
@ Bearing Seal - 8
® Wheel Bearing -
® Brake Rotor -
(j) Rear Wheel -
® Bearing Spacer -
® Damper -
@) Outer Bearing Spacer -
® Bearing -
® Sprocket -
® Sprocket Bearing Spacer -
® Retaining Ring -
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
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. sprocket.
5. Pull belt off dnve
99 . . ty Servi·ce Manual
- 17 Indian Motorcy cle Scout / Scout Six
27619 R02 - 201 s. Industries Inc. 8.39
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- STEERING / SUSPENSION
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8
3. Inspect the back surface of sprocket hub CD where
it contacts the seal sleeve. Replace if worn or if
surface is rough.
4. Inspect the machined sealing surface of the spacer
sleeve ©. Replace the spacer sleeve if it is
grooved or otherwise damaged.
9927619 R02 - 201 S - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
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DRIVE SPROCKET INSTALLATION 8. Install lock plate Q) and tighten screws © until
lightly seated on plate.
4. Clean shaft threads and sprocket nut to remove all Drive Sprocket Lock Plate Fasteners:
previous thread locking agent. 88 in-lbs (10 Nm)
5. Apply a light film of anti-seize compound to
splines of shaft. Place belt onto front sprocket, 11. Remove the clutch shaft holding tool and install the
place sprocket over splines of output shaft. clutch assembly. See Clutch Installation, page
5.19.
6. Apply Loctite TM 262 to threads of shaft and nut.
12, Install the drive sprocket cover. See Drive
7. Install drive sprocket nut and torque to Sprocket Cover Removal/ Installation, page 8.39.
specification.
13. Adjust belt tension and wheel alignment. See
Drive Belt Adjustment, page 2.38.
Install Clutch Shaft Holding Tool (PF-51232) on clutch
shaft prior to tightening sprocket nut.
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3. Visually inspect the cushion drive damper CD for DRIVEN SPROCKET INSTALLATION
cracks or deformation. Replace damper .if damage 1. Install cushion damper CD into wheel hub.
is found.
Install sprocket assembly CD onto wheel hub'
i _ _-. ·_-_._·._- _- -~--·r ··--.-··-•_. ·._·_._-_·'
-.· _•.-_- ·._~ ~r~· ,;·--~
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2.
making sure the cushion damper is properly
engaged.
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If the drive system has been in service for 5000 miles
or more, replace both front and rear sprockets along 3. Install the LH wheel spacer CD into the sprocket
with the belt if any one item is damaged or worn roller bearing.
beyond a normal polished appearance.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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/ ()
' '/
(
I 0
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
, , · · Polaris Industries Inc. 8.45
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6. Loosen right and left axle adjusters ©. 12. Torque fasteners to specification.
8. Remove washer (J) and axle ® from swing arm. 19.965 - 19.990mm 19.965 - 19.990mm
. I
REAR WHEEL INSPECTION
9. Push wheel forward and slide drive belt to the I. Set up a dial indicator to -measure. axial and radial
LEFT side off of the rear sprocket. runout of the wheel and compare to service limit.
10. Remove rear wheel assembly by sliding it to the See Visual Inspection/ Runout, page 8.68.
rear of the motorcycle. 2. Visually inspect wheel for cracks or other damage.
11. Installation is performed by reversing the
3. Replace wheel if it fails visual or measured
removal procedure. inspection.
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REAR WHEEL BEARING INSPECTION 4. Carefully pry seal G) out of RH side of hub.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc. 8.47
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5. Remove the ABS tone ring (if applicable) CD and 1. With the rear wheel properly supported, remove
brake disc®· the lower shock fastener G) ·and upper shock
fastener CD and remove shock absorber.
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SHOCK ABSORBER INSPECTION 5. Inspect eyelets and ® for cracks, damage or loose
1. Measure spring installed height and record so ride fitting eyelet. Replace shock if either eyelet is
height adjustment can be returned to rid,er's cracked.
preference.
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',~
"·'--·,.
"'
4. Working from the RH side of the swingarm, gently
pry the seals Q) out of the bearing bore.
9927619 R02 - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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5. Install shock absorber assembly. See Shock Ab- 6. Install upper belt guard and torque fasteners CD
sorber Installation, page 8.50. two screws on the back side of guard to
6. Install swingarm assembly. See Swingarm Installa- specifica_tion.
tion, page 8.53.
SWINGARM INSTALLATION
Drive belt must be installed on the drive sprocket
prior to installing the swingarm.
1. Clean inside of the swingarm shaft bores in both
sides of-the frame midcastings.
2. Grease swingarm pivot shaft.
3. Lift the swingarm into position in the frame.
4. Install washer (J) on swingarm shaft. Slide the
swingarm shaft ® into the left side of the frame.
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I
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED
Rear Wheel Feels "Loose" or Loose fasteners Torque to specification
Wobbles
Distorted (bent) rear wheel Replace wheel
Rear Suspension Too Hard Incorrect preload adjustment Adjust to rider & load
Rear Suspension Too Soft Incorrect preload adjustment Adjust to rider & load
Wheel Drags (Turns Hard) Incorrect drive belt adjustment Adjust drive belt tension
Tire contact with object or chassis Determine point of contact and correct
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GENERAL
SERVICE NOTES
If a consumer wishes to replace the Original Equipment Manufacturer (OEM) tires with another brand of tire,
Indian Motorcycle recommends contacting the tech-line of the tire manufacturer being considered to ensure
compatibility. Indian Motorcycle makes no other recommendation other than the OEM tires. Tires other than
OEM may or may not adversely affect the handling characteristics of the motorcycle or may not have adequate
tire clearance.
The use of tires other than original equipment may cause instability which can lead to a crash resulting in
serious injury or death. Use only the recommended tires inflated to the recommended tire pressures. Operating
the motorcycle with damaged rims creates a safety hazard including air pressure loss, steering imbalance and/
or reduced steering control. Do not attempt to repair or straighten damaged rims.
Overloading and under-inflation lead to premature tire wear. Do not deviate from the specifications for loading
or inflation.
SERVICE SPECIFICATIONS
Refer to Steering / Suspension Chapter (Front Wheel and Suspension) for front wheel specifications.
Refer to Steering / Suspension Chapter (Rear Wheel and Suspension) for rear wheel specifications.
9927619 R02 - 20'15 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
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Tire Specifications
POSITION TIRE TYPE/ SIZE TIRE PRESSURE MINIMUM TREAD
DEPTH
Front Kenda Kruz K673F- 130/90-16 72H 36 PSI (248 kPa) 1/16 in (1.6 mm)
Rear Kenda Kruz K673 - 150/80-16 71H 40 PSI (276 kPa) 1/16 in (1.6 mm)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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Tread Block Cupping (Usually Front Tire -See Below) Normal Braking Wear
OZONE CRACKING
Ozone cracking usually shows up on the sidewalls of tires and is caused by sunlight, electric motor emissions,
smog, or other environmental factors. Ozone cracking does not pose a problem unless the cracks reach the cords.
If this occurs, moisture may penetrate the carcass of the tire causing cord separation. Tires showing signs of
severe ozone cracking (cords visible at the bottom of the cracks) must be replaced.
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TIRE CHANGING
There are three generally acceptable methods to dismount and mount a motorcycle tire to its rim. For each of the
three methods, there are countless variations.
The three general methods are:
• Pneumatic or electrically operated tire machine
• Manually operated tire machine
• Manual manipulation of tire irons
Indian Motorcycle permits and recommends all three of the general methods, but realizes that careless or
improper work habits can damage both the tire and rim no matter which method is used. With any of the
methods, care must still be taken to avoid damaging the rim, tire, inner tube (if applicable), brake disk, or
sprocket. ·
The pneumatic or electrically operated tire machine is preferred because it is the most efficient method to
dismount and mount tires.
The manually operated tire machine is the next preferred method. It can be just as efficient as a power assisted
tire machine but with some of the machines it may be necessary to remove the belt driven sprocket in order to
gain sufficient clearance for tire removal.
Manual manipulation is the least preferred method since it will generally not deliver the same efficiency as the
other methods and greater care needs to be taken when performed. Care must be taken when using tire irons to
not damage or stress the tire bead, Also, the opposite bead needs to be in drop center of wheel during mounting
and dismounting of the tire.
Be very careful not to damage the rim, tire, inner tube, brake disk, or sprocket regardless of which method is
used.
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TIRE REMOVAL
This procedure is written assuming that a pneumatic, electric, or manually operated rim-clamp type tire
machine is being used.
1. Remove wheel / tire assembly from motorcycle. See Steering / Suspension Chapter for front wheel
removal and rear wheel removal.
2. Remove valve core G) from valve stem and let all air escape.
3. Mount the wheel assembly onto a tire bead breaker and break the bead starting at the valve stem and
continue around the circumference of the rim as necessary.
4. Flip the wheel assembly over and repeat STEP 3 on the other side.
Take great care not to bend or otherwise damage the brake disc and/or belt driven sprocket. If the bead
breaker being used interferes with either the brake disk and/ or belt driven sprocket, remove the disc or
sprocket as required.
5.
Mount the tire and wheel assembly on the tire machine per the manufacturers instructions.
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6. Carefully work around the circumference of the upper bead CD with the tire lever until it is completely off of
the rim.
7. Lift the lower tire bead up until the tire lever can be positioned and the tire completely removed.
8. Work around the circumference of the rim until the tire can be lifted free of the rim.
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TIRE ~NSTALLATION
This procedure is written assuming that a pneumatic, electric, or manually operated rim-clamp type tire
machine is being used.
Balance Dots
Indian Motorcycle does not recommend the use ofliquid balancer/sealers. These are a form of temporary
repair which may adversely affect ply material and mask secondary damage caused by the penetrating object.
Reliance upon sealants can result in sudden tire failure and accident.
Directional Arrows
Tires CD have directional arrows that must be observed when installing tires to rims CD.
The wheel assemblies must be free of foreign debris that would affect balancing.
Carefully inspect the wheel bearings, seals and axle for damage or corrosion.
Never apply grease, oil, gasoline, spray type lubricants or anything other than rubber lubricant or a neutral
soap and water solution to the tire bead. Doing so can damage the tire.
2.
Mount the tire and wheel assembly on the tire machine per the manufacturers instructions.
3. Orient tire correctly as to the directional arrows.
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4. Push tire on to rim until one bead is installed. It shouldn't be necessary to use tire irons to put one side of the
tire onto the rim. Remember to k~ep bead(s) in the drop center of the wheel whenever possible.
Be sure both beads are forced as far as possible into the drop center of the rim.
8
9. Install valve core if it was removed.
10. Line up balance dot.
11. Confirm that the directional arrows are pointing in the correct direction.
12. Bounce tire on the floor several times while rotating tire. This will expand tire bead outward slightly which
will make tire inflation easier.
13. Inflate tire observing the precautions listed below.
Tire Inflation & Precautions
• Wear approved eye protection
• Lubricate the tire beads with a tire mounting lubricant before inflation.
• Lock assembly on mounting machine or place in safety cage before inflating to seat beads
e Use extension gauge and hose with slip-on air chuck.
• Stand back with no part of your body within the perimeter of the assembled tire and rim.
• Inflate with core in valve stem
• Never inflate above 42 psi to seat beads
• If beads do not seat by 42 psi. Deflate and repeat procedures. Never use a volatile substance or rubber "donut"
to aid bead seating.
14. Inspect the line molded onto the tire side walls. It must be the same distance from the rim all the way around
the tire. If the distance varies it indicates that tire is not seated properly.
15. If tire is not seated correctly, deflate and unseat the tire, lubricate the tire beads and repeat inflation
procedure.
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16. Install wheel assembly onto balance stand and spin. Observe the wheel assembly while it is spinning to make
sure the tire is seated properly.
17. Adjust tire pressures to specifications.
18. Balance tire/ wheel assembly.
FOR REPAIRED TIRES: Speed should not exceed 50 MPH for the first 24 hours after repair and repaired tire
should never be used over 80 MPH. Inspect inflation pressure after tire cools for at least three hours following
run-in.
FOR NEW TIRES: Replacement of OEM tires or replacement with differently constructed tires will not
immediately produce improved reactions the same as the original tires when new. When new tires are installed,
they should not be subjected to maximum power or hard cornering until a reasonable "scrub" period of
approximately 100 miles has been covered. This will permit the rider to become accustomed to "feel" of new
tires or tire combination, and achieve optimum road grip.
Inspect and adjust tire inflation pressure after tire cools down for at least three hours following "run-in".
TIRE BALANCING
It is essential that the wheel assembly be balanced before use and rebalanced each time the tire is removed.
Wheel balance affects stability, handling and overall safety of the motorcycle.
While it is possible to balance a wheel assembly with axle and grease-free wheel bearings as the pivot point, it
is not recommended. Use an inspection stand that has knife edge bearings and its own axle.
3. Spin the wheel assembly. Allow it to stop on its own and mark the highest (lightest) part of the wheel.
4. Repeat the spinning process to verify the heaviest part of the wheel.
5. Place balance weights at the lightest portion of wheel in small increments.
6. After each addition of weight, spin the wheel assembly and allow it to stop by itself.
7. When correct amount of weight has been added to wheel, it will no longer stop in the same location and the
wheel assembly is balanced.
Do not add more than 85 grams (3.0 oz.) of weight to the front or rear wheel.
If more than the recommended weight is necessary to balance the wheel, dismouri.t the tire and rotate it 90°
without regard to the yellow balance dot, and re-balance the wheel / tire.
Adhesive Weight P/N 1521682
8. Install wheel / tire assembly onto motorcycle. See Steering / Suspension Chapter for front wheel
installation and rear wheel installation.
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STEERING / SUSPENSION
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STEERING/ SUSPENSION
WHEEL INSPECTION
VISUAL INSPECTION/ RUNOUT
1. Clean the rim of all rubber particles and corrosion.
2. Inspect wheel for cracks and/or distortion.
3. Inspect bead seating area for scratches, distortion, or damage that could prevent proper sealing.
4. Measure wheel for radial runout CD.
5. Measure wheel for axial runout CD.
Measure runout on tire bead sealing surface of wheel. Be sure surface is clean.
6. Compare measurements of axial and radial runout to specifications. See Service Specifications, page 8.57.
Replace wheel if any measurement exceeds Service Limit.
7. Clean the sealing surfaces of the rim thoroughly. Use a soft brush (nylon) soap and water if necessary.
Do not scratch or damage sealing surfaces of rim. Loss of air pressure can cause a loss of control and an
accident, resulting in serious injury or death.
Only permanent plug-patch repairs of small tread area punctures from inside the dismounted tire are
recommended. Never perform an exterior repair and never use an inner tube as a substitute for a proper repair.
Speed should not exceed 50 MPH for the first 24 hours after repair and the repaired tire should never be used
over 80 MPH. Inspect inflation pressure after tire cools for at least three hours following initial operation.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
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STEERING I SUSPENSION
The Scout model uses directional tires and wheels. Pay close attention to markings to ensure proper tire and
valve stem orientation.
Orientation
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-STEERING I SUSPENSION
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STEERING / SUSPENSION
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- STEERING / SUSPENSION
NOTES
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BRAKES
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· · Polaris Industries Inc. 9.1
- BRAKES
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BRAKES
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.. ' Polaris Industries Inc. 9.3
-BRAKES
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9.4 Polaris Industries Inc.
BRAKES
/,·-···"'
( 11 )
'\ ~
\ ~
"n I
-~~l:
~,.
.........................
® Rubber Diaphragm -
@) Front Master Cylinder Cover -
® Master Cylinder Cover Fastener (front) 13 in-lbs (1.5 Nm)
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
'· Polaris Industries Inc. 9.5
BRAKES
© Sealing Washer -
® Banjo Fastener 16 ft-lbs (22 Nm)
® Sealing Washer -
(J) Rubber Diaphragm -
® Master Cylinder Cover (rear) -
® Master Cylinder Cover Fasteners 13 in-lbs (1.5 Nm)
(rear)
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9.6 Polaris Industries Inc.
BRAKES
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · · Polaris Industries Inc. 9.7
BRAKES
. ABS Models
/,-·---, \
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( 15)
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® Clevis -
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc. 9.9
- BRAKES
(~~:~\.::~:::i:::::~r0.
t~· ~"
t' , ............ ,
( 10 1
\.~... ~-., .... /
CD Brake Pads -
CD Caliper Slide Pin (lower) · 18 ft-lbs (24 Nm)
-
Q) Bracket -
© Lower Dust Boot -
® Upper Dust Boot -
® Piston -
(J) Piston Seal -
® Pad Spring -
® Caliper Body -
@) Pad Retaining Pin 80 in-lbs (9 Nm)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
9.10 Polaris Industries Inc.
BRAKES
CALIPER
CD Brake Pads -
(1) Mount Bracket -
0) Guide Pin -
Piston -
©
® Dust Seal -
® Caliper Body -
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc.
9.11
-BRAKES
( 13 ·,l
\ /
·,-........ ,,.·
CD Bracket -
@ Lower Dust Boot -
® Upper Dust Boot -
® Piston -
(j) Dust Seal -
® Pad Spring -
® Caliper Body -
@) Pad Retaining Pin 80 in-lbs (9 Nm)
® Clip -
® Wear Pad -
® Square Seal -
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
9.12 Polaris Industries Inc.
BRAKES
(2017)
G) Brake Pads -
(I) Mount Bracket -
CD Caliper Slide Pin (lower) 18 ft-lbs (24 Nm) ...
© Piston -
® Lower Dust Boot -
® Bleeder Fastener 60 in-lbs (6.8 Nm) 9
(j) Pad Retaining Pin 80 in-lbs (9 Nm)
® Caliper Body -
® Pad Wear Clip -
®) Upper Dust Boot -
® Caliper Slide Pin (upper) 18 ft-lbs (24 Nm)
@ Pad Spring -
® Clip -
® Piston Seal -
9927619 R02_ - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
. '.· · Polaris Industries Inc. 9.13
-BRAKES
ABS MODULE
-,
-~
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l ~
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
9.14 · Polaris Industries Inc.
BRAKES
Before working on an Indian Motorcycle equipped The Anti-Lock Brake System is a safety feature
with anti-lock brakes, review and understand all designed to prevent wheel lock-up and improve
general brake system, brake fluid, and ABS specific control of the motorcycle during extreme braking
precautions and system information. Do not attempt events, including:
maintenance or repair of the anti-lock brake system
• Panic braking
without the proper tools.
$ Slick surface braking (such as wet road surfaces)
• Surface transitions (from asphalt to oily asphalt or
cobblestone, etc.)
Proper brake system bleeding is extremely
important to ensure adequate lever reserve in the Here are a few general points to note about ABS:
system. Always perform the Brake Lever Reserve test " The anti-lock brake system cannot be turned OFF.
described in this manual after bleeding the anti-lock • The ABS indicator lamp (located on the Instrument
brake system. Cluster) always illuminates when the key is in the
ON position and remains on until the anti-lock
system activates, which occurs when vehicle speed
• Operating with non-recommended tires or improper exceeds 6 mph (IO kph).
tire pressure may reduce the effectiveness of the 0
If the lamp is not illuminated when the key is ON,
anti-lock brake system. connect Digital Wrench and perform an ABS System
• Always install the recommended size and type of inspection to determine the cause.
tires specified for the vehicle. When the ABS lamp is illuminated, the anti-lock
• Always maintain the recommended tire pressure. brakes will not activate, but the conventional brake
• Indian Motorcycle DOT 4 Brake Fluid is system will continue to operate normally.
recommended. Change every 10,000 miles (16,000 If the lamp continues to illuminate after the vehicle
km) or 2 years, whichever comes first. speed exceeds 6 mph (10 kph), the system is not
• The anti-lock brake system will not prevent wheel functioning. Connect Digital Wrench and perform an
lock-up, loss of traction, or loss of control under all ABS System inspection to determine the cause.
conditions. Always adhere to all safe motorcycle • When the anti-lock brakes engage during a braking
riding practices as recommended. event, the rider will feel pulsing at the brake lever
• It is not unusual to leave tire marks on the road or pedal. Continue to apply steady pressure to the
surface during a hard braking event. brakes for the best stopping performance.
• The anti-lock braking system does not compensate • The wheel speed sensor-to-pulse ring air gap is
for or reduce the risk associated with: adjustable. Shims can be added or removed to
• excessive speed bring the air-gap into specification. See adjustment
• reduced traction on rough, uneven or loose surfaces .procedure outlined in this chapter.
• poor judgement • The ABS system can be reprogrammed.
0
improper operation • The ABS light is controlled via CAN BUS.
0
Wheel speed sensors provide feedback for anti-lock 9
brake operation.
.. If fuse is open or removed, the ABS light will remain
ON after 6 mph (IO kph). ABS will not be active.
Normal (conventional) braking will be available
provided the system components (master cylinder,
lines, calipers, etc.) are in working order.
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BRAKES
2. Withdraw speed sensor and remove any existing 8. Withdraw speed sensor and remove any existing
shims. shims.
3, Noting their position, clip cable ties securing the 9. Noting their position, clip the cable ties securing
harness to the motorcycle. the speed sensor harness to the rear brake line.
4. Locate connector inside the headlight and 10. Locate connector below the ABS module and
disconnect the wheel speed sensor. above the voltage regulator. Disconnect the wheel
Installation - Front speed sensor.
Installation - Rear
5. Reverse procedure to install.
11. Reverse procedure to install.
6. Verify speed sensor air gap is within specification.
Perform adjustment procedure if necessary. See 12. Verify speed sensor air gap is within specificatio·n.
Wheel Speed Sensor Air Gap Adjustment, page Perform adjustment procedure if necessary. See
9.18. Wheel Speed Sensor Air Gap Adjustment, page
9.18. .
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9.17
-BRAKES
~ C::..Jt
r-
I
-
L.:
I
t
Wheel Speed
I
Pulse Ring Air Gap
Sensor Connector
2. If the Wheel Speed Sensor air gap is out of
specification, proceed to step 3.
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BRAKES
Removal
8. Disconnect the electrical connectors from the ABS
1. Disconnect the negative battery cable. Module.
2. Position motorcycle in an upright position with the 9. Disconnect hydraulic lines G) from ABS module
front wheel clamped in a wheel vise. and cap off lines to prevent contamination.
3. California Models ONLY: Remove the
evaporative em1ss1ons charcoal canister, if
equipped. Refer to, page 1.12.
4. Remove the swingarm assembly. Refer to , page
8.61 procedure.
6. Remove the voltage regulator. Refer to Regulator /
Rectifier Replacement, page 10.33procedure.
6. Remove the fastener G) securing the bottom ABS
Module mount.
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9.19
BRAKES
This brake system requires ethylene-glycol based Keep these points in mind when bleeding
fluid (DOT 4). Do not use or mix different types of hydraulic brakes:
fluid such as silicone-based or petroleum-based.
• The master cylinder reservoirs have limited
capacities. It is easy to empty them during the
bleeding procedure. This introduces air into the
system which you are trying to purge. Watch the
Do not use brake fluid taken from old, used or reservoir closely and add fluid when necessary to
unsealed containers. Never reuse brake fluid. Brake keep the level above the LOW mark and prevent air
fluid can accumulate moisture, reducing it's from re-entering the system.
performance. • Apply only light to moderate pressure to the lever or
pedal when bleeding the brake system. Extreme
pressure or rapid movement will cause a surge of
fluid through the small orifices of the brake system
when the bleeder screw is opened and could
Brake fluid is poisonous. Keep brake fluid tightly introduce air into the system by means of cavitation.
sealed and out of reach of children. • Small amounts of air can become trapped in the
banjo bolt fittings at the master cylinder(s) and
junction points of brake lines. These fittings can be
purged of air by following a standard bleeding
A soft, spongy feeling in the brake lever and/ or procedure at these fittings (instead of the bleed
brake pedal could indicate a hazardous condition in screw on caliper) if necessary to speed the bleeding
the brake system. Do not operate the motorcycle process. This is usually only needed if system was
until the failure in the brake system is corrected. completely drained of fluid. Bleed each line
connection, starting with the fitting closest to the
master cylinder, working toward the caliper, and
ending with the bleed screw.
• Always torque banjo bolts and other brake system
fasteners and components to specified torque.
• Always install NEW genuine Indian Motorcycle
replacement parts and rubber parts upon assembly.
Apply special lubricant where indicated (included
in service kits).
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9.20 :· Polaris Industries Inc.
BRAKES
-----------------
A yacuum bleeder is recommended for ABS system
bleeding and can also be used to bleed conventional
(non-ABS) brake systems. One style of bleeder is The use of a vacuum bleeder is recommended. DO
shown below. NOT allow fluid level in reservoir to drop below the
LOW mark at any time during the bleeding
procedure.
Repeat entire bleed procedure at least once.
When bleeding or flushing the system, monitor fluid Fill rear brake fluid reservoir and leave cover off
3.
level in master cylinder reservoir constantly. DO NOT so fluid can be added as it is drawn through the
allow fluid level to fall below the LOW level.
system.
Use only DOT 4 brake fluid from a sealed container. 4. Open bleed screw about 1/4 turn.
5. Pump brake pedal repeatedly with smooth full
strokes while adding brake fluid to the reservoir as
EMPTY LINES - If system is dry or very low on fluid required. For best results pump the pedal at · a
due to parts replacement or disassembly, fill fairly rapid rate but avoid pumping too fast or fluid
reservoir and pump lever or pedal slowly through may become aerated. After about 2 cups of fluid
stroke range until air bubbles no longer rise through have been run through the system, the bleeder 9
the fluid into the reservoir. hose should have clear, bubble-free fluid running
FLUSHING THE SYSTEM - Brake systems should be through it.
flushed every 2 years or more often if the fluid is 6. Close bleeder screw and fill the brake fluid
discolored. To flush the system, follow normal brake reservoir.
bleeding process, and pump fluid through the
system until fluid moving through the bleeder hose is 7. Repeat the entire bleeding process to be sure all air
clear. Do not allow reservoir level to fall below the is purged from the system.
LOW level or complete system bleeding will be
8. Torque all bleed screws to specification and install
required.
the rubber caps.
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' Polaris Industries Inc. 9.21
-BRAKES
10. Clean the reservoir cover, diaphragm, and 7. Fill fluid reservoir and install diaphragm and
reservoir sealing surface. If diapJ;tragm is cover. Torque cover screws to specification.
extended, return it to normal (flat) position. Install
diaphragm and cover.
11. If pedal is not firm, repeat bleeding procedure and Master Cylinder Cover Fasteners (front):
insect brake system. 13 in-lbs (1.5 Nm)
ABS FRONT BRAKE BLEEDING 8. Perform Brake Lever Reserve Inspection. See
1. Pull brake lever forward to ensure smooth lever Brake Lever Reserve Inspection, page 9 .23.
operation.
2. Remove front brake fluid reservoir cover CD and
leave it off so fluid can be added as it is drawn
through the system,
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BRAKES
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9.23
BRAKES
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9.24 · Polaris Industries Inc.
BRAKES
.Always replace brake pads as a set and always Wash the brake caliper components with new brake
replace pads in both front calipers at the same time. fluid (DOT4) before reassembly. Do not wipe the
brake fluid off after washing the components.
I. Remove the front brake caliper from the fork by
removing the two fasteners CD. 6. Apply grease to primary and secondary pin bolt
bore on the main caliper and bracket.
9
11. Inspect brake fluid in reservoir and set to proper
level.
3. Pull out bracket © from the body. 12. Slowly pump lever to ·set brake pads against disc.
4. Push each pad back by hand to gain clearance for Lever should be firm, not spongy. If lever is
new pads. spongy, inspect pad installation, bleed brake lines
and inspect brake disc.
13. Install reservoir cover and torque to specification.
Brake fluid will be forced back into the reservoir
when pads are pushed back. Remove reservoir cover
and monitor fluid level while pushing the pads and Master Cylinder Cover Fastener (front):
pistons back. 13 in-lbs (1.5 Nm)
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· · Polaris Industries Inc.
9.25
- BRAKES
. . .·. · · . ·,•@ll·-··-1
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BRAKES
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Polaris Industries Inc. 9.27
-BRAKES
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9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
9.28 Polaris Industries Inc.
BRAKES
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
.; · · Polaris Industries Inc. 9.29
- BRAKES
8. Slide piston ® out with spring. Note spring 15. Carefully install spring / piston assembly into
orientation for assembly of new spring (new master cylinder bore. Work the front piston seal
parts). carefully past the chamfer and into bore. Use care
not to damage or fold the seal when working it
past the chamfer.
16. Continue to install the piston until the rear seal is
past the chamfer. Push and hold the piston in far
enough to allow the retaining ring to be installed.
17. Be sure retaining ring is fully seated in the groove.
18. Clean the bore from the retaining ring outward, so
the outer edge of the new dust boot adheres
properly and will not dislodge from the bore.
19. Install new boot, seating the outer edge fully in the
bore and engage outer lip of boot in piston
groove.
9. Clean master cylinder with isopropyl alcohol and 20. Apply non-petroleum grease from kit to brake
dry with compressed air. DO NOT soak in alcohol lever contact surface.
for more than 30 seconds. DO NOT aim
pressurized air directly at the level sight glass. 21. Install master cylinder on handlebar. Torque
clamp fasteners to specification.
10. Inspect cylinder bore and chamfer of bore for
corrosion, scratches, scoring, or pitting. Replace
master cylinder if any of these conditions are
Brake Lever Perch Fasteners:
evident.
12 ft-lbs (16 Nm)
11. Measure the diameter of the bore. Replace master
cylinder if worn beyond the service limit.
·Master Cylb:l(ier Bore Diameter Service Limit: O. 504
· · in (12~8 mm.) ...· ·
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BRAKES
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- BRAKES
12. Measure the outside diameter of each piston in two FRONT CALIPER SERVICE (2017)
spots 90° apart, 5mm from outer edge. Repeat
measurement 5mm from inner edge. Replace
piston if worn beyond service limit at any Brake fluid and brake cleaners will damage paint,
measuring point. plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on
Front CaliperPiston OutsideDiarnete:r the brake system. If brake fluid is spilled on cosmetic
.. · Std Size: T.18in (30.0 mm) surfaces, immediately rinse the area with a mild
SERVICE LIMIT:J~I 71 in(29~9 min) solution of soap and water until all traces of brake
fluid are removed. Make sure the master cylinder
reservoir being worked on is level before removing
the cap.
Install all new rubber parts during assembly. Do not
reuse old seals or boots.
13. Apply special lubricant from service kit to new Replace all rubber parts upon assembly. Keep parts
piston seals and dust seals. in order for assembly. The top and bottom pistons in
14. Apply non-petroleum grease (included in kit) to the caliper are the same size.
outer surface of all pistons.
15. Install piston seals and dust seals in caliper body. 1. Remove banjo fastener G), sealing washers, and
brake hose from caliper assembly and allow it to
16. Install pistons in their respective bores. drain into a container. Cover the end of brake line
17. Install brake pads. Torque retaining pin and set to prevent debris from entering.
screw to specification.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
9.32 Polaris Industries Inc.
BRAKES
3. Cover the brake hose connection on the caliper 12. Measure the outside diameter of each piston in two
and clean the outer surfaces of caliper assembly spots 90° apart, 5mm from outer edge. Repeat
with brake cleaner (commercially available) or measurement 5mm from inner edge. Replace
isopropyl alcohol. Dry with compressed air. piston if worn beyond service limit at any
4. Remove clip @, pad retaining pin CD and brake measuring point.
pads. Piston Outside Diameter
SERVICE LIMITS
Std Size: 1.1782 in (29'.927 mm)
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·· ' · Polaris Industries Inc. · 9.33
-BRAKES
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9.34 · Polaris Industries Inc.
BRAKES
3. Remove mounting fasteners Q) from master 12. Install the master cylinder and torque the jamb
cylinder to footpeg. Remove the ~aster cylinder. nut. mounting fasteners, and brake line banjo bolt
to specification.
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· ,. . Polaris Industries Inc. 9.35
-BRAKES
REAR CALIPER SERVICE (2015-16) 10. Measure diameter of each bore and piston.
1. Remove the brake pressure switch from the banjo Replace caliper assembly or parts if worn beyond
bolt. service limit.
2. Remove banjo bolt G) and sealing washers from ~~a.r Caliper Bore Diameter;
rear caliper and allow fluid to drain into a Std Bore:J .185 in (30.2.mm)
container. SERVICE LIMITS: 1. ~ 93 i.n.•(30.3 mm).
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
9.36 - Polaris Industries Inc.
BRAKES
23. Bleed brake system. See ABS Rear Brake Bleeding, 8. Clean caliper thoroughly with isopropyl alcohol.
page 9.21. Dry with compressed air. Clean seal grooves
thoroughly. Any residue left behind in the grooves
(2017) could cause caliper pistons to stick and result in
brake drag.
1. Unplug the pressure switch connector (above the 9. Inspect bore and surface of piston for corrosion,
voltage regulator) and remove the cable ties which scratches, scoring, or pitting. Replace caliper
hold the wire to the brake cable. assembly if any of these conditions are evident.
2. Remove banjo fastener G) and sealing washers 10. Measure diameter of each bore and piston.
from rear caliper and allow fluid to drain into a Replace caliper assembly or parts if worn beyond
container. service limit.
Bore Diameter:
SERVICE LIMITS
Piston Diameter:
.... SERVICE LIMITS .
. Std Size: l.1782 in (29.927 rrun)
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-BRAKES
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
9.38 - · Polaris Industries Inc.
BRAKES
u D NG
PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED
Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component
Erratic Braking Fluid Leakage (Internal of Master Cylinder) Replace Master Cylinder
Action Worn Pads Replace Brake Pads
Oil Contamination of Brake Pads and/ or Brake Pads Must Be Replaced. Disc May Be
Disc Cleaned.
Air In System Bleed Air From System
Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
Excessive Brake Disc Runout Level.
Worn or Damaged Wheel Bearings Replace Brake Disc.
Loose Front Axle Nut or Clamps or Loose Rear Replace Wheel Bea.rings.
Axle Torque Correctly
Caliper Mount Surface Uneyen Or Misaligned; Inspect I Repair
Missing or Damaged Fasteners Replace Line(s)
Clogged or Restricted Hydraulic Line Replace Bracket
Caliper Bracket Misaligned, Bent or Distorted Install New Screws. Torque to
Loose Brake Disc Specification
Brake Pads Glazed Replace Pads. Avoid Needless Heavy
Braking for 100-200 miles (Burnish New
Brake Pads).
------------------------------ ------+------------------~
Poor Brakes or Air In System Bleed Air From System
No Brakes When Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
First Applied. Brake Disc is Bent or Warped Level.
Brake Lever Caliper Misalignment Replace Brake Disc
Pressure Present External Leak Determine Cause and Correct
If Lever Is Internal Leak (master cylinder) Repair or Replace Damaged Component
"Pumped". Faulty Brake Hose Repair or Replace Master Cylinder
Inspect for Bulges / Replace
----------------------~------ -·-------------~---------1
Brake Pedal or Brake Disc Bent or Warped Replace Brake Disc
Brake Lever Mounting Surface of Brake Disc Uneven/ Disc Repair or Replace as Necessary
Pulsates Loose Repair or Replace as Necessary
Caliper Mount Surface Uneven Or Misaligned;
Missing or Damaged Fasteners
Excessive Lever Air in System Bleed Air From System
or Pedal Travel / Loose Mounting Hardware Repairas Necessary
Spongy Brake Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid 9
Feel. Incorrect Brake Fluid Used Level.
See "Weak I Erratic Brakes" and Poor Brakes" Flush System and Replace With Correct
possible causes above. Fluid
Fluid Leakage Loose Banjo Fittings Tighten to Specified Torque
Damaged Banjo Fitting Sealing Washers Replace
Cracked / Damaged Hose Replace
Worn Master Cylinder Piston, Caliper Piston(s) Repair / Replace Master Cylinder or
or Seals Wheel Caliper.
Diaphragm (master Cylinder reservoir) Inspect I Replace Cover, Cap, Diaphragm
Leaking or Reservoir as Required
Fluid level too high (new brake pads installed Correct fluid level
without removing added fluid)
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
· Polaris Industries Inc. 9.39
-BRAKES
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
9.40 · , · Polaris Industries Inc.
ELECTRICAL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
_: Polaris Industries Inc. 10.1
- ELECTRICAL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.2 Polaris Industries Inc.
ELECTRICAL
10
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· . Polaris Industries Inc. 10.3
- ELECTRICAL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.4 · Polaris Industries Inc.
ELECTRICAL
CAUTION.
WIRE ROUTING
Make sure that all wires are routed correctly away
from moving parts, hot exhaust, or sharp edges.
FUSES
Fuses are in place to protect circuit wiring and
components. Always determine the cause of an open
fuse before installing a new fuse.
Do not increase the value of the fuse to correct the
problem.
Do not use wire, tin foil or other substitutes for fuses.
ELECTRONIC COMPONENTS
Semiconductor parts used in electronic components
will not withstand careless handling.
Do not drop or strike parts that contain
semiconductors such as the ECM or rectifier/
regulator. Dropping electronic components can
cause damage to the component.
Follow instructions supplied in this chapter, including
Fuel Delivery I EFI Chapter (Fuel Injection) and
Electrical Chapter (Ignition System), very carefully
when working on electronic components. Failure to
follow instructions may cause irreparable damage to 10
the part being inspected.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
• Polaris Industries Inc. 10.5
-ELECTRICAL
SERVICE SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
ITEM SPECIFICATIONS
Electrical (General) Ignition System Distributor-less Transistorized Dual Coil Type
Ignition
Starting System Electric
Charging System Permanent Magnet / 3 Phase / Full Wave
Rectification
Regula tor/Rectifier Solid State Three Phase Voltage Regulator/Rectifier
Lighting System 12VDC
ITEM SPECIFICATIONS
Alternator No Load AC Output @ 800 - 1000 RPM (Engine cool) 14A (168 Watts)@ Idle
Alternator No Load AC Output@ 2000 RPM (Engine cool) 29A (348) @ 2000 RPM
Stator Coil Resistance (@ 21 °C / 70°F) (Black to each other black)
(Disconnect regulator - see test.) 146 milliohrns ±20%
Stator Coil Resistance To Ground (Each black wire) Infinity (no continuity)
Regulator/Rectifier Regulated Voltage 14.3 - 14.7 V DC
Alternator Output (Amps / Watts) 32A (460 Watts) @ 6000 RPM
Type Leoch:
Voltage 12 Volts DC
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10.6 ' ' Polaris Industries Inc.
ELECTRICAL
ITEM SPECIFICATION
Battery Voltage, No Load Above 12.5 V DC
Resistance: Between Any Two Commutator Bars Continuity (0 Ohms)
Resistance: Commutator to Armature Shaft Infinity (01 on Fluke TM 73)
Resistance: Battery Input Terminal to Insulated Brush Continuity (0 Ohms)
Resistance: Bat. Input Terminal to Starter Motor Case Infinity (01 on Fluke TM 73)
Starter Motor Operating Amp Draw 140 - 160 Amps
Starter Motor No Load Amp Draw (Bench Test) 30 - 37 Amps after initial surge
Starter Torque Limit Clutch Break-Away Torque 50 - 60 ft-lbs (70 - 80 Nm) when new
10
ASSEMBLY VIEWS
STARTER MOTOR/ SOLENOID COMPONENTS
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10.8 - -· · Polaris Industries Inc.
ELECTRICAL
STATOR COMPONENTS
G) Stator - ..
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"'' · · · Polaris Industries Inc. 10.9
- ELECTRICAL
99276 J 9 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.10 · Polaris Industries Inc.
ELECTRICAL
® Battery Box -
(j) Engine Coolant Reservoir -
® Coolant Reservoir Heat Shield -
® Coolant Reservoir Heat Shield Fastener - (QTY. I) 8 ft-lbs (11 Nm)
10
@) Self Threading Nuts -
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· Polaris Industries Inc. 10.11
- ELECTRICAL
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10.12 Polaris Industries Inc.
ELECTRICAL
9927619 R02 - 201 S - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual 10.13
·. Polaris Industries Inc.
- ELECTRIC.AL
Measure voltage with a digital multimeter. If lower 4. Inspect terminals for corrosion. If corrosion is
than 12.5 V DC, battery must be recharged again in found, remove battery and clean terminals with a
accordance with step 1 and 2 above. solution of baking soda and water. Finish process
by cleaning terminals (both battery and battery
3. After charging battery and letting it sit for 30 cables) with a wire brush.
minutes or more, check battery voltage again. If 5. Install battery. See Battery Installation, page 10.12.
battery voltage is still below 12.5 V DC, replace
the battery. 6. Once connections are secured, apply a thin film of
di-electric grease to terminals.
BATTERY CHARGING - IN SERVICE 7. Install seat. See Seat Removal/ Installation,· page
l, Measure battery voltage with a digital multimeter. 7.8.
The reading should be above 12.50 V DC. If
battery voltage is lower than 12.50 V DC battery
must be charged according to the instructions
BATTERY TESTING
given below.
The recommended battery tester for all Indian
Motorcycle batteries is special tool PU-50296. See
Special Tools Index, page 1.15.
Do not remove caps on battery while recharging. Do
not attempt to inspect or add fluid to a maintenance Conductance describes the ability of a battery to
free battery. conduct current. A conductance tester functions by
sending a low frequency AC signal through the battery
and a portion of the current response is captured, from
2. Charge battery at 1.2 amps for S to 10 hours.
this output a conductance measurement is calculated.
Conductance testing is more accurate than voltage,
specific gravity, or load testing.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
10.14 · · Polaris Industries Inc.
ELECTRICAL
SERVICE
SAFETY INFORMATION
Always disconnect the battery (negative terminal first) before servicing the starter motor.
.. Inspect the condition of the battery before troubleshooting the starter system. Also inspect main engine ground
and battery cable connections.
Starter motor turns slowly. Engine Low battery. Faulty starter motor or See Troubleshooting Flow Chart 2
may or may not start. drive mechanism. Engine
mechanical problem.
Starter motor turns, but engine Starter torque limit clutch slipping. See Troubleshooting Flow Chart 3
does not turn.
Starter motor turns at normal Ignition Problem Electrical Chapter
speed, but engine does not start. Engine Problem Engine / Cooling / Exhaust
Fuel Delivery Problem Chapter ~:-'
:.·:
Fuel Delivery / EFI Chapter '·
10
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual 10.15
-- .. Polaris Industries Inc.
- ELECTRICAL
~
40A
Main
Fuse
B
l!J
0 ~ ~a:
:,:
~
Battery a- RD
Start
Solenoid
,-,-----~r-------~~
BK
I
~
(l)
Starter
'DB1YE B LH
Control
f'"y BKlWH Pl
Ir
RD/BK P2
BKIWH P3 RH
Control
P4 '
BKJ'NH PS
ECM 1 GSS
Top
View
ECM1
ECM2
~
PK/BK
BN/YE =========::::~==11:=l·•~::;::==.i
OG/WH=~l:::::1.~0G/WH~8
~ - I R ~ - PVJBK . P7
r~
l==ll==L~===== DB/YE P2
lz;;z::;z::;z::;=:;~ YE1WH :. Pl
Chassis
Ground
9927619 R02 - 2015 - 17 Indian. Motorcycle Scout / Scout Sixty Service Manual
10.16 ' Polaris Industries Inc.
ELECTRICAL
t
!Test Battery!-+- Fail-+-· Inspect Chaxging System
---
Pass
t
Does Starter Solenoid Click _..,._ Yes - - - - - - - - - - - · - - - - - - - - _ : . _ - - - - - - - - - - - - - ,
When Button Is Pushed?
t
No
t
-+- Sta."tterTuxns ~~ !Repair or Replace Switch(es)j
t
( Bypass Starter Relay Switch Circui!] --.... St:utex Turns - ~ _
E
Problem is N'O'l' il:tHigh Current Portion of Starting System
Inspect Switching Circuit ·----
t
~ s Starter Relay I -+- StarterTu:1:1:u, --1>- ['Rei,la.ce :Ha~~r Relay)
t
Starter Doesn't Turn
t
-
Byp;;; - of Startinj _ _,,__ St t T
Ground (-) Side ~ rrto~t;ge fu-;pTests for<-)
System ----,,.--- a.r er ur.ns -· · · Hig:h Current .Side of Starter
t
Starter Doesn't Turn
9927619 R02 - 2016 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
Polaris Industries Inc.
10.17
-ELECTRICAL
These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive ammeter
clamp and aDMM.
!Inspect Battery! _.,.. Battery Condition Poor --Ill- Service Battery or Replace
. . Inspect Charging System
t
Battery Condition Good
t
!Perform Starter Current Draw1'estJ _...,.. !Slow Crank and Low Draw I
t t
['sioy, Crank and High Draw!
t
IPel'form (+) Side Voltage Test I~ ~~ag':.E;cop Above Lirniij -...._~ ICorrect Problem and Ret;{J
t
!voltage Drop Within .Allowable Limit !
t
( Perform (-) Side Voltage Tesij ~ - ~ ~ x o p Above ~;;J --~ ICorrect Problem a n d ~
+
~rnal Starter Problem J_.,... c·---"
lnter~al Start~r Problem found-;J
t - -
Rebmld / Rer.dace Sta::te:r Motor
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10.18 ·· Polaris Industries Inc.
ELECTRICAL
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10.19
-ELECTRICAL
9927619 ROZ - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.20 ., ·' · Polaris Industries Inc.
ELECTRICAL
GEAR POSITION SWITCH NEUTRAL INDICATOR TEST 5. If indicator is not lit with transmission in neutral:
Symptoms of a faulty Gear Position Switch may • Place the RUN/STOP switch in the STOP position and
include: · turn motorcycle power off.
• Starter motor does not operate when transmission is " Roll the motorcycle forward and back enough to
in neutral, verify that it is in neutral.
• Locate the gear position switch CD wire connector CD
but... located near the engine at the rear of the cases
" Starter motor does operate when clutch is pulled in. above the voltage regulator.
1. Place the ignition switch in the RUN position to
power up the electrical system.
2. Place engine stop switch in the RUN position.
3. Shift transmission into Neutral.
4. Observe neutral indicator light.
r~i1'1I}Y~
!\·~,-- \\/;
·.v·.·.~~h~
j'·· J ~; :··'\'
'~:. •~.·-.~.:1.-.- . -t~A:.-,.',~~.:"'.~£L~-
. ·.:".~., , .·......" . -..,;J>-""-1·:.
::_·~ ~,:.;~
0 (·.:::.:.c::L
.· i ....· .. -~-
~
. E,?i.·. .·. . · .·. ·.• ·. '··.·.·,.·.·.·~.'!.J.~.•~·.' "s\ ~.:.-~-.
8, \Q~···:
:·:·J·.·'
·--.·.J··.
·..
,;-•·.·.~-
.. -.- .....--;
9927619 R02 - 2016· - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
· ·· · , Polaris Industries Inc. 10.21
- ELECTRICAL
• Test the gear position switch resistance between the CLUTCH SWITCH CIRCUIT TEST
switch connector terminal 1 and chassis,g:i;ound. The symptom of a faulty clutch switch circuit is:
• Starter motor will not operate with transmission in
gear and clutch lever pulled in. Starter operates with
transmission in neutral. Use an ohmmeter to
determine if continuity is present when the switch is
closed (lever pulled in).
1. Transmission can be in neutral or in any gear.
2. Disconnect the clutch switch connectors.
3. Set multimeter to measure resistance and insert
meter leads into appropriate jacks.
4. Connect red (+) lead of multi meter to either of the
clutch switch terminals and the black meter lead to
the other clutch switch terminal.
5. Operate clutch lever while observing meter
display.
• Compare reading to the resistance specification.
6. Pull clutch lever to the handlebar. Meter should
display continuity or very low resistance (less than
G.ear Po~ition SVvitcltreut{al Resistance 1 ohm) when the clutch switch closes.
Specification:lQ±O~SO .
7. Release clutch lever, meter should display 01
6. If resistance reading is not within specified (open line).
parameters, replace neutral switch or repair 8. If clutch switch does not test as described inspect
wiring as necessary. clutch switch, clutch switch wiring or mounting of
7. If neutral indicator switch is working correctly and switch to clutch lever for fault.
neutral indicator did not light with the transmission 9. If switch is mounted correctly and physically
in neutral; inspect neutral lamp and circuit wiring operates but does not open and close electrically,
for a open/short circuit. replace switch.
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10.22 Polaris Industries Inc.
ELECTRICAL
3.
CAUTION
The clutch switch has a locating pin on the bottom
side which slide into the clutch lever perch. Use
caution when removing the clutch switch so the 1
locating pin does not break off.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual 10.23
Polaris Industries Inc.
- ELECTRICAL
Secure motorcycle on the side stand and place This procedure requires the use of an inductive
transmission in neutral for the following test. ammeter to read current draw and a volt meter to
monitor battery voltage during the test.
1. Place the transmission in neutral.
2. Disconnect positive cable CD from starter motor.
Do not allow any part of the jumper cable clamp
to touch the chassis or any other ground.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.24 Polaris Industries Inc.
ELECTRICAL
9. Press starter switch and crank starter for about 5 8. Torque the starter motor positive terminal nut to
seconds and observe both meters and the specification.
tachometer.
10. The battery voltage should remain above 9.6 volts.
Battery Cable to Starter Motor Nut:
11. The amperage draw of the starter should not 62 in-lbs (7 Nm)
exceed 160 amps.
Starter current draw @ 77°F (25°C): ::::;i'GO Amps
Ensure that the ignition switch is turned off. STARTER CLUTCH REMOVAL
Remove the negative cable at the battel'y before
removing the starter motor. • See Starter Drive Removal, page 6.20.
9927619 ROZ - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
-, · · · Polaris Industries Inc. 10.25
- ELECTRICAL
The battery must be fully charged and in good condition to obtain accurate readings. Battery charging current is
automatically reduced by the regulator / rectifier if the regulator/ rectifier unit reaches a critical temperature
(overheated). The system should be cool when testing DC charging output or when testing the regulator /
rectifier to ensure accurate readings. Refer to test procedure for individual charging system components for
more information.
START
i
lMeasure Current Drain! _...... Incorrect --+-
Excessive Loads (Acey Draw)
Shorted Wiring
Shorted Compenents
(Disconnect any accy items to
i
Correct
see if load disappears)
i ll
Inspect Regulated Voltage & --+- 3. VDC _ _ VDC I____,. . . Inspect Battery & Battery Connections
8 14 7
Amperage Output . . Perform Battery Load Test
i
Inspect Voltage Reg/Rect 2-pin
and 3-pin connector. Inspect BK
wire (-) and BK/RD wire (current
I
_...... Reg/Rect Faulty _...... Replace Reg/Rect Unit
· ·
I
path) back to battery (+)
I
[Inspect Stator --+- Stator Faulty _...... ~place stator]
i
Stator OK ---fllo---
Faulty Wiring or Connectors
Damaged Rotor Magnet
i
ITest Reg/Rect Unit I --+- Reg/Rect Faulty --+- IReplace Reg/Rect Unit I
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.26 · ·· · · · · Polaris Industries Inc.
ELECTRICAL
Current drain is suspect if battery discharges when 1. Remove seat. See Seat Removal I Installation, page
motorcycle is not in operation (short periods of 7.8.
storage).
2. Place the inductive ammeter over the positive (+)
l. Remove seat. See Seat Removal / Installation, page battery cable.
7.8.
3. Set multi meter to V DC scale.
2. Disconnect ground cable(-) from battery.
4. Connect voltmeter red (+) lead to battery red ( +)
3. Set multimeter to read milliamps (mA) and insert lead arid black (-) voltmeter lead to battery black
meter leads into appropriate jacks. Connect red (-) lead.
meter lead to ground cable eyelet and connect
black meter lead to battery negative (-) terminal.
l";"'
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· · ·· · · · Polaris Industries Inc. 10.27
- ELECTRICAL
8. Use results obtained from preceding tests and the STATOR AC VOLTAGE OUTPUT TEST
following descriptions to determine if charging
system is functioning properly.
CHARGING SYSTEM OPERATING Set multimeter to VAC (alternating current). Engine
CORRECTLY: Ammeter goes up a small amount, cold. Regulator / Rectifier disconnected (2-pin and 3-
then stabilizes slightly above +O amps. Volt meter pin connector). Engine must be running. Be sure to
rises toward 14.8 ± V DC, drops off a little and heed the following Warnings and Cautions.
starts to stabilize.
LOW BATTERY: Amperage continues to rise,
voltage levels off as battery is absorbing voltage.
Charging system may be okay. Need to charge HOT COMPONENTS: The engine and exhaust
battery fully or use a good battery and repeat test. system become very hot during operation and
Meters will indicate similar reading to the remain hot for a period of time after the engine is
overcharging chart. shut off. Wear insulated protection for hands and
CHARGING SYSTEM UNDERCHARGING: Ammeter arms or wait until the engine and exhaust system
drops to O or remains below O (negative reading) have cooled sufficiently before working on the
at all rpm, volt meter remains the same or goes machine.
down. Go to voltage drop inspection.
CHARGING SYSTEM OVERCHARGING: Ammeter
rises well above O and remains there or continues
to rise. Volt meter goes well above 14.8 V DC and CARBON MONOXIDE: Never run an engine in an
may continue to rise. enclosed area. Exhaust contains poisonous carbon
EXCESSIVE LOAD: Current levels off or starts to monoxide gas that can cause loss of consciousness
drop, voltage continues to rise. Load may be and may lead to death. If you must run the engine to
excessive (accessories or shorted components). do some repairs, do so in an open area or with an
Determine if excessive loads are present. exhaust evacuation system operating.
Disconnect accessories and re-test.
9. Turn ignition key off.
I 0. Remove inductive ammeter clamp. VOLTAGE/ ARCING: Use caution not to touch any of
the connections or allow the exposed terminals to
11. Install seat. See Seat Removal / Installation, page
7.8. come close to any other part of the vehicle or other
objects, as an arc may occur.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
10.28 ', " · ' · Polaris Industries Inc.
ELECTRICAL
3. Connect one lead of the multi meter to pin A CD STATOR RESISTANCE TEST
and one lead to pin B CD on. the 3-pin stator
connector. CAUTION
The engine must not be running while performing the
following resistance test.
. ................................._,.,,.____ . :___•,
6. Repeat test for pins A CD & CG). 3. Connect one meter lead to pin A CD and the other
lead to pin B CD on the stator connector. No.te
7. Repeat test for pins B CD & C G). resistance value .
.· No]oadAC Volts@ 800 RPJY.1: Approx 24VAcDJ
VAC. - · --·-·.....
····- .... :-:--·~:!::
The test results obtained in step 10 can read more Stator Resistance: Less than 1 Ohm
than 34 VAC, but it is important that they are all
approximately equal. 4. Repeat test for pins A CD & CG).
5. Repeat test for pins B CD & C G).
[ No load AC Volts @ 2000 RPM: Approx 34VAC
6. If resistance values do not match specification,
inspect stator and replace as necessary.
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··· ·.. · · · · Polaris Industries Inc. 10.29
-ELECTRICAL
3. Repeat test for other two stator leads (CD & CD) to
ground. ·
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10.30 ···· Polaris Industries Inc.
ELECTRICAL
--------------- ---~-~,---~-
4. Remove fasteners CD from stator wire guide CD.
10
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- ELECTRICAL
FLYWHEEL REMOVAL
See Flywheel Removal, page 5.22.
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10.32 · Polaris Indus'tries Inc.
ELECTRICAL
10
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-ELECTRICAL
IGNITION SYSTEM
GENERAL INFORMATION GENERAL PRECAUTIONS
SERVICE NOTES • This ignition system is controlled electronically and
There are many hazards present when working on or no provisions are available to inspect or change
around the ignition system. Read and pay close ignition timing. A timing light is still valuable as a
attention to the following warnings and cautions when diagnostic tool.
working on any component in this section. • Poor connections are the most common cause of
ignition problems. Inspect all connections and
replace the spark plugs before doing extensive
ignition system troubleshooting.
Never run an engine in an enclosed area. Exhaust • Make sure the battery is fully charged and that the
contains poisonous carbon monoxide gas that can charging system is operating correctly.
cause loss of consciousness and may lead to death. If • A signal from the Crankshaft Position Sensor must
you must run the engine to do some repairs, do so in be present at the ECM for spark to occur.
an open area or with an exhaust evacuation system
operating.
SPECIAL TOOLS
SPECIAL TOOL PART NUMBER
The engine and exhaust system become very hot Electrical Tester Kit PV-43526
during operation and remain hot for a period of time
Digital Multimeter Commercially Available
after the engine is shut off. Wear insulated protection
for hands and arms or wait until the engine and Inductive Timing Light Commercially Available
exhaust system have cooled before working on the
machine.
SERVICE SPECIFICATIONS
ITEM SPECIFICATIONS
Some procedures call for the engine to be run in
order to warm the engine to operating temperature. Spark Plug NGKMR7F
If this is done the exhaust pipes can "blue" if a Spark Plug Gap 0.030 in (0.80 mm)
cooling air stream is not provided by means of a shop
fan directed the exhaust system. Ignition Switch/ Primary 0.6 - 0.8 Ohms ± 20%
Cables
Resistance Secondary
Values N/A
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10.34 · · Polaris Industries Inc.
ELECTRICAL
IGNITION
IGNITION COIL REMOVAL/ INSTALLATION
1. Place the IGNITION and RUN / STOP switch in the
OFF/STOP position.
2. Remove the seat. See Seat Removal / Installation,
page 7.8.
3. Remove the fuel tank. See Fuel Tank Removal,
page 4.14.
4. Remove air box. SeeAir Box Removal, page 3.4.
5. Remove the ignition coil fastener G).
10
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· ·· Polaris Industries Inc. 10.35
- ELECTRICAL
TROUBLESHOOTING
BASICS
Before troubleshooting the ignition system, ensure that TEST LEAD ADAPTER KIT
the engine STOP/RUN switch is in the RUN position, 1. Tests in this section may include the testing of
the battery is fully charged, and system related fuses voltage and / or resistance at the connectors for
are not open (blown). Check visually for corroded, various sensor and system components. Use the
loose, or broken connections in critical areas (e.g. appropriate test adapter lead when performing
sensor connector). Check for loose wire pins in the these tests. at connector pin(s).
individual sensor connectors and at the ECM
(mounted on right side of the battery box). 2. Forcing an incorrect or oversized probe into a
connector may cause inaccurate test results (due
Don't forget the spark plugs! to lack of a solid mechanical connection to the
The Ignition System Troubleshooting flow chart (and terminal). It can also damage the connector being
the accompanying text) is designed to help you probed or the connector housing, creating another
troubleshoot ignition system problems. It will not lead problem which greatly complicates the diagnostic
you to faulty or fouled spark plugs. Always inspect process. Extreme care must be taken not to
spark plug condition first (and replace if necessary) introduce problems while probing a connector.
when troubleshooting ignition system problems. Electrical Tester Kit: PV-43526
Be sure that the spark plugs are the correct heat range
and are the correct size specification.
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10.36 -· Polaris Industries Inc.
ELECTRICAL
Inspect Engine,
Check Spark .>-,:~ Compression and
Fuel System
Test B+ Voltage
Test Ignition Coil
on Red wire at
ECM Ground
ignition coil with
Signal
POWER ON
Inspect Crankshaft
Position Sensor Check Main
Circuit and Power, Grounds
Perform and Signal Circuits
Resistance Test
OKAY Check
Sensor Pole, NOT OKAY
Timing Wheel Replace the CPS
Teeth, and Wiring
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· - , Polaris Industries Inc. 10.37
- ELECTRICAL
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10.38 · · Polaris Industries Inc.
ELECTRICAL
IGNITION COIL POWER/ GROUND SIGNAL TEST 3 14. Repeat the test on the other outside wire in the
Power To Ignition Coil connector.
Battery voltage must be present at the ignition coil (Pin • If no pulse is present, test the Crankshaft Position
B) when the power button is switched on and the Sensor.
electrical system powered up. • If the signal is present on one wire and not the other,
test related wiring and connections.
1. Disconnect the electrical connector from the
" If both signals are present and there was battery
ignition coil. See Ignition Coil Removal /
voltage on the RD wire (center terminal) but still no
Installation, page 10.35.
spark, test the ignition coil windings. (Test 5).
2. Set the multimeter to measure VDC and insert the
meter leads into the appropriate jacks.
3. Connect the black lead to ground (on the engine).
4. Connect a small thin test adapter lead to terminal
1 of the ignition coil primary connector and the
red meter lead to the test adapter.
5. Turn ignition key ON to power up the motorcycle
electrical system and place the STOP/RUN switch
in the RUN position.
6. Battery voltage should appear on terminal 1 of the
coil connector (RD wire).
7. With transmission in Neutral, crank the engine.
Battery voltage should again be present on center
wire.
Ignition Coil Ground Signal
The following steps will test the ECM (Ground)
Signal To _Ignition Coil
ECM ground signal must be present at terminal 3
of the ignition coil primary harness connector. The
signal will appear as a pulse on the met~r b~tween
Ground(-) and Open (01).
8. Set the multimeter to measure resistance (.0).
9. Place a small thin test adapter into terminal 3 of
the ignition coil connector (the WH wire) and
connect one meter lead to the test adapter..
10. Ground the other lead to the engine.
11. Place transmission in Neutral.
12. Turn the ignition key ON to power up the
motorcycle electrical system and place the STOP/
RUN switch in the RUN position.
10
13. Crank the engine with the electric starter and
watch the display on the multi meter. The meter
display should pulse evenly while engine is
cranking, indicating a ground signal is present.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · Polaris Industries Inc. 10.39
- ELECTRICAL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.40 · ·· Polaris Industries Inc.
ELECTRICAL
SERVICE NOTES
Keep the following notes in mind when diagnosing an
electrical problem:
0
Refer to wiring diagram for stator and electrical
component resistance specifications.
" When measuring resistance of a component that has
a resistance value under 10 Ohms, remember to
subtract meter lead resistance from the reading.
Connect the leads together and record the
resistance. The resistance of the component is equal
to tested value minus the lead resistance.
" Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being
performed (i.e. 10 A jack for current readings).
Refer to the Owner's Manual included with your
meter for more information.
• Pay attention to the prefix on the multi-meter
reading (K, M, etc.) and the position of the decimal
point.
" For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or
power supply.
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Battery Tester PV-50296
Electrical Tester Kit PV-43526
Smartlink Module Kit PU-47471
USB to Serial Adapter PU-50621
10
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
· · Polaris Industries Inc. 10.41
-ELECTRICAL
_:/·-··,.,
1-1:t,\::·~;;,·,.---1'. 4 l
\,........ _.,,/'
® Headlight Bucket -
(J) Head Light to Lower Triple Mount 18 ft-lbs (24 Nm)
Fastener
992'1619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.42 Polaris Industries Inc.
ELECTRICAL
G) Taillight -
License Plate Lamp -
CD
:,,:··
G) Washer (QTY. 2) -
1,
® Washer (QTY. 3) -
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual 10.43
: .. •1, ,.. · · · Polaris Industries Inc.
- ELECTRICAL
FUSE BOX
":.,.,.··
.~·<,.-·
(/
'·· .....
. f ·.fj
I.\
i '
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.44 ' ·· · ·· Polaris Industries Inc.
ELECTRICAL
10
9927619 RO~ - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· . Polaris Industries Inc. 10.45
- ELECTRICAL
9927619 R02 - 2016 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.46 · · · ·' Polaris Industries Inc.
ELECTRICAL
Cl Not Used - -
C2 Starter Relay Output Power Fuse Box C2 Start Solenoid
C4 Fuel Pump / Coil Fuse Output Fuse Box Bus 1B Fuse Box C4
(Main Fuse)
Dl Not Used - -
D2 Starter Solenoid Relay Control ECM 1 (El41) D2
10
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· Polaris Industries Inc.
10.47
- ELECTRICAL
CON~IECTOR
PIN REFERENCE
CONNECTOR #I CONNECTOR #2 CONNECTOR #3
FRONT FRONT FRONT
VIEW VIEW VIEW
8
lQlo lQlo
,tidl
[gJ
[gjo
CJ
CJ
[gJ
=
fgJ
lQl=
CJ
0 4
I
4
I
~ 00--00] DD
DD
DD
DD
D 0
D o_J
i;:;
J
B
~[]
~
08R-JWPF-VSLE-D
t21
08T-JWPF-VSU'.··D
~
02T-JWPF-VSLE-S
RECEPTACLE HOUSING TAB HOUS ! NC3 TA.B HOUSING
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.48 · Polaris Industries Inc.
ELECTRICAL
10
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
". · Polaris Industries Inc. 10.49
- ELECTRIC.AL
5. Remove Bulb @.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.50 : Polaris Industries Inc.
ELECTRICAL
10
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
,, Polaris Industries Inc. 10.51
- ELECTRICAL
TAIL LAMP SERVICE 2. Working from beneath the rear fender, access the
LED TAIL/ BRAKE LIGHT OPERATION three tail light nuts CD and remove along with
The multiple LED tail / brake lamp functions much like washers.
a conventional incandescent tail / brake lamp. LED
lights require a regulated current supply to prevent
damage, so a current regulation circuit is incorporated
inside the tail lamp unit. Direct 12 volt battery power
can be applied directly to the brake or tail lamp wire
for testing purposes, but polarity MUST be observed
or the LEDs will be permanently damaged.
Tail / Brake Light Power Supply:
When the motorcycle is powered ON, battery voltage
is delivered to the TAlL / BRAKE LEDs on the BN / PINK
wire from the Headlight Relay. Current through each
TAlL LED (WHITE wire) is limited (inside tail lamp
unit) to approximately 260 mA.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.52 ·· · · Polaris Industries Inc.
ELECTRICAL
10
TURN SIGNAL/ HAZARD SYSTEM SERVICE 2. Remove screw G) and nut CD to remove turn signal
TURN SIGNAL OPERATION from front fork.
Turn Signal Auto Cancel Functionality
Verify function of the following components for correct
turn signal operation.
Q Turn Signal Switch
e Hazard Flasher Switch
• Vehicle Speed Sensor
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.54 · · Polaris Industries Inc.
ELECTRICAL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
, .. ..,.: . Polaris Industries Inc.
10.55
- ELECTRICAL
INSTRUMENTATION
INSTRUMENT CLUSTER
The instrument cluster includes the speedometer, indicator lamps and Multi-Function Display (MFD).
2015-16 2017
• G) Speedometer
• @ Indicator Lights
• ® Multi-Function Display (MFD)
For detailed information regarding MODE selection and Multi-Function Display operation refer to the Owner's
Manual.
Indicator Lights
LIGHT INDICATES CONDITiON MODEL
YEAR
The turn signal indicator flashes when the left,
right, or both turn signals (hazard) are active. If
Turn Signal (2015-16)
there is a problem in the signal system, the lamps
will flash at twice the normal rate.
This lamp illuminates when battery voltage is low.
Low Battery Voltage / Turn non-essential accessories off to conserve
Charge Status power. Make sure the charging system is
operating properly.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.56 · · - Polaris Industries Inc.
ELECTRICAL
2015-17
The light will remain on if the tilt sensor shuts
down the engine. If abnormal sensor or engine
Check Engine operation is detected the light will remain on as
long as the fault condition exists. Retrieve the
error codes for diagnosis.
Units with ABS ONLY: The indicator remains on
until the anti-lock system activates, which occurs
Anti-Lock Brakes NOT when vehicle speed exceeds 6 MPH (10 km/h).
Activated When the lamp is illuminated, the anti-lock brakes
will not activate, but the conventional brake
system will continue to operate normally.
When metric mode is selected, speed displays in
Km/h Vehicle Speed Units
kilometers per hour.
When standard mode is selected, speed displays
MPH Vehicle Speed Units
in miles per hour.
The turn signal indicator flashes when the left turn
signal (hazard) is active. If there is a problem in the
Left Turn Signal signal system, the lamps will flash at twice the
normal rate.
9927619 R02 - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
- Polaris Industries Inc. 10.57
ELECTRICAL
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 MFD and t9 change settings in the display. The LH mode switch CD is located on
the backside of the LH switch cube.
MODES AVAILABLE
Odometer Engine Speed
Trip Odometer 1 Clock
Trip Odometer 2 DC Voltage
Gear Indicator
Odometer
The odometer displays total distance traveled.
Trip Odometers
The trip odometers (Trip 1 and Trip 2) display total distance traveled since being reset. To reset a trip odometer,
toggle to the trip odometer, then press and hold the LEFT-TOGGLE switch until the trip odometer resets to zero.
Engine Speed
Engine Speed displays in revolution per minute (RPM).
DC Voltage
The volt meter displays battery voltage. If the engine is not running, approximate battery voltage displays. If the
engine is running, approximate charging voltage displays.
Gear Position
Gear position displays at all times while the engine is running, unless a fault occurs with the gear position sensor.
9927619 R02 - 2015 - 17 Indian Motorcycle Scou.t / Scout Sixty Service Manual
10.58 .• Polaris Industries Inc.
ELECTRICAL
9927619 R02 - 2016 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
· · . Polaris Industries Inc. 10.59
- ELECTRICAL
SWITCH TESTING 6. Locate the rear brake light switch connector G).
BRAKE LIGHT SWITCH TEST
1. Place the motorcycle in an upright position with
front wheel clamped in a wheel vise.
2. Locate the brake light switch connector CD on the
right control and disconnect.
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.60 · · Polaris Industries Inc.
ELECTRICAL
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
; Polaris Industries Inc. 10.61
- ELECTRICAL
~
40A
Main
Fuse
a
Battery 111m RD
Start DG/WH===~!=====
Solenoid BK ---l!lllllllllillllr,Ul!lllilll_ __
Starter~
DB/YE 8 LH
Control
BK~
---BK:WH f'l
Ir
RD/BK P2
RH
BVJWH
YE/WH ·· P4
P3
. Control
BK/WH PS
:0:_. -----
• GSS
Top
View kd-~
RD/BK. lli!lilli!fill_iitlilil_ _ _ _M
ECM1
ECM2
YE/WH =·::~==~~-
os1YE
· - ~ YEIWH ·· P1
P2
=
· .::;·: -~; ImrnR I Module
load In
·.
~:::====:=::::tl:::::f ~~-OG/WH~g
~ll!@!!l--il!i8 PVJBK P7
1=::H==n====== DB/YE . P2
l.:::z::=z=:::==::;:::z; Yl:/WH : Pl
(Q)
V"
Chassis
Ground
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
10.62 Polaris Industries Inc.
ELECTRICAL
Engine r ~ TMAP
Relay ~Sensor
T
Rear
Injector
Front
Coil
Ignition mm:_____ _
_
- SHLD
RCIU
BK
SHLD
2
3
fji]CPS
·c r·m
Coile a
R fl::_
lJwH
·
3 -~
Ignition
GY
Top
View
= ECMl
.l. WH
::
ECM2
Ignition WH
Switch ECM2
Fuse Box
.---------------·
I I
I
-----l!IIIRD
I
1 Fuel Pump
: Relay
I VT/BK --11!1!111111 -----if!i!ijOGJBN ·. 19
I
I
I
I
I
========iz BK/BU
111111------111111111111111111111 BK
·
I
I
I
I
t I
I _______ ·- _______ I
.l.
Fuel Pump Chassis
Fuse Ground
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
Polaris Industries Inc. 10.63
ELECTRICAL
Throttle
Body ETC Grip
WH/BK
PIN FUNCTIQr" FUNCTION
1
2
ETC MOTOR /..
TPS SIGNAL RETURN
. . ibWH/RD . P6 PEDAL POSITION SENSOR 2 SIGNAL
PEDAL POSITION SENSOR 2 RETURN
TPS +3.3V REFERENCE
ETC MOTOR 1+1
~ PEDAL POSJTON S<'NSOR 2 +5V SUPPLY
PED.AL POSITION SENSOR 1 SIGNAL
l P5 PEDAL POSITION SENSOR 1 .. RETURN
j PS PPS 1 +5\1 REFERENCE
I
1
Cl O kl.I
~ ~ 8~ a.
10 :0 ' ; ~
ECM2
r
ECM, ECM 1
Top View
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
10.64 Polaris Industries Inc.
2015-2017 SCOUT HARNESS-CHASSIS,SCHEMATIC
1<c•swrn:,.. .,001,w.cvcccs~c
NOmswrn::J,!NORW.u:tOl'EI<
REAR 02
1·:1C'AA:§li'";ii,:;f~fO=;~,,d -
FRONT lNJECTOR
1·:·i ,:"'""':::'~~;:;,._., I
REA.R INJECTOR
I''" I;.'. ':, ru, ruec= .",':;',;:', I
FUEL PUMPJ
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ABS_FWSS
w= CH~SS1S6ROUNO
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Starting Circuit
-Scout
0
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~
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Main
Fuse
B
0
"'
I
Battery RD
Start
Solenoid
B IRRRRR I
"'
;·:,Y DB/YE
L:JL".Jl.'.'JL:Jl.'.'J LH
Control
Bl<!WH Pl
RD/BK P2
BK/WH
YE/WH
P3
P4
I ffiTo RH
Control
BK/WH PS
Ignition
Switch
Top
View
ECM 1
DB/YE
··"fJ e GSS
ITT WH/YE
RD/BK
-·,~--=~8
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0880 \ Load
oooo Module In
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ft::::=:=:::=:=:::=:::=:=:::=::=:nn~
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DB/YE ~ P2 I
YE/WH •· Pl
t/
Chassis
Ground
Engine Ignition
-Scout
~
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l.JwH/GY
Engine TMAP
Relay BN/PK 3 Sensor
'f OG/BN . 4
"'
~
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Injector [J::: -·-"'"
Front
Coil
Ignition
m8 1
3
::
WH
-------~
- SHLD
~ RDLl~
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SHLD
2
3
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Re~r
(011
Ignition
m 81 ::
3 WH ::::::::::::::::::;::;::.,~
- GY ~42
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0
0
00
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gg g g
00 0 0
00 O O
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15
,2'
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WH 54
ECM2
D ECM2
Switch
WH/GY
M
--
WH/DB
Fuse Box
r---------------1 BN/PK
I
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I OG/DG
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VT/YE
"T
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I VT/BK OG/BN 19
I
I BK/BU 6
I
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I
I
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----------------
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Fuel Pump Chassis
Fuse Ground
Engine Throttle Control
-Scout
!Mil l""° rM
VT/RD J YE/BK
Throttle
Body 6
BN/WH
; II 11 11
WH/GN
WH/BK
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Top View
Inspection ............................................................ 8.15
ABS Module, Replacement ....................·..................... 9 .19
ABS System
Special Tools ......................................................... 9.4
Air Box Balance Shaft
Assembly View ..................................................... 4.10 Assembly View ..................................................... 6 .16
Installation ............................................................ 3.5 Installation ........................................................... 6 .18
Removal. ............................................................... 3.4 Removal ............................................................... 6.18
Air Filter Service Specifications ............................................. 6 .4
Replacement ......................................................... 2.9 Special Tools ......................................................... 6.3
Assembly View Battery
Air Box ................................................................ 4.10 Current Drain Test ............................................... 10.27
Balance Shaft ........................................................ 6 .16 Inspection ................................................... 2.33, 10.14
Battery ............................................................... 10.11 Installation .................................................. 2.35, 10.12
Brake Line Routing .................................................. 9. 7 Load Test ........................................................... 10.20
Clutch .................................................................. 5.6 Maintenance ......................................................... 2.32
Clutch Pinion Shaft. ................................................. 5.5 Removal ...................................................... 2.34, 10.12
Controls ................................................................ 8.5 Safety Precautions ................................................. 10.4
Cooling System ..................................................... 3.18
Cooling System Hoses ............................................ 2.15
Crankcase ............................................................. 6. 7
~~:~r:;::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::·i~:f!
Battery Box
Crankshaft ........................................................... 6.10 Assembly View ................................................... 10.11
~:;~!~~-::::::::::::::::::::::::::::::::::::::::::::::::::::::.s'_44~~::~
Engine Removal ..................................................... 3.8
Installation ......................................................... 10.13
Removal ............................................................. 10.13
Battery, In Service
Exhaust ................................................................ 3.91 Charging .................................................... 2.33, 10.14
Fenders ................................................................ 7.3 Battery, New
;~~l~ ~~~~.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~:~ Charging .................................................... 2.33, 10.14
Bearing Clearance Inspection .................................... 6.30
Frame ................................................................... 7.4 Bearing Selection
Front Brake ............................................................ 9.5 Connecting Rod .................................................... 6.31
Front Caliper ................................................ 9.10, 9.12 Belt
Front Wheel ......................................................... 8.11
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc. IX.I
Replacement ............................................. ... 9.24-9.25 C
Brake Pads, Rear
Replacement ............................................. . :. 9.26-9.27 Caliper, Front
Brake Pedal Assembly View ............................................. 9.10 9.12
Inspection ............................................. ............... 2.22 Installation ............................................. ............ .'. 9 .34
Lubrication ............................................. .............. 2 .22 Rebuilding ............................................. ...... 9.31-9.32
Brake System Removal. ............................................. ......... 9.31-9.32
ABS Brake Fluid Change ......................................... 9.21 Caliper, Rear
ABS General Information ........................................ 9 .15 Assembly View ............................................. 9.11, 9.13
ABS Module Replacement ....................................... 9 .19 Rebuilding ............................................. ...... 9.36-9.37
ABS Module, Assembly View ................................... 9.14 Removal ............................................. .......... 9.36-9.37
ABS System Safety Precautions ................................ 9.15 Carn Chain
Bleeding ............................................. ......... 9.21-9.22 Installation ............................................. .............. 3 .53
Disc, Inspection ............................................. ....... 9.28 Removal. .............................................. ................. 3 .53
Front Brake Pads Replacement ........................ 9.24-9.25 Service Notes ............................................. .......... 3.49
Front Caliper Installation ........................................ 9.34 Carn Chain Guide, Lower
Front Caliper Service ..................................... 9 .31-9 .32 Installation ............................................. .............. 3 .55
Front Master Cylinder Service ................................. 9.29 Removal. ........................... _................................... 3.53
Lever Reserve Inspection ........................................ 9.23 Carn Chain Guide, Upper
Precautions ............................................. ............. 9.20 Installation ............................................. .............. 3 .59
Rear Brake Pads Replacement ......................... 9.26-9.27 Removal ............................................. .................. 3.49
Rear Caliper Service ...................................... 9.36-9.37 Cam Chain Tensioner
Rear Master Cylinder Service .................................. 9.34 Inspection ............................................. ............... 3 .50
Service Notes ............................................. ........... 9 .3 Installation ............................................. .............. 3 .59
Service Specifications ............................................. 9.4 Removal ............................................. .................. 3.49
Special Tools ............................................. ............ 9.4 Cam Chains
Troubleshooting ............................................. ....... 9 .39 Assembly View ............................................. ........ 3.44
Vacuum Bleeder ............................................. ....... 9 .21 Carn Drive Shaft
Wheel Speed Sensor Adjustment (Air Gap) ............... 9.18 Installation ............................................. ...... 3.54-3.55
Wheel Speed Sensor Replacement ........................... 9 .17 Removal. ............................................. ................. 3.52
Brake System, Bleeding Carn Tirning ............................................. ................ 3.57
Front Brakes ............................................. ............ 9.22 Camshaft
Rear Brakes ............................................. ............. 9.21 Inspection ............................................. ............... 3.63
Brake System, Front Sprocket Removal. ............................................. .... 3 .50
Disc Removal/ Installation ...................................... 8.16 Timing ............................................. .................... 3.47
Brake System, Front Brake Camshaft Drive Sprocket
Assembly View ............................................. ......... 9 .5 Installation ............................................. .............. 3 .55
Brake System, Front Caliper Camshaft Sprocket
AssernblyView ............................................. 9.10, 9.12 Installation ............................................. .............. 3.57
Brake System, Line Routing Timing ............................................. .................... 3.57
Assembly View ............................................. ......... 9. 7 Camshaft, Drive Sprocket
Brake System, Rear Carn Drive Shaft
Disc Removal/ Installation ...................................... 8.48 Removal. ......,. ............................................. ....... 3 .51
Brake System, Rear Brake Rernoval ............................................. .................. 3.51
Assembly View ............................................. ......... 9.6 Camshafts
Brake System, Rear Caliper Assembly View ............................................. ........ 3. 45
Assembly View ............................................. 9.11, 9.13 Charcoal Canister ............................................. ....... 2.28
Brake System, Rear Master Cylinder Charging System
Assembly View ............................................. ......... 9.9 Output Test. ............................................. ........... 10.27
Brakes Service Notes ............................................. .......... 10.4
Brake Pedal, Inspection .......................................... 2.22 Service Specifications ............................................ 10.6
Brake Pedal, Lubrication ......................................... 2.22 Special Tools ............................................. ........... 10.5
Fluid Level Inspection ............................................ 2 .25 Troubleshooting ............................................. ..... 1O.26
Front Brake Lever, Inspection .................................. 2 .21 Checking Oil Level ............................................. ...... 2 .1 o
Front Brake Lever, Lubrication ................................. 2 .21 Clutch
Brakes, Front Assembly ............................................. ................ 5 .1 7
Brake Pad Inspection ............................................. 2.26 Assembly View ............................................. ......... 5. 6
Brakes, Rear Disassembly ............................................. ............ 5 .14
Brake Pad Inspection ............................................. 2.27 Inspection ............................................. ............... 5 .16
Braking System Installation .......................... .'................................ 5 .19
ABS Overview of Operation ..................................... 9.16 Pinion Shaft Bearing Inspection ................................. 5.8
ABS System Components ........................................ 9 .16 Pinion Shaft Seal Replacement .................................. 5.9
Break-In, Engine ............................................. .......... 2.8 Rack, Removal/ Installation .................................... 5 .13
Breather Removal ............................................. .................. 5.13
Inspection ............................................. ............... 2.27 Service Notes ............................................. ........... 5.2
Service Specifications ............................................. 5.2
9927619 R02 - 201 S - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
IX.2 · Polaris Industries Inc.
Special Tools ......................................................... 5.2 Crankcase Emission Control ...................................... 1.12
Troubleshooting .................................................... 5.24 Crankcase Ventilation
Clutch Cable · Inspection ............................................................ 2.27
Lubrication ........................................................... 2.19 Crankcase, Left Side
Removal/ Installation ............................................. 8.13 Assembly ............................................................. 6.36
Clutch Lever Crankcase, Right Side
Free Play Adjustment ............................................. 2.20 Assembly ............................................................. 6.37
Lubrication ........................................................... 2.20 Crankshaft
Clutch Pinion Shaft Asse1nbly View ..................................................... 6. 10
Assembly View ...................................................... 5.5 Cleaning .............................................................. 6.35
Clutch Rack Inspection ............................................................ 6.34
Removal/ Installation ............................................. 5.13 Installation ........................................................... 6.37
Clutch Switch Locking for Service ........ .'.. , ..................................... 6.6
Circuit Test ......................................................... 10.22 Main Bearing Inspection ..... ; ................................... 6.35
Removal/ Installation ........................................... 10.23 Main Bearing Oil Clearance .................................... 6.36
Test ................................................................... 10.61 Removal ............................................................... 6.27
Clutch, Pinion Shaft Service Notes ........................................................ 6.3
Installation ............................................................ 5.9 Service Specifications ............................................. 6.4
Removal. ............................................................... 5.8 Special Tools ......................................................... 6 .3
Coil, Ignition Troubleshooting .................................................... 6.42
Removal/ Installation ........................................... 10.35 Crankshaft Position Sensor
Compression Test Test/ Replace ................................... , ................... 4.38
Engine ................................................................. 2.31 Crankshaft Position Sensor (CPS) Resistance
Compression Test (Wet) Inspection ........................................................... 10.40
Engine ................................................................. 2.32 Current Drain
Connecting Rod Testing .......... , ................................................... 10.27
Bearing Clearance Inspection ................................. 6.30 Cylinder
Bearing Inspection .................... ., .......................... 6.30 Assembly View ..................................................... 3.80
Bearing Selection .................................................. 6.31 Bore Measurement ................................................. 3.82
Inspection .................................................... 3.86, 6.28 Inspection ............................................................ 3.82
Installation ........................................................... 6 .35 Installation ......................................... , ................. 3.88
Removal. ............................................................. ,6.28 Misfire ................................................................. 4.40
Side Clearance ..................................................... 6.28 Removal ............................................................... 3 .82
Connecting Rod, Big End Service Notes ....................................................... 3.78
Inspection .............................................. " ...... °' •••• 6.29 Service Specifications ............................................ 3.79
Connecting Rods Special Tools ........................................................ 3..JS 1
9927619 R02 - 2015 ~ 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
Polaris Industries Inc. IX.3
Guided Diagnostics ............................................. .. 4.41 Locking the Crankshaft.. .......................................... 6.6
Overview ·············································· ···:···········4.41 Oil / Filter Change ............................................. .... 2 .11
Serial Number Location .......................................... 4.42 Timing ............................................. .................... 3.47
Update Information ............................................. ... 4. 41 Engine Break-In Procedure ......................................... 2.8
Update Process ............................................. ........ 4.42 Engine Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Version Updates ............................................. ....... 4.42 · Engine Removal
Discs, Brake Assembly View ............................................. ......... 3.8
Inspection ............................................. ............... 9 .28 Preliminary Steps ............................................. ...... 3.9
Drill Sizes Removing Engine from Frame ................................. 3.11
Metric ............................................. .................... 1.22 Service Notes ............................................. ........... 3.6
SAE ............................................. ........................ 1.22 Service Specifications ............................................. 3.7
Drive Belt Special Tools ............................................. ............ 3.7
Adjustment. ............................................. ............. 2.38 EVAP ............................................. ......................... 1.12
Alignment ............................................. ............... 2.38 EVAP System ............................................. .............. 2 .28
Inspection ............................................. ............... 2.35 Evaporative Emissions Control ................................... 1.12
Installation ............................................. .............. 8.38 Evaporative Emissions System .................................... 2 .28
Removal. ............................................. ................. 8.38 Evaporative System
Specifications ............................................. .......... 2.36 Line Routing, 49 State ............................................. . 4.6
Tension Measurement ............................................ 2.36 Line Routing, CA ............................................. ....... 4.7
Tension Specifications ............................................ 2.37 Exhaust
Drive Gear Assembly View ............................................. ........ 3 .91
Inspection ............................................. ............... 6.20 Head Pipe, Removal. ............................................. . 3.94
Drive Sprocket Iv'Iuffler Removal ............................................. ....... 3.92
Inspection ............................................. ............... 8.41 Muffler, Installation ............................................. ... 3.93
Installation ............................................. .............. 8.42 Exhaust Emission Control .......................................... 1.11
Removal. ............................................. ................. 8.39 Exhaust Valve Lash-Tappet Selection Matrix ................ 3.75
Drive Sprocket, Cover
Removal/ Installation ............................................. 8.39
Driven Sprocket
Inspection ............................................. ............... 8.43
F
Installation ............................................. .............. 8. 44 Fault Codes ............................................. ................ 4.27
Removal. ............................................. ................. 8. 43 Fender, Front
Installation ............................................. ............... 7 .9
Removal ............................................. ................... 7.9
E Fender, Rear
Installation ............................................. .............. 7 .10
ECM Removal ............................................. .................. 7 .10
Connector Map ............................................. ........ 4.25 Fenders
Connectors ............................................. ............. 4.34 Assembly View ............................................. ......... 7 .3
Disconnect ............................................. .............. 4.34 Final Drive
Pinout Chart ............................................. ............ 4.2S Troubleshooting .............................................. .....·. 8.56
Pinout Testing ............................................. .......... 4.33 Flywheel
Reflash Procedure ............................................. .... 4.45 Installation ............................................... .............. 5.23
Removal/ Installation ............................................. 4.34 Removal ............................................. .................. 5.22
ECM Connector Map ............................................. . 10.37 Foot Pegs
ECM Replacement Information ................................... 4.41 Assembly View ............................................. ......... 7 .5
EFI Foot Pegs, Driver
Service Notes ............................................. ........... 4.3 Installation ............................................. ............... 7 .6
Service Precautions ............................................. ... 4.5 Removal ............................................. ................... 7 .6
Service Specifications ......... ~ ................................... 4.4 FootPegs,Passenger
Special Tools ............................................. ............ 4.4 Installation ............................................. ............... 7. 7
Electrical System Removal ............................................. ................... 7. 7
Service Notes ............................................. ........ 10.41 Fork
Special Tools ............................................. ......... 10.41 Assembly ............................................. ................ 8.23
Electronic Fuel Injection (EFI) Assembly View ............................................. ......... 8.9
Sensor Locations ............................................. ...... 4.11 Disassembly ............................................. ............ 8.19
Electronic Throttle Control Module Installation ............................................. .............. 8.26
Removal. ......... ·............................................. ........ 4.39 Removal ............................................. .................. 8.17
Emission Control Systems .......................................... 1.11 Frame
Emission Sources ............................................. ........ 1.11 Assembly View ............................................. ......... 7. 4
Engine Removal / Installation ............................................. 7 .12
Assembly View ............................................. 3.44-3.46 Service Notes ............................................. ........... 7 .2
Compression Test. ............................................. .... 2.31 Special Tools ............................................. ............ 7 .2
Compression Test (Wet) ......................................... 2.32 Front Axle
Installation ............................................. .............. 3.12 Inspection ............................................. ............... 8.15
Limiting / Misfire ............................................. ...... 4.40 Front Brake
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
IX.4 Polaris Industries Inc.
Assembly View ...................................................... 9.5
Front Fork
Inspection ...................................... : ..................... 8.22 Gear Position Switch
Front Wheel Neutral Indicator Test. .......................................... 10.21
Assembly View .................... ·................................. 8.11 Test ................................................................... 10.61
Bearing Inspection ................................................ 8.16 Gear Ratios .............................................................. 6.4
Inspection ............................................................ 8.15 Gross Vehicle Weight Rating (GVWR) ........................... 1. 7
Removal/ Installation ............................................. 8.14 Guided Diagnostics .................................................. 4.41
Front Wheel & Suspension
Troubleshooting .................................................... 8.31
Front Wheell H
Bearing Replacement ............................................. 8.17
Fuel Filter Handlebar
Replacement ........................................................ 4.16 Assembly View ...................... _................................ 8. 7
Fuel Injection Removal I Installation ............................................. 8.12
Overview of Operation ........................................... 4.24 Head Light
Fuel Injector Assembly View ................................................... 10.42
Removal/ Installation ............................................. 4.37 Bulb Replacement ............................................... 10.50
Resistance Test ..................................................... 4.3'1 Head Pipe ............................................................... 3.94
Fuel Level Sensor Exhaust
Resistance Test ....................................... -. ............. 4.20 Head Pipe, Installation ........................................ 3.95
Fuel Line Installation ........................................................... 3.95
Routing, 49 State ..................................................... 4.6 Headlight
Routing, CA ................................................ ., ......... 4.7 Aim Adjustment .................................................... 2.42
Fuel Pressure Aim Inspection ...................................................... 2.41
Inspection ................................................... , ........ 4 .12 Horn
Specification ......................................................... 4.12 Removal/ Installation ........................................... 10.51
Test ..................................................................... 4.12
Fuel Pump
Current Draw Test ................................................. 4.22
Installation ........................................................... 4.17
Pressure Test ........................................................ 4.12 Idle Speed
Adjustment. .......................................................... 2.18
Removal. .............................................................. 4 .15
Supply Voltage Test ............................................... 4.21 Ignition Coil
FuelRail Power and Ground Signal Test ............................... 10.39
Removal/ Installation ........................................... 10.35
Removal/ Installation ............................................. 4.37
Fuel System Resistance Test ................................................... I0'.40
Assembly View ...................................................... 4.8 Ignition Cover
Depressurization ................................................... 4.13 Removal and Installation ......................................... 7. f 1
Ignition System , '"'
EFI Overview ........................................................ 4.24
Service Notes ..................................................... 10.34
Inspection ............................................................ 2.29
Service Specifications .......................................... 10:34
Line Routing, 49 State .............................................. 4.6
Line Routing, CA .................................................... 4.7 Special Tools ...................................................... 10.34
Test 1: Battery Voltage Inspection ........................... 10.38
Priming ............................................................... 4.23
Test 2: Spark ....................................................... 10.38
Service Notes ..... ,, .................................................. 4.3
Test 3: Ignition Coil Power and Ground Signal .......... 10.39
Service Precautions ................................................ 4.5
Service Specifications ............................................. 4.4 Test 4: Ignition Coil Resistance .............................. 10.40
Special Tools ......................................................... 4.4 Test Flowchart ..................................................... 10.37
Troubleshooting .................................................... 4.49 Testing Precautions .............................................. 10.36
Fuel Tank Troubleshooting Basics ........................................ 10.36
Assembly View ...................................................... 4.9 Inspection ................................................ , .............. 8.46
Installation ; .......................................................... 4 .19 Fuel Supply .......................................................... 2.29
Instrument Cluster
Mounting .............................................................. 4.9
Removal. .............................................................. 4 .14 Overview ........................................................... 10.56
Removal I Installation ............. , ............................. 1O.59
Vent Inspection (49 State) ....................................... 2.28
Vent Inspection (CA) .............................................. 2.28 Instrument Panel
Fuse Box Removal I Installation ............................................. 7.11
Assembly View ................................................... 10.44 Intake Manifold
Fuse Application Chart ......................................... 10.46 Removal I Installation ............................................. 4.12
Intake Valve Clearance·-Tappet Selection Matrix .......... 3.74
Location ............................................................... 2.40
Locations ........................................................... 10.45
Fuses
Location ............................................................... 2.40 L
Replacement ........................................................ 2.40
License Plate Light
Assembly View ................................................... 10.43
99~7619 R02_ - 2016 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
· Polaris Industries Inc. IX.5
Removal/ Installation ........................................... 10.62 Output Shaft Seal
Load / Tip Over Module . Replacement ........................................................ 8.42
Connector Map ................................................... 10.48
Load / Tipover Module .............................................. 4.39
Load/Tip Over Module p
Removal/ Installation ........................................... 10.49
Lubricants ................................................................ 2.6 P-Codes .................................................................. 4.27
Paint
Color, By Model .. . . .. . .. .. .. . . . .. .. . .. . . .. .. . .. . .. . .. . .. . .. .. . . .. .. . 1.9
M PCVSystem
Inspection ............................................................ 2.27
Main Bearing Pinion Shaft, Clutch
Inspection ............................................................ 6.35 Bearing Inspection ................................................. 6.8
Oil Clearance Inspection ........................................ 6.36 Installation ....................................... :; ................... 6.9
Maintenance Removal ................................................................ 6.8
Engine Breal(:-In Procedure ...................................... 2 .8 Seal Replacement ................................................... 6.9
Service Notes ........................................................ 2.8 Piston
Special Tools ......................................................... 2.8 Assembly View ......................................... '. ........... 3 .80
Table .................................................................... 2.6 Clearance Worksheet. ............................................ 3 .83
Maintenance, Specifications ........................................ 2.3 Inspection ............................................................ 3.86
Manufacturer Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Installation ........................................................... 3.87
Master Cylinder, Front Profile & Orientation .............................................. 3.81
Rebuilding ........................................................... 9. 29 Removal ............................................................... 3.84
Removal. .............................................................. 9 .29 Service Notes ....................................................... 3.78
Master Cylinder, Rear Service Specifications ............................................ 3.79
Assembly View ...................................................... 9 .9 Special Tools ........................................................ 3.78
Rebuilding ........................................................... 9 .34 Piston Pin
Removal. .............................................................. 9 .34 Inspection ............................................................ 3.86
Master Torque Table .............. ·................................... 1.18 Piston Ring
Misfire Detection ...................................................... 4.40 Inspection ............................................................ 3.86
Model Number Designation ........................................ 1.2 Installation ........................................................... 3.87
Model Number Location ............................................. 1.3 Profile & Orientation .............................................. 3.81
Muffler Removal.., ............................................................ 3.84
Installation ........................................................... 3.93 Pressure Oil Pump
Removal. .............................................................. 3.92 Installation ........................................................... 3 .28
Removal. .............................................................. 3.27
Primary Cover
N Assembly View ...................................................... 6.3
Primary Drive
Noise Emission Control ............................................. 1.1 l Service Notes ........................................................ 6.2
Service Specifications ............................................. 6.2
Special Tools ......................................................... 6.2
0 Troubleshooting .................................................... 6.24
Primary Drive Cover ·
Oil Change Installation ............................................................ 6. 7
Checking Oil Level ................................................ 2 .10 Removal ................................................................ 5.7
Oil Change Procedure ............................................... 2.11 Priming the Fuel System ............................................ 4.23
Oil Cooler Publication Part Numbers ........................................... 1.8
Inspection ............................................................ 3.30
Installation ........................................................... 3.30
Removal. .............................................................. 3.30
Oil Level
R
Check ................................................................. 2.10 Radiator
Oil Pressure Sensor Installation ........................................................... 3 .36
Test ..................................................................... 3.25 Removal ............................................................... 3.35
Oil Pump Radiator Inspection/ Cleaning ................................... 2.16
Assembly View ..................................................... 3.21 Rear Axle
Oiling System Inspection ............................................................ 8.46
Assembly View ..................................................... 3.21 Rear Brake
Cooling System ..................................................... 3.16 Assembly View ...................................................... 9 .6
Oil Flow Diagram .................................................. 3.24 Rear Sprocket
Oil Pressure Test ................................................... 3.26 Inspection ............................................................ 8.43
Service Notes ....................................................... 3.16 Installation ........................................................... 8.44
Service Specifications ............................................ 3.16 Removal. .............................................................. 8.43
Special Tools ........................................................ 3.16 Rear Wheel
Troubleshooting .................................................... 3 .16 Assembly View ..................................................... 8.37
9927619 R02 - 2015 - 17 Indian Motorcycle Scout I Scout Sixty Service Manual
IX.6 · Polaris Industries Inc.
Bearing Inspection ................................................ 8.47 Crankshaft ............................................................ 6.4
Bearing Replacement ............................................. 8.4 7 Cylinder .............................................................. 3.79
Inspection ..................................... : ...................... 8.46 Cylinder Head/ Valves .......................................... 3.42
Removal/ Installation ............................................. 8.45 EFI ....................................................................... 4.4
Rear Wheel and Suspension Engine Removal ..................................................... 3.7
Assembly View ..................... , ..................... , ......... 8.35 Front Suspension .................................................... 8.4
Special Tools ....................................... , ................ 8.33 Front Wheel .......................................................... 8.4
Reflash Authorization ................................................ 4.45 Fuel System ........................................................... 4.4
Regulated Voltage Test ............................................ 10.27 Ignition System ................................................... 10.34
Regulator / Rectifier Oiling System ....................................................... 3.16
Assembly View ................................................... 10 .10 Piston .................................................................. 3.79
Connector Inspection ........................................... 10.32 Primary Drive ........................................................ 5.2
Diode Leakage Test ............................................. 10.33 Rear Suspension .................................................... 8.34
Replacement ...................................................... 10.33 Rear Wheel .......................... ·................................ 8.34
Regulator/ Rectifier, Bracket Starting System ..................................................... 10.6
Replacement ...................................................... 10.33 Tires .................................................................... 8.57
Ride Height Wheels ................................................................ 8.57
Adjustment ........................................................... 2.46 Shift Arm
Inspection ............................................................ 2.45 Removal/Installation .............................................. 5. 12
Rings Shift Drum
End Gap Measurement ........................................... 3.85 Assembly View ..................................................... 6 .15
Installation ........................................................... 3.87 Inspection ............................................................ 6.25
Profile & Orientation .............................................. 3.81 Removal ............................................................... 6.24
Removal ............................................................... 3 .84 Shift Fork
Assembly View ..................................................... 6.15
Removal. .............................................................. 6.24
s Shift Pedal
Adjustment. .......................................................... 2.24
Scavenge Oil Pump Inspection ............................................................ 2.24
Installation ................................ , .......................... 3. 2 7 Shift Ratchet
Removal. .............................................................. 3.26 Inspection ............................................................. 5.9
Seat Installation ........................................................... 5.11
Removal/ Installation .............................................. 7 .8 Removal ................................................................ 5.9
Sensor Diagnostics ................................... , . ;............. 4.33 Shift Shaft Seal
Sensors Replacement ........................................................ 5.12
Location ............................................................... 4.11 Shifting ..
Service Notes Troubleshooting .................................................... 5.24
Body .................................................................... 7.2 Shock Absorber ·t
Brake System ......................................................... 9 .3 Inspection ............................................................ 8149
Clutch .................................................................. 5.2 Installation ........................................................... s:5·0
Crankshaft ............................................................ 6.3 Removal ............................................................... 8. 48
Cylinder .............................................................. 3.78 Shock, Rear
Cylinder Head/ Valve Train .................................... 3.41 PreloadAdjustment ............................................... 2.46
EFI ....................................................................... 4.3 Preload Inspection ................................................. 2.45
Electrical System ................................................. 10.41 Side Stand Switch
Engine· Removal ..................................................... 3.6 Test ................................................................... 10.61
Front Suspension .................................................... 8.3 Side-stand
Front Wheel .......................................................... 8.3 Inspection ............................................................ 2.42
Fuel System ........................................................... 4.3 Lubrication ........................................................... 2.43
Ignition System ...................... ;............................ 10.34 Removal/ Installation ............................................. 2.43
Maintenance .......................................................... 2.8 Spark Plug
Oiling System ....................................................... 3.15 Gap ..................................................................... 2.30
Piston .................................................................. 3.78 Inspection ............................................................ 2.30
Primary Drive ........................................................ 5.2 Installation ........................................................... 2.30
Rear Suspension .................................................... 8.33 Removal ............................................................... 2.29
Rear Wheel .......................................................... 8.33 Special Tools ........................................................... 1.15
Starting System ..................................................... 10.4 ABS System ........................................................... 9.4
Tires .................................................................... 8.57 Balance Shaft ......................................................... 6.3
Transmission ......................................................... 6.3 Body .................................................................... 7.2
Wheels ................................................................ 8.57 Brake System ......................... .'............................... 9.4
Service Specifications ............................................... 8.5 7 By System ............................................................ 1.13
Balance Shaft ......................................................... 6.4 Charging System ................................................... 10.5
Brake System ......................................................... 9.4 Clutch .................................................................. 5.2
Charging System ................................................... 10.6 Crankshaft ............................................................ 6.3
Clutch .................................................................. 5.2 Cylinder .............................................................. 3.78
Connecting Rods .................................................... 6.4 Cylinder Head/ Valves .......................................... 3.42
9927619 R02 - 2015 - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
· · Polaris Industries Inc. IX.7
EFI ........................................................... ~ ........... 4.4 Removal. .............................................................. 5.21
Electrical System ........................................ :···· .... 10.41 Steering Head
Engine Removal ..................................................... 3.7 Bearing Adjustment ............................................... 8.29
Frame ................................................................... 7.2 Bearing Inspection ................................................ 2.44
Front Suspension .................................................... 8.3 Storage
Front Wheel .......................................................... 8.3 Battery ................................................................. 2.34
Fuel System ........................................................... 4.4 Suspension, Front
Ignition System ................................................... 10.34 Assembly View ...................................................... 8.9
Locating ............................................................... 1.13 Fork Assembly ...................................................... 8.23
Maintenance .......................................................... 2.8 Fork Installation .................................................... 8.26
Oiling System ....................................................... 3.15 Fork Removal. ....................................................... 8.17
Ordering Information ............................................. 1.14 Service Notes ........................................................ 8.3
Piston .................................................................. 3.78 Service Specifications ............................................. 8.4
Primary Drive ........................................................ 6 .2 Special Tools ............................... :;;-.. ·:.: .................. 8.3
Rear Wheel and Suspension .................................... 8.33 Suspension, Front Fork
Starting System ..................................................... IO .5 Disassembly ......................................................... 8.19
Transmission ......................................................... 6 .3 Suspension, Rear
Specifications ........................................................... 1.4 Service Notes ....................................................... 8.33
Sprocket, Drive Service Specifications ............................................ 8.34
Inspection ............................................................ 8.41 Troubleshooting .................................................... 8.55
Installation ............................... , ........................... 8.42 Swing Arm
Removal. .............................................................. 8.39 Inspection ............................................................ 2.44
Sprocket, Driven Swingarm
Inspection ............................................................ 8.43 Assembly View ..................................................... 8.35
Installation ........................................................... 8.44 Bushing / Bearing Replacement ............................... 8.52
Removal. ................................................. , ............ 8.43 Installation ........................................................... 8.53
Sprocket, Rear Removal. .............................................................. 8.51
Inspection ............................................................ 2.40
Stake Nut
Installation ....................................................... ., .. 6.41 T
Starter
Solenoid, Ground Circuit Test.. .............................. 10.20 Tail Light
Starter Motor Assembly View ................................................... 10.43
Assembly View ................... , .............................. , .. 10 .8 Operation Overview ............................................ 10.52
Current Draw Test ......................................... ; ..... 10.24 Removal/ Installation ........................................... 10.52
Drive Gear Thermostat .............................................................. 3 .39
Installation ........................................................ 6.21 Thermostat Cover
Drive Gear, Removal .............................................. 6.20 Removal / Installation ............................................. 7 .11
Inspection ............................................................ 6.20 Throttle Body
Installation .................................................. 6.21, 10.25 Removal/ Installation ............................................. 4.39
Removal. ............................................................ 10.25 Throttle Control. ..................................................... 10.64
Safety Information ............................................... 10.15 Timing Marks .......................................................... 3.47
Starter Solenoid Tire
Ground Circuit Test ............................................. 10.20 Balancing ............................................................. 8.66
Positive Circuit Test ........................................... ;. 10.24 Changing ............................................................. 8 .61
Starting Circuit Cupping .............................. _................................ 8.60
Starting Circuit Wiring Diagram ............................. 10.62 Removal ............................................................... 8.62
Starting System Repair Precautions ................................................. 8.68
Circuit Operation ................................................ 10.16 Service Specifications ............................................ 8.57
Diagnostic Table ................................................. 10 .15 Tread Wear .......................................................... 8.59
Service Notes ....................................................... 10.4 Troubleshooting .................................................... 8. 71
Service Specifications ............................................ 10.6 Valve Stem ........................................................... 8.69
Special Tools ........................................................ 10.5 Valve Stem, Metal .................................................. 8.69
Troubleshooting .................. , ............................... 10.18 Wear Patterns ............................................... 8.59-8.60
Troubleshooting, No Crank ................................... 10.17 Tire, Metal Valve Stem
Troubleshooting, Starter Drive ............................... l 0.19 Installation ........................................................... 8.69
Wiring Diagram .................................................. 10.16 Tire, Valve Stem
Stator Inspection ............................................................ 8.69
Assembly View ..................................................... 10.9 Tires ....................................................................... 8.64
Ground Continuity Test ........................................ 10.30 Balance Dots ......................................................... 8.64
Installation ......................................................... 10.32 Directional Arrows ................................................. 8.64
Output Test. ........................................................ 10.28 Inflation/ Precautions ............................................ 8.64
Removal. ............................................................ 10.31 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Resistance Test ................................................... 10.29 Inspection ............................................................ 2 .18
Stator Cover Ozone Cracking .................................................... 8.59
Installation ........................................................... 5.21 Pressure ............................................................... 2 .18
9927619 R02 - 2015 - 17 Indian Motorcycle Scout / Scout Sixty Service Manual
IX.8 Polaris Industries Inc.
Service Notes ....................................................... 8.57 Valve Stem, Metal
Size Specifications ................................................. 2 .18 Installation ........................................................... 8.69
Specifications ................................. .'......... , ............ 1.3 Valve Timing ........................................................... 3.57
TMAP Sensor Valve Train
Overview ............................................................. 4.35 Special Tools ........................................................ 3.42
Replacement ........................................................ 4.35 Valves
Tools, Special .......................................................... 1.15 Assembly View ..................................................... 3.46
Torque Specifications Inspection ............................................................ 3.68
Master ................................................................. 1.18 Wear Patterns ....................................................... 3.69
Trademark Information ............................................ , .... 3 Vehicle Identification Number ..................................... 1.2
Transmission Vehicle Model Conversion Process .............................. 4.4 7
Gear Ratios ........................................................... 6.4 VIN Decoder ............................................................ 1.2
Gear Train ............................................................ 6.17 VIN Location............................................................. 1.3
Inspection ............................................................ 6.25 Voltage Output Test ................................................ 10.27
Installation ........................................................... 6.38 Voltage Regulator
Power Flow ........................................................... 6.17 Assembly View ................................................... 10.10
Removal. .............................................................. 6.24
Service Notes ........................................................ 6.3
Special Tools ......................................................... 6 .3
Troubleshooting .................................................... 6.42
w
Transmission, 5 speed Water Pump ............................................................. 3.36
Assembly View ..................................................... 6 .13 Assembly View ................................................... ,. 3.20
Transmission, 6 speed Wheel
Assembly View ..................................................... 6.11 Inspection ............................................................ 8.68
Triple Clamp Troubleshooting .................................................... 8. 71
Assembly View ...................................................... 8.8 Wheel Bearings, Front
Bearing Adjustment ............................................... 8.29 Inspection ............................................................ 2.44
Installation ........................................................... 8.29 Wheel Speed Sensor
Removal. .............................................................. 8.27 Adjustment (Air Gap) ............................................. 9.18
Troubleshooting Replacement ........................................................ 9.17
Brake System ........................................................ 9 .39 Wheel, Front
Crankshaft ........................................................... 6.42 Assembly View ..................................................... 8.11
Final Drive ........................................................... 8.56 Bearing Inspection ................................................ 8.16
Front Wheel & Suspension ...................................... 8.31 Bearing Replacement ............................ , ........ : ....... 8.17
Misfire Detection ................................................... 4.40 Inspection ............................................................ 8 .15
Rear Suspension .................................................... 8.85 Removal I Installation ............................................. 8.'14·
Rear Wheel .......................................................... 8.55 Service Notes ........................................................ 8.'3.
Tire ..................................................................... 8.7 l Service Specifications ......................................... , ... (4
Transmission ........................................................ 6.42 Special Tools ......................................................... 8.,3
Wheel ................................................................. 8.71 Wheel, Rear '
Turn Signal Bearing Inspection ................................................ BA 7
Operation Overview ............................................ 10.64 Bearing Replacement ............................................. 8.47
Turn Signal, Front Inspection .......... , ................................................. 8.46
Removal/ Installation ........................................... 10.54 Removal / Installation ............................................. 8. 45
Turn Signal, Rear Service Notes ....................................................... 8.33
Removal/ Installation ........................................... 10.54 Service Specifications ............................................ 8.34
Troubleshooting .................................................... 8.55
Wheels
V Service Notes ....................................................... 8.57
Service Specifications ............................................ 8.57
Vacuum Bleeder ....................................................... 9 .21 Wiring Diagram ......................................................... 65
Valve Clearance Ignition System ................................................... 10.63
Adjustment ........................................................... 2.47
Valve Clearance Assembly ........................................ 3.61
Valve Clearance Inspection ................................ , ....... 2 .46
Valve Cover
Installation ........................................................... 3.60
Removal. ..................................................... , ........ 3.60
Valve Guide
Removal I Installation ............................................. 3.70
Valve Seat
Inspection ............................................................ 3.70
Reconditioning ..................................................... 3. 70
Valve Spring, Free Length .......................................... 3.67
Valve Stem
Inspection ............................................................ 8.69
9927619 R02 - 201 S - 17 Indian Motorcycle Scout/ Scout Sixty Service Manual
·· Polaris Industries Inc. IX.9