2015-16 Indian Scout Service Manual

C
C.
(
2015 - 2016 Scout
Service Manual
Chapter Summary
CHAPTER 1: GENERAL I SPECIFICATIONS

CHAPTER 2: MAINTENANCE
CHAPTER 3: FRAME/BODY
CHAPTER 4: LUBRICATION I COOLING
CHAPTERS: FUEL DELIVERY I EFI I EXHAUST

CHAPTER 6: ENGINE REMOVAL
CHAPTER 7: CYLINDER HEAD I VALVES

CHAPTERS: CYLINDER I PISTON
CHAPTER 9: CLUTCH I PRIMARY I SHIFT

CHAPTER 10: TRANSMISSION I CRANKSHAFT
CHAPTER 11: FRONT WHEEL I SUSPENSION

CHAPTER 12: REAR WHEEL I SUSPENSION
CHAPTER 13: TIRES

CHAPTER 14: BRAKES
CHAPTER 15: STARTING I CHARGING
CHAPTER 16: IGNITION SYSTEM
CHAPTER 17: CHASSIS ELECTRICAL

(
[_
l
GENERAL I SPECIFICATIONS
CHAPTER I
VEHICLE INFORMATION .............. ... ............ .. .............................. .. ................. 1.2
MODEL NUMBER DESIGNATION ..... . .......................................................... .. .... 1.2
ENGINE NUMBER LOCATION . . . ... .. ................................................................. 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ............................................ 1.2
VIN LOCATION ..................... . ............... . ..... ....... .. . ... . ...... • ..... ..... . . ....... . ... 1.3
MANUFACTURER LABEL ........................................................................... . .. 1.3
TIRE INFORMATION LABEL ........................................................................... 1.3
GENERAL SPECIFICATIONS ....... ... . .... .................... .... ........ .. . . ... . ............. .. ...... 1.4
2015 - 2016 SCOUT SPECIFICATIONS . ................................................................ 1.4
VEHICLE LOADING . .. ......... .. ...... . . . ..... ... . ... .. ..... ............ ... . . . . ................... . ..... 1.6
GROSS VEHICLE WEIGHT RATING (GVWR) ........................................... . ..... . ........ 1.6
PUBLICATIONS AND TECHNICAL LITERATURE ....................................................... 1.7
PUBLICATION PART NUMBERS ......................................... . ...... ...... .................. 1. 7
REFINISHING . ............................................................................................ 1.8
PAINT COLORS BY MODEL ... . ............. .... .. ... .. .. ........ .. ....... .. . ... ........... . ... . . . ..... 1.8
EMISSION INFORMATION . .... . ........... . .... .. ................................ . ............. .... ..... 1.9
EMISSION CONTROL SYSTEMS ....................................................................... 1.9
EMISSION SOURCES .................................................................................. 1.9
EXHAUST EMISSION CONTROL ....................................................................... 1.9
NOISE EMISSION CONTROL ........... . ...... .... ...... . ....... ... .... . .... .. .... ...... ... . ........ .. 1.9
CRANKCASE EMISSION CONTROL .............. ......................... ...... .... ... ........... .. . 1.10
EVAPORATIVE EMISSION CONTROL (CALIFORNIA MODELS) ................. . ...... ... . .. . ... ... . . 1.10
SPECIAL TOOLS ......................................................................................... 1.11
USING SPECIAL TOOLS ............................. .. .. . .... . ..... .... .............................. 1.11
TOOL ORDERING INFORMATION ....... . ... ....... . ................................ . ................ 1.12
SPECIAL TOOLS INDEX ..... .. .... . . .. ..... ... ........... . ....... ..... ......... ..... ........ .. ... ... . 1.13
REFERENCE .......... ....... .... ..... . ... .. . .. ...... .................................. . ........... .. .. . . 1.16
SAE TAP DRILL SIZES ........ ... .. . .... ........... .. . ........................ .. . ... ............ . ...... 1.16
METRIC TAP DRILL SIZES ............................................................................ 1.16
DECIMAL EQUIVALENTS .............................................................................. 1.17
FAHRENHEIT TO CELSIUS ............ ... ... .... .................................. ... ............ . .... 1. 18
MEASUREMENT CONVERSION CHART .. . ........................................................... 1.18
9926140 R02 - 2015 - 2016 Scout Service Manual

1.1
VEHICLE INFORMATION (
MODEL NUMBER DESIGNATION
Example: Nl5MSAOOAA
GRP MY TYPE MODEL LINE DISP NET MARKET COLOR

BRAKE HP CONFIG
!st 2nd/ 4th digit* 5th digit* 6th digit* 7th digit* 8th digit* 9th digit 10th digit
digit 3rd
digit
<
N 15 M =Mid-size S = Scout A= Standard 0 = 11 33 cc (69 O=I OOhp A= 49 State A = Thunder Black
ci) V-Twin I= 78hp B = 50 State H = Thunder Black
I = Scout Sixty - C= Canadian Smoke
999cc (61 ci) V- E=EU(YVVTA) R = Indian Red
Twin J = Japan (SVA) S = Black Hills
Silver
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively.
First 3 digits, 9th digit, and I 0th digit are used in model number only. They are not used with the 17 digit VIN.
C
ENGINE NUMBER LOCATION

The engine number CD is stamped into the bottom of
the LH engine case. The stamping identifies the
engine model and serial number.
(
VEHICLE IDENTIFICATION NUMBER (VIN)

DESIGNATION
Example: 56KTCAAAOE3000024
Vehicle Descriptors Vehicle Identifiers
World Mfg. ID Chee-

Chas- Type Disp k Mfg
HP Series MY* Individual Serial No.
sis Digit
I 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

1.2
VIN LOCATION
The vehicle identification number G) is stamped on the
right side of the steering head.
MANUFACTURER LABEL
The manufacturer label G) located on the left side of
the steering head contains the following information:
Vehicle Identification Number (VIN)
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating (GAWR)
Tire Type and Load Information.
·· =
TIRE INFORMATION LABEL

See Manufacturer label for tire information. See
Manufacturer Label, page 1.3.
9926140 R02 - 2015- 2016 Scout Service Manual

1.3
GENERAL SPECIFICATIO NS
2015 - 2016 SCO UT SPECIFICATIO NS
YEAR MODEL
NUMBERS
2015 Scout Nl5MSAOOAA,
AB, AH , AR, BA,
BB, BH, BR, CA,
CB, CH, CR, EA,
EB , EH , ER
2016 Scout Nl6MSBOOAA, AJ,
AL, AM, AN, AP,
BA, BJ, BL, BM,
BN, BP, CA, CJ, {
CL, CM, CN, CP
Nl6MSB1 lAA,
AK, AR, BA, BK,
BR, CA, CK, CR,
EA, EK, ER
2016 Scout N l 6MSAOOAR, BR,
(
ABS CR, EJ, EL, EM,
EN, ER, EP
Chassis Engine
Dry Weight 516 lbs (235 kg) Engine Number 1204691
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 k g)
337 lbs (153 kg)
Rating, Front
Engine 69 cid (1133 cc) ; Sixty- 61 cid
Gross Axle Weight Displacement (999 cc) (
651 lbs (296 kg)
Rating, Rear
Engine Cooling Liquid
Maximum Load 428 lbs (194 kg)
Compression Ratio 10.7:1 , (Sixty) - 11.0:l
Overall Length 91.0 in (2311 mm)
Compression 210 - 230 psi (1448 - 1586 kPa)
Overall Width 34.6 in (880 mm) Pressure
Overall Height 47.5 in (1207 mm) DOHC, 4 Valves Per Cylinder, C
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 (135 mm) Bore x Stroke mm); (Sixty) - 3.661 in x 2.898 in
Total Storage (93 mm x 73.6 mm)
NIA
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 I Trail 29° I 4.7 in (119.9 mm)
Spark Plug Type I
NGK MR7F I 0.030 in (0.8 mm)
Gap
Two 02 Sensors I Single three-
Exhaust System
way catalyst in each muffler
992 6140 R02 - 201 5- 201 6 Scout Service Manual

1.4
Fuel System Suspension

Fuel System Electronic Fuel Injection (MEl 7) Front Suspension Conventional Telescopic Fork
Fuel Delivery Electronic Fuel Pump (in tank) Front Travel 4.7 in (120 mm)
Fuel Pressure 58 psi ( 400 kPa) Front Tube
41mm
Diameter
Throttle Body Bore 2.362 in (60 mm)
Rear Shock Monotube Dual Shocks
Fuel Capacity 3.5 gal (13.2 L)
Rear Swingarm Steel Weldment
Fuel Reserve
0.5 gal (1.9 L) Rear Travel 3.0 in (76 mm)
Capacity
Recommended
91 Octane Wheels I Brakes
Fuel
Kenda Kruz K673F - 130/ 90-16
Front Tire I Size
Electrical 72H
Stator Rated Output 460 W @ 3000 RPM Front Wheel I Size Cast I 16 in X 3.5 in
Front Tire Air 36 PSI (248 kPa)
Battery 12V I 12 AH I 210 CCA, Pressure
Maintenance Free AGM
Single Solid Disc I 2 Piston
Headlights Osram HB2 12V 60/ 55W Front Brake Calipers
Tail I Brake I LED (non-serviceable) Kenda Kruz K673 - 150/ 80-16
License Rear Tire
71H
Turn Signals RYlOW Rear Wheel Cast I 16 in X 3.5 in
Starting System Electric Start Rear Tire Air 40 PSI (276 kPa)
Ignition System Bosch ME-17 Pressure
Single Solid Disc I 1 Piston
Rear Brake Caliper
Drivetrain
Brake Fluid Type DOT4
Transmission 6 Speed I Sliding Mesh; Sixty - 5
Speed I Sliding Mesh All specifications are for the standard Indian Scout
models. Specifications may change with the addition
Clutch Wet, Multi-Plate, Coil Spring
of custom order options and I or accessories. Indian
Primary Drive Wet, Gear Drive Motorcycle Company reserves the right without prior
notice to discontinue at any time at its discretion any of
Primary Reduction l.652:l the items herein or change specifications or designs
Ratio without incurring any obligation to the customer.
Final Drive I Ratio Belt I 2.357: I
Belt Type I Width Carbon Fiber Reinforced Belt
141 Tooth, 22 mm
Gear Shift Pattern I Down, 5 Up
(Sixty) - 1 Down, 4 Up
Transmission Gear
Ratios:
)
!st 2.769:l
2nd l.882:1
3rd l.500:1
4th l.273: 1
5th 1.125: I; Sixty - l.036: 1
6th l.036: l; Sixty- N/ A

1.5
VEHICLE LOADING
GROSS VEHICLE WEIGHT RATING (GVWR)
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. C
The maximum load capacity of your motorcycle is the

maximum weight you may add to your motorcycle
without exceeding the GVWR. This capacity is
determined by calculating the difference between
your motorcycle's GVWR and wet weight.
{
Refer to the specification section of this manual or the
Manufacturing Information I VIN label on the
motorcycle frame for model-specific information.
Refer to Information label section in this manual for
location on the motorcycle.
When determining the weight you will be adding to
your motorcycle, to ensure you do not exceed the (
maximum load capacity, include the following:
• operator body weight
• passenger body weight
• weight of all riders' apparel and items in or on
apparel
• weight of any accessories and their contents C
• weight of any additional cargo on the motorcycle

1.6
PUBLICATIONS AND TECHNICAL LITERATURE

PUBLICATION PART NUMBERS
Some Indian Motorcycle publications, such as Owner's
Manuals and Parts Books may be available on-line at
the Indian Motorcycle website; http://www.
indianmotorcycle.com/
Service Manuals and Owner's Manuals can be
purchased through any authorized Indian motorcycle
dealer. The part numbers are listed in the following
table.
SERVICE OWNER'S
MODEL MANUAL PART MANUAL PART
NUMBERS NUMBERS
2015 Indian 9925346 9924830
Scout
Motorcycle
(U.S.)
2015 Indian 9925346 9924831
Scout
Motorcycle
(CAN)
2015 Indian 9925346 9924343

Scout
Motorcycle
(INT'L)
2016 Indian 9926140 9926136

Scout
Motorcycle
(U.S.)
2016 Indian 9926140 9926136
Scout
Motorcycle
(CAN)
2016 Indian 9926140 9926136

Scout
Motorcycle
(INT'L)
J 9926140 R02 - 2015 - 2016 Scout Service Manual

1.7
REFINISHING
PAINT COLORS BY MODEL
2015 Scout 2016 Scout
MODEL PAINT COLOR PAINT MODEL PAINT COLOR PAINT

NUMBER CODE NUMBER CODE
(
Nl5MSAOOAA Thunder Black P-266 Nl6MSBOOAA Thunder Black P-266
(Gloss)
Nl5MSAOOAH Thunder Black P-463
Smoke Nl6MSBOOBA Thunder Black P-266
Nl5MSAOOAR Indian Red P-639 (Gloss)
Nl5MSAOOBA Thunder Black P-266 Nl6MSBOOCA Thunder Black P-266

(Gloss) [
Nl5MSAOOBH Thunder Black P-463
Smoke Nl6MSBOOEA Thunder Black P-266
(Gloss)
Nl5MSAOOBR Indian Red P-639
Nl5MSAOOBS Black Hills Silver P-581 Nl6MSBOOAJ Wildfire Red 676
Nl5MSAOOCA Thunder Black P-266 Nl6MSBOOABJ Wildfire Red 676

Nl5MSAOOCH Thunder Black P-463 Nl6MSBOOCJ Wildfire Red 676
Smoke
Nl6MSBOOEJ Wildfire Red 676
Nl5MSAOOCR Indian Red P-639
Nl6MSBOOAS Smoke Silver 581
Nl5MSAOOCS Black Hills Silver P-581
Nl6MSBOOBS Smoke Silver 581
Nl5MSAOOEA Thunder Black P-266
Nl6MSBOOCS Smoke Silver 581 C
Nl5MSAOOEH Thunder Black P-463
Smoke Nl6MSBOOES Smoke Silver 581
Nl5MSAOOER Indian Red P-639 Nl6MSBOOAH Smoke (Thunder) 463
Black
Nl5MSAOOES Black Hills Silver P-581
Nl6MSBOOBH Smoke (Thunder) 463
Black (
Nl6MSBOOCH Smoke (Thunder) 463
Black
Nl6MSBOOEH Smoke (Thunder) 463
Black
Nl6MSAOOAR Indian Red 639
Nl6MSAOOBR Indian Red 639
Nl6MSAOOCR Indian Red 639
Nl6MSAOOER Indian Red 639

1.8
EMISSION INFORMATION
EMISSION CONTROL SYSTEMS NOISE EM ISSION CONTROL
The U. S. Environmental Protection Agency and Tampering with Noise Control Systems is Prohibited.
California Air Resources Board (CARE) require Federal law prohibits the following acts or causing
manufacturers to certify that their motorcycles comply thereof:
with applicable exhaust emissions standards during
their useful life, and that motorcycles built after 1. The removal or rendering inoperative by any
January 1, 1983 comply with applicable noise emission person other than for purposes of maintenance,
standards for one year or 6,000 Ian (3,730 mi) after the repair or replacement, any device or element of
design incorporated into the motorcycle for the
time of sale to the ultimate purchaser, when operated
and maintained according to the instructions purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in
provided.
use,or
2. The use of the motorcycle after such device or
EMISSION SOURCES 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 EMI SSIO N CO NTROL 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 I 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.
9926140 R02 - 2015 -2016 Scout Service Manual

1.9
CRANKCASE EMI SS ION CONTR OL EVAPORATIVE EMI SS ION CONTROL

The crankcase emission control system is comprised (CALIFORNIA MODELS)
of a closed system that routes crankcase emissions California models are equipped with an Evaporative
through the air cleaner into the combustion chamber. Emissions Canister (1). Activated charcoal inside the
canister temporarily stores fuel system vapors until
the engine is started and the motorcycle is driven. The
Electronic Control Module (ECM) automatically opens
a Purge Control Valve under certain conditions, and (
engine intake vacuum draws vapors out of the
canister.
COLOR DESCRIPTION
Green Engine Oil (liquid)
Red Engine Oil (mist)
Blue Engine Vapors
9926 140 ROZ - 201 5 - 20 16 Scout Service Manual

1.10
SPECIAL TOOLS
USING SPECIAL TOOLS The Special Tools Index located in this chapter
Special tools have been designed exclusively for provides a comprehensive list and pictorial
servicing the specialized components found on Indian representation of the special tools used throughout
Motorcycles. By using these tools, service technicians this service manual. The Special Tools section at the
can maximize efficiency and minimize the likelihood beginning of each chapter provides a short list of the
of causing damage to the motorcycle during service. tools required to perform procedures specific to that
How To Use This Book chapter.

1.11
TOOL ORDERING INFORMATION

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory,
while other tools may be substituted with a similar tool, if available. Indian Motorcycle recommends use of the
Special Tools referenced in the chapters of this service manual when servicing any Indian Motorcycle product.
Dealers may order special tools through Indian Motorcycle 's official tool supplier, Bosch Automotive Service
Solutions, by phone at l-800-345-2233 or on-line via your dealer website at https://polaris.service-solutions.com/
0PDLARlS'
;:Folow-ui,
-- ·i )
Special Alert!i
COMJ:t' tJ HkCiltCtc: (Ol'S ) (
= ~.$.!.;Ji.lad,,..
· :News, f omis .I. Linb;
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HOME I HOWTOORDER I ORDERfORM I WARRAmY I CONTACTUS I CREDITAPPUCATION I ~ \IIEWCART
COMMERCIAi.
SIDEXSIDE
SNOWMOBILE
VICTORY
U:ViGEM
PERSONAL WATfRCRAfT
DIAuNOSTIC SOFTWARE
GENERAl TOOLS
TOOL NEWS NEW TOOLS
PROMOTIONS
Welcome to the Polaris & Victory
Special Service Tools Site l
This site offers an exclusive line of special service
tools and diagnostic product designed specifically
SPX Corporation's to reduce labor limes and· ensure a quality repair-
maximizing your dealership ROI.
Service Solutions
business becomes Ta!';e a mome nt to browse the site as we are
continuously updating it with improved tool
Bosch Automot.i ve i nformation. Also, be sure to watch for newly
Service Solutions released tools appearing in the ~.ew Tools Section
just to the right
Cid Far
,M,Jru tnfo @; BOSCH If you have any questions or need more information
lnvent~d.forlite than provided on your Polaris & Victory on-line
catalog, please call 1--800-345-2233.

1.12
SPECIAL TOOLS INDEX

ABS Tool Battery Tester Bearing Removal Kit
PV-50104 PU-50296 PU-51324
Belt Tension Meter Crankcase Separator Tool Crankshaft Locking Pin

PV-43532 PF-51234-A PF-51235-A
Fuel Tank Fitting Plug 12mm Fork Spring Compressor Fuel Pressure Adapter
PV-50567 PV-49463 PV-48656

1.13
(
Fuel Pressure Gauge Oil Pressure Gauge Output Shaft Seal Tool
PU-43506A PV-43531 PF-51243
Relay Bypass Tool Smartlink Module Kit Swingarm Bushing Tool

PU-49466 PU-47471 PF-51237
,...;,
. 1J111ita1wrenc11 F
[~
Smarllinlt
Diavnast1cl111£113'•Module
l'aR1ff.Ol•t0.00
,:,;:.;f:;s; 0
... PCILAAIS
·
-
I
i1..-~
;----a
=•
USB to Serial Adapter Engine Transmission Lock Tool Flywheel Puller
PU-50621 PF-51612 PA-49316 l
9926140 R02 - 20 15 - 2016 Scou t Service Manual

1.14
Fork Socket Adapter I Cartridge Engine Case Assembly Cup Mainshaft I Crankcase Installer
Tool PF-51663 PV-45030
PF-51664-2
Cup Adapter Engine Stand Adapter Fork Oil Seal Driver

PF-51665 PF-51609 PF-51610
Water Pump Seal Installation Tool Fork Seal Installation Tool

PF-51608 PF-51611

1.15
REFERENCE
SAE TAP DRI LL SIZES METRIC TAP DRILL SIZES
THREAD SIZE I DRILL THREAD SIZE I DRILL DECIMAL NEAREST
DRILL
SIZE SIZE TAP SIZE EQUIVA- FRAC-
SIZE
LENT TION
#0-80 3/64 1/2-13 27/64
3x.50 #39 0.0995 3/ 32
#1-64 #53 1/2-20 29/ 64 (
3x.60 3/32 0.0937 3/32
#1-72 #53 9/16-12 31/64
4x.70 #30 0.1285 1/ 8
#2-56 #51 9/ 16-18 33/ 64
4x.75 1/8 0.125 1/8
#2-64 #50 5/ 8-11 17/ 32
5x.80 #19 0.166 11/64
#3-48 5/ 64 5/ 8-18 37/ 64
5x.90 #20 0.161 5/32 {
#3-56 #45 3/ 4-10 21/32
6xl.OO #9 0.196 13/ 64
#4-40 #43 3/ 4-16 11/16
7xl.OO 16/64 0.234 15/ 64
#4-48 #42 7/ 8-9 49/ 64
#5-40 #38 7/ 8-14 13/16
8xl.OO J 0.277 9/ 32
#5-44 #37 1-8 7/ 8 8xl.25 17/ 64 0.265 17/ 64

(
#6-32 #36 1-12 59/ 64 9xl.OO 5/ 16 0.3125 5/ 16
#6-40 #33 1 1/8-7 63/ 64 9xl.25 5/ 16 0.3125 5/ 16
#8-32 #29 1 1/8-12 13/ 64 lOxl.25 11/32 0.3437 11 / 32
#8-36 #29 1 1/ 4-7 1 7/ 64 lOxl.50 R 0.339 11/32
#10-24 #24 1 1/4-12 1 11/64 l lxl.50 3/ 8 0.375 3/ 8
#10-32 #21 1 1/ 2-6 1 11/32 12xl.50 13/ 32 0.406 13/ 32
#12-24 #17 1 1/2-12 1 27/ 64 12xl.75 13/ 32 0.406 13/32
#12-28 #15 1 3/ 4-5 1 9/16

1/4-20 7 1 3/4-12 1 43/ 64
1/ 4-28 3 2-4 1/ 2 1 25/ 32
5/ 16-18 F 2-12 1 59/64
5/16-24 I 2 1/ 4-4 1/ 2 2 1/32
3/ 8-16 0 2 1/2-4 2 1/4
3/ 8-24 Q 2 3/ 4-4 2 1/2
7/16-14 u 3-4 2 3/ 4
7/ 16-20 25/ 64

1.16
DEC IMAL EQUIVALENTS 47/ 64 in= .7344 in [19 mm= .7480 in]
1/ 64 in= .0156 in 3/ 4 in= .75 in
1/32 in= .0312 in [l mm= .0394 in] 49/ 64 in = .7656 in
3/ 64 in= .0469 in 25/ 32 in= . 7813 in [20 mm= . 787 4 in]
1/ 16 in= .0625 in 51/64 in = . 7969 in
5/ 64 in= .0781 in [2 mm= .0787 in] 13/ 16 in= .8125 in [21 mm=. 8268 in]
3/ 32 in= .0938 in 53/ 64 in= .8281 in
7/ 64 in= .1094 in [3 mm= .1181 in] 27/ 32 in= .8438 in
1/8 in= .1250 in 55/ 64 in= .8594 in [22 mm= .8661 in]
9/ 64 in= .1406 in 7/ 8 in= .875 in
5/ 32 in= .1563 in [4 mm= .1575 in] 57/ 64 in= .8906 in [23 mm= .9055 in]
11/64 in= .1719 in 29/ 32 in= .9063 in
3/ 16 in= .1875 in [5 mm= .1969 in] 59/64 in= .9219 in
13/ 64 in= .2031 in 15/1 6 in= .9375 in [24 mm= .9449 in]
7/ 32 in= .2188 in 61/64 in= .9531 in
15/ 64 in= .2344 in [6 mm= .2362 in] 31/32 in= .9688 in [25 mm= .9843 in]
1/4 in= .25 in 63/ 64 in= .9844 in
17/ 64 in= .2656 in [7 mm= .2756 in] 1 in= 1.0 in
9/ 32 in= .2813 in
19/ 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= .375 in
25/ 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= .4375 in
29/64 in = .4531 in
15/ 32 in= .4688 in [12 mm= .4724 in]
31/64 in = .4844 in
1/2 in= .5 in [13mm = .51 18 in]
33/ 64 in= .5156 in
17/ 32 in= .5313 in
35/ 64 in= .5469 in [14 mm= .5512 in]
9/16 in = .5625 in
37/ 64 in= .5781 in [15 mm= .5906 in]
19/ 32 in= .5938 in
39/ 64 in= .6094 in
5/ 8 in= .625 in [16mm=. 6299 in]
41 / 64 in= .6406 in
21/32 in = .6563 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
9926140 R02 - 2015 - 20 16 Scout Service Manual

1.17
FAHRENHEIT TO CELSIUS
MEASUREMENT CONVERSION CHART
~C to °F: 9 (°C + 40) , 5 - 40 = °F
UNIT OF MULTIPLIED
°F to °C: 5 (°F + 40) , 9 - 40=°C COVERTS TO
MEASURE BY
DEGREESF DEGREESC ft-lbs X 12 = in-lbs
32 0 in-lbs x.0833 = ft-lbs
(
41 5 ft-lbs X 1.356 =Nm
50 10 in-lbs x.0115 =kg-m
59 15 Nm x.7376 = ft-lbs
68 20 kg-m X 7.233 = ft-lbs
77 25 (
kg-m X 86.796 = in-lbs
86 30
kg-m X 10 =Nm
95 35
in X 25.4 =mm
104 40
mm x.03937 = in
113 45
in X 2.54 =cm
122 50
mile X 1.6 =km
131 55
km x.6214 = mile
140 60
Ounces (oz) X 28.35 = grams (g)
149 65
Fluid Ounce X 29.57 =CCs
158 70
grams (g) x.035 = Ounces (oz)
167 75
176 80 = Fluid Ounces
cc's x.03381 (oz)
185 85
lbs x.454 =kg
194 90
kg X 2.2046 = lbs
203 95
212 100 = Cubic
Cubic Inches X 16.387
Centimeters
Cubic
x.061 = Cubic Inches
Centimeters
Imperial pints x.568 = liters (1)
liters (1) X 1.76 = Imperial pints
Imperial quarts X 1.137 = liters (1)
= Imperial
liters (1) x.88 quarts .C
Imperial quarts X 1.201 = US quarts
= Imperial
US quarts x.833 quarts
US quarts x.946 = liters
liters X 1.057 = US quarts
US gallon X 3.785 = liter

1.18
UNIT OF MULTIPLIED
COVERTS TO
MEASURE BY
liter x.264 = US gallon
Pounds force
per square inch X 6.895
=Kilo pascals
(kPa)
(psi)
Kilo pascals
=Pounds force
X .145 per square inch
(kPa)
(psi)
Kilo pascals
x.01
=Kilograms
(kPa) force per cm2
Kilograms force
X 98.l
= Kilo pascals
per cm2 (kPa)
p (3 .14159) x R2 x H (height) = Cylinder

Volume

1.19
<
NOTES

1.20
MAINTENANCE
·CHAPTER2
MAINTENANCE
MAINTEN".ANCE QUICK REFERENCE GUIDE .... .. ......... .. ................. ... .......... .. ......... 2.3
SPECIFICATIONS ................................. ..... .................... ... ........................ 2.3
PERIODIC MAINTENANCE INTERVAL TABLE ................... ... ...................... .. .... ....... 2.5
GENERAL INFORMATION ............................................................................... 2.7
SERVICE NOTES ...................................................................................... 2. 7
SPECIAL TOOLS ....................................................................................... 2.7
BREAK-IN PROCEDURE ........ . ...... . ......................... . . ...... .............................. 2.7
MAINTEN".ANCE PROCEDURES ......................................................................... 2.8
AIR FILTER REPLACEMENT .... ..... ................ .. . ... . . ....................................... ... 2.8
ENGINE OIL LEVEL CHECK ........................................................................... 2.8
ENGINE OIL & FILTER CHANGE ............. . .... . .... .. ........ .. . .. ... ........... . .. ................ 2.9
COOLING SYSTEM OVERVIEW ........... ... ........................... ... .............. ... ...... . .. 2. 10
COOLANT STRENGTH I TYPE ........ . ..... ... ........... ............... .. .... ........ . ..... . .... ... . 2.10
COOLANT LEVEL INSPECTION ...................................................................... 2 .10
COOLING SYSTEM PRESSURE TEST ...................... .... ........ ...... ............... . ..... . .... 2 .11
COOLING SYSTEM PRESSURE CAP TEST ....................................................... . . . ... 2 .11
COOLING SYSTEM HOSES ........................................................................... 2 .12
RADIATOR INSPECTION I CLEANING ................................................................ 2.13
COOLANT DRAIN I FILL .................. .. ............ ... ........... . .... . . ... . . .. . ...... ... ........ 2. 14
IDLE SPEED I FAST IDLE SPEED ...................................................... ... ... .. ........ 2.15
TIRE PRESSURE I SPECIFICATIONS .................................................................. 2.15
CLUTCH CABLE INSPECTION I LUBRICATION . . ............... .. .... ..... ...... . ................. .. . 2.16
CLUTCH LEVER LUBRICATION . . .. ........ .. .... .... ......... . ....... . . . ...... . ......... .. .... .. ..... 2.17
CLUTCH LEVER FREE PLAY .......................................................................... 2.17
FRONT BRAKE LEVER INSPECTION .................................................................. 2.18
FRONT BRAKE LEVER LUBRICATION ............. . ...... . ..... . ... ... ............ ... .............. ... 2.18
BRAKE PEDAL INSPECTION ................. .. ... . . . .... .... ..... .... ... . ... . ..... .. ................. 2 .18
BRAKE PEDAL LUBRICATION ..................... .. ................... . ........................... .. 2.19
SHIFT PEDAL INSPECTION I LUBRICATION .......................................................... 2.21
SHIFT PEDAL ADJUSTMENT .......................................................................... 2.21
BRAKE FLUID LEVEL INSPECTION . ... .... ... ...... .... . .. ...... . .............. .... . . .. .. ........ . ... 2.22
FRONT BRAKE PAD INSPECTION ..................................................................... 2.23
REAR BRAKE PAD INSPECTION . ............ ............. . . . ........................ ... ... . ........ . . 2.23
CRANKCASE VENTILATION SYSTEM .. ................. .... ...... .. .. ... .................. .... ....... 2.23
FUEL TANK VENT INSPECTION (49 STATE) .......................................................... 2.24
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA MODELS) .............................. 2.24
FUEL SUPPLY HOSE I FUEL RAIL INSPECTION .................................................. . .... 2.26
SPARK PLUG REMOVAL .............................................................................. 2.26
SPARK PLUG INSPECTION I GAP ..................................................................... 2.26
SPARK PLUG INSTALLATION ......................................................................... 2.27
ENGINE COMPRESSION TEST ...... ..................................... .. . . ................. . .... . . 2.27
ENGINE COMPRESSION TEST (WET) ............................... . ........ . ......... . ............. 2.28

2.1
MAINTENANCE
BA'ITERY ........ .. . .... .......... . ... .. .... . ..................................... . .... .. .................. 2 .28 (
BA'ITERY INSPECTION . ........ ...... .. ... .............. . ....... . ...... .. . .. .. . ... .. ... . ... .... .... ....... 2.28
BA'ITERY CHARGING .... . ............... .. . .. ............... . .. .. .. . ............. . ................... . ... 2.29
BA'ITERY STORAGE ........................... . .................. . . .. ................... . ...... . .......... 2.29
BA'ITERY, REMOVAL ..... .. ................... . ............... ... ............... _............... . ... . ...... 2.29
BA'ITERYINSTALLATION ................... . ...... . . . ................................. . ................... 2 .30
(
DRIVE BELT INSPECTION . ............ ... .. . . . ... . ................ . ....................... . ............... 2.31
DRIVE BELT SPECIFICATIONS ..... . ............................. .... . .. ............. .. . ... ........ ....... 2 .31
DRIVE BELT DEFLECTION DATA .................................................................. . .. 2.31
DRIVE BELT FREQUENCY TENSION DATA ............... . ... . ........... .. ... . ..... . ............... . 2.31
DRIVE BELT TENSION ..................................................................................... 2.31
DRIVE BELT ADJUSTMENT ............ . .... ...... ........... . ... . . . ............ . .... ... ........... . ....... 2.32
SPROCKET INSPECTION . .. ...... . .... . . ......... . ................................................ .. ...... 2.34
FUSE REPLACEMENT ... .. ..................................... . .................... . .... . .......... .. .... 2.34
HEADLIGHT AIM INSPECTION ........... . .. .. .......... .... ....... . ............. . ............ . .. ... ..... . 2. 35
HEADLIGHT AIM ADJUSTMENT ....... ..... . ............................... . ... . ..... . ......... .. . .. ...... 2.35
SIDE-STAND INSPECTION. ................ . ... . ................. .. ......... . .............................. 2.35
SIDE-STAND REMOVAL I INSTALLATION ..... . ... .. . . .. . . ... . .. . . . . ........ ... ........ . ............... . .. 2.36
(
STEERING HEAD I FRONT WHEEL INSPECTION . . .. . . .. . . . ........... . ................................... 2.37
SWING ARM INSPECTION ............................ .. ......... ... ...... . ... .... . .. . . . . .... . ......... .. . 2.37
REAR SHOCK PRELOAD INSPECTION . . . . .. . .. .. .. . ......... . . .. . . ..... ........... . ........ . . ... . . .. ..... . 2.38
REAR SHOCK PRELOAD ADJUSTMENT ... . . .. . . ...... . ... .. ... . .. . ... .. .............. .. . . ........ . . . ..... . 2 .38
VALVE CLEARANCE INSPECTION ... . .. .. ... .................. .. ......................................... 2.39 (
VALVE CLEARANCE ADJUSTMENT ....... . .. . .................... . . . ................. .. .. . . . . .. ... . . . ..... 2.39
9926 140 R02 - 20 15 - 2016 Scout Service Manual

2.2
MAINTENANCE
MAINTENANCE QUICK REFERENCE GUIDE

SPECIFICATIONS
General Specifications
ITEM STANDARD SERVICE LIMIT
Battery Type I CCA 12 Volt / 12 AH / 210 CCA -
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 I Fast Idle Speed 1100 RPM ±50 RPM

Oil Pressure, Lubrication @ 40 PSI (275 kPa) ± 20 % 32 PSI (220 kPa)
3000 rpm Engine at operating temperature .
Ride Height (Rear Spring Pre- See adjustment procedure outlined in this -
Load) chapter
Spark Plug Type I Gap NGK MR7F GAP - .030 in (0.8 mm) -
Tire Pressure Front: 36 PSI (248 kPa) -
Rear: 40 PSI (276 kPa)
Tire Tread Depth (Minimum) - .063 in (1.6 mm)
Valve Lash (Int. I Ex.) 0.006 in (0 .152 mm) I 0.008 in (0.203 mm) -

2.3
(
MAINTENANCE
Torque Specifications Fluid Specifications

DESCRIPTION TORQUE DESCRIP- FLUID TYPE CAPACITY
SPECinCATIONS TION
Air Filter Screws - MS 24 in-lbs (2.7 Nm) Brake DOT4 -
X 0.8 X 16 (QTY.6) Hydraulic
Fluid
Axle Nut, Rear 65 ft-lbs (88 Nm) (
Engine I 15W60 Full 4.5 Qts (5.2 L) Dry
Battery Terminal 45 in-lbs (5.08 Nm) Transmission Synthetic Engine
Screw Oil
Battery Bracket 84 in-lbs (9.49 Nm) Fork Oil Indian 11.3 oz (335 cc)
Screw Motorcycle per leg
Fork Oil (
Battery Cable to 63 in-lbs (7 .1 Nm)
Starter Motor Fuel 91 Octane 3.5 gal (13.2 L) I
(Recommend- Reserve 0.5 gal
Brake Bleeder 48 in-lbs (5.4 Nm)
ed) (1.9 L)
Screws (Caliper)
Coolant I Polaris 2. 77 Qts (2.63 Ltrs)
Brake Lever Pivot 84 in-lbs (9.49 Nm)
Antifreeze Extended Life
Bolt
50/ 50 (
Camshaft Carrier 84 in-lbs (9.49 Nm)
Bolls
Clutch Cable Guide 48 in-lbs (5.4 Nm)
Jam Nut
Clutch Lever Bolt 84 in-lbs (9.49 Nm)
Clutch Perch Clamp 145 in-lbs (16.38 Nm)
Bolt
Drive Sprocket Nut 133 ft-lbs (180 Nm)
Drive Sprocket Nut 88 in-lbs (10.0 Nm)
Retainer Plate
Fuel Tank Mounting 18 ft-lbs (24.5 Nm)
Screws
Master Cylinder 14 in-lbs (1.6 Nm)D
Cover Screws (Front)
Master Cylinder 14 in-lbs (1.6 Nm)
Cover Screws (Rear)
Oil Drain Plugs (2) 15 ft-lbs (20.0 Nm)
Oil Filter 115 in-lbs (13 Nm) or
approximately 3/4 to 1 full
turn after seal contacts the
filter mount sealing surface
Shift Rod Jam Nuts 96 in-lbs (10.8 Nm)
Sidestand Pivot Bolt 35 ft-lbs (47.4 Nm)
Spark Plugs 106.2 in-lbs (12 Nm)
992 6 140 R02 - 20 15 - 20 16 Scout Service Manual

2.4
MAINTENANCE
PERIODIC MAINTENANCE INTERVAL TABLE

ENGINE MILES (KILOMETERS)
s0 s0 s0 s0 s0 s0 s0 s s0 s s0
s0 0 0
0 0
'2'
0 0 0
co
0
0 0
0
0 0
0
e ~ e "'
:=, ~ "'e 0
~ ~ "'e '2'
e "'t!. 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
0 0 0 0 0
"' "'"' "' 0
.... ....
"'
0
0
0 0
0
0 0
0
"' 0
"' "'"' "' '2' '2'

"'
(') (')
Air Filter I I I R I R I R I R I R
Crankcase Ventilation System I I I I I I I I I I I I
Cooling System I Radiator I 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
Engine Mount Fasteners I
Engine Oil* R R R R R R
Engine Oil Filter* R R R R R R
Evaporative Emission Control

System (CA. Only) I I I I I I I I I I I I
Exhaust System 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 I Oil System

Inspection 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 I I I I I I R
Valve Lash Clearance 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

2.5
MAINTENANCE
CHASSIS MILES (KILOMETERS) (
s0 s0 s0 s0 s0 s0 s0 s s0 s0 s0
s0 0
e0
c:,
0
::!:,
0
c:,
e
0
0
c:,
-
0
0
"'
c:,
0
~
~
0
c:,
0
"'ec:,
c:,
0
0
::!:,
c:,
c:,
0
co
::!:,
c:,
c:,
0
"'
~
c:,
c:,
0
~
e
0
c:,
0
"'
t:..
c:,
c:,
0
0
ec:,
c:,
Battery
I/')
I
I/')
"'
1
c:,
I/')
I
- -
c:,
0
I
c:,
I/')
I
c:,
0
"'
I
c:,
I/')
"'
I
0
c:,
t"')
I
c:,
I/')
t"')
I
-0
c:,
~
I
c:,
I/')
~
I
0
0
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
Control Cable Ends I I L I L I L I L I L (

Fasteners I I I I I I I I I I I I
Front Brake Lever L I L L L L L L L L L L

Front Fork Oil** I I I R I I R I I R I
Front Forks and Front Axle I I I I I I I I I I I I
Ge ar Shift Pe dal I I I I I I I I I I I I C
Head Light I 1 I I I I I
Rear Brake Pe dal I I I I I I I I I I I I
Rear Shock Absorber I I I I I I I I I I I R

Rear Wheel Alignment I I I I I I I I I I I I
Road Test p p p p p p p p p p p p
Sidestand I Sidestand Safety

L 1 L I I I I I I I I I
Switch
Steering Bearings I I I I I I I I I I I I
Shock Bushings and Fasteners I I I I I I I I I I I I
Swing Arm, Rear Axle, Swing

Arm Pivot, and Pivot Bearings I I I I I I I I I I I I
Tires I 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

2.6
MAINTENANCE
GE NERAL INFORMATIO N
SERVICE NO TES • Upon initial start-up, do not allow the engine to idle
Periodic Maintenance Overview for long periods.
• Avoid fast starts with wide open throttle. Drive
Inspection, adjustment and lubrication of important
slowly until the engine warms up.
components are explained in the periodic
• Avoid running the engine at extremely low RPM in
maintenance chart.
higher gears (lugging the engine).
Inspect, clean, lubricate, adjust and replace parts as
necessary. When inspection reveals the need for
replacement parts, use genuine Indian Motorcycle Break-In Guidelines
parts available from your Indian Motorcycle dealer.
ODOMETER BREAK-IN
PROCEDURE
Service and adjustments are critical. If you're not 0-90 Miles (0-145 km) Do not operate for
familiar with safe service and adjustment extended periods above
procedures, have a qualified dealer perform these 1/3 throttle or at any one
operations. throttle position. Vary
engine speed frequently.
91-300 Miles (146-483 Do not operate for
SPECIAL TOO LS km) extended periods above
PART NUMBER 1/ 2 throttle or at any one
TOOL DESCRIPTION
throttle position. Vary
Brake Lever Reserve PV-50104 engine speed frequently.
Tool
301-500 Miles ( 484-805 Do not operate for
Battery Tester PU-50296 km) extended periods above
3/ 4 throttle.
Belt Tension Meter PV-43532
500 Miles (805 km) Perform the break-in
Oil Filter Wrench PU-50105
maintenance procedure
Shock Spanner Wrench PV-46993 outlined in the Periodic
Maintenance Interval
Bosch Automotive Service Solutions: 1-800-345- Table located in this
2233 or https:/ /polaris.service-solutions.com/ chapter.
BREAK -I N PRO CE DUR E

Engine break-in for Indian Motorcycles occurs in the
first 500 miles (800 km) of operation. Indian
Motorcycles are manufactured using the best possible
materials and manufacturing techniques , but the final
machining process is the break-in. During this break-
in period, critical engine parts wear and polish to
correct operating clearances. Read, understand and
follow all break-in procedures to ensure the long-term
performance and durability of the engine.
CAUTION
.J Failure to properly follow the engine break-in
procedures outlined in this manual can result in
serious damage to the engine. Follow all break-in
procedures carefully. Avoid full throttle operation and
other condition that may place an excessive load on
the engine during the break-in period.
Observe the following precautions during the break-in

period:

2.7
MAIN1'ENANCE
MAINTENANCE PROCEDURES
AIR FILTER REPLACEMENT ENGINE OIL LEVEL CHECK
With the semi-dry sump lubrication system, the
engine oil level on the dipstick will fluctuate,
If the motorcycle is operated in wet or dusty depending on the motorcycle's position and engine
conditions, more frequent servicing is required. The speed when the engine is turned off. To ensure a
air filter element cannot be cleaned. Replace the proper reading of the engine oil level, follow all
filter when necessary. inspection procedures closely. (
Engine MUST BE AT FULL OPERATIN"G

Allow engine and exhaust to cool completely before TEMPERATURE when checking oil level.
disconnecting fuel line or removing tank. Protect fuel
tank finish when removing, storing, and installing l. With the motorcycle in an upright (vertical) (
tank. position, run the engine for 30 seconds.
Store the fuel tank in a secure location with a drain pan 2. Stop engine.
positioned to catch any fuel that may leak or drip from 3. Place the machine on a level area and hold it in an
disconnected hoses or fittings. upright (centered) position.
1. Remove the seat. SeeSeat Removal I Installation,
page 3.9. C
2. Remove the Fuel Tank. SeeFuel Tank Removal,
page 5.20.
3. Remove the six air filter fasteners CD.
(_
5. Reinsert the dipstick and thread in until fully

seated.
6. Remove the dipstick and view oil level.
4. Inspect filter element CD and replace if dirty, wet,
or oil fouled.
5. Reverse steps to install filter. ~
\.,a,'
6. Torque air filter fasteners CD to specification. ~~ ( "FULL" )
·\7---
A loose fitting cover or improperly installed filter

element may allow debris to enter the engine which
may cause premature engine wear.

2.8
MAINTENANCE
7. 7. Clean the engine oil filter mount sealing surface

and surrounding area.
CAUTION
8. Place a small amount of oil on the new oil filter seal
Oil level will NOT be accurate if checked on a cold
and spin filter on until the filter seal contacts the
engine. DO NOT ADD oil to bring to FULL mark on a
sealing surface. Tighten oil filter to specification.
cold engine, as this can result in overfilling.
TORQUE
Oil level should be between the ADD and FULL Oil Filter: 115 in-lbs (13 Nm) or approximately 3/ 4
lines on dipstick. If oil level is low, add Indian to I full turn after seal contacts the filter mount
Motorcycle 15W60 Full Synthetic engine oil and sealing surface
repeat steps 3 - 6 until the reading is within the
safe operation range. 9. Use new sealing washers and reinstall the drain
Do not overfill! Approximate volume from ADD to FULL plugs. Torque to specification.
is 1/2 US qt (.47 L).
ENGINE OIL & FILTER CHA NG E

10. Use a funnel to add 3 US quarts (2.8 Liters) of
Engine MUST BE WARMED before performing the Indian Motorcycle 15W60 Full Synthetic engine oil
following procedure. through the engine oil dipstick hole.
CAUTION 3 US quarts will bring the engine oil level at or near

CAUTION HOT COMPONENTS the "FULL" mark on the dipstick. For a new or rebuilt
Wear insulated gloves and use caution handling (dry) engine add an additional .5 US quart (.47
these parts. Liters).
11. Securely support the motorcycle in a vertical

1. Run engine until warm, then turn engine off.
"centered" position, idle engine for approximately
2. Securely support the motorcycle in a vertical 30 seconds.
"centered" position.
12. Remove oil dipstick and wipe clean, then reinsert
3. Place an oil drain pan under the engine oil drain and fully tighten dipstick. Remove dipstick and
plugs G) and CD. read the engine oil level. Add engine oil as
required to bring oil level to the dipstick full mark.
DO NOT OVERFILL!
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).
13. Refer to the Checking Engine Oil, page 2.8 section

in this chapter for setting proper oil level.
If the low oil pressure indicator remains illuminated

longer than usual after an oil change, do not increase
RPM above idle until indicator lamp goes out or
4. Remove the drain plugs and sealing washers. engine may be damaged.
5. Allow oil to drain completely. Dispose of oil

properly.
6. Remove oil filter G) and allow oil to drain. Dispose
of oil filter properly.
9926140 R02 - 20 IS - 20 16 Scout Service Manual

2.9
MAINTENANCE
14. Check for leaks around drain plug and oil filter. COO LANT LEVEL INSPECTIO N
1. The pressure cap CD is located under the fuel tank.
Recycle used oil and oil filter in accordance with
local regulations.
,
COOLING SYSTEM OVERVIEW
Use Indian Motorcycle 50/ 50 Extended Life Coolant

only. Do not mix coolant types.
The engine coolant level is controlled or maintained

by the recovery system. The recovery system
components are the recovery bottle, filler neck,
pressure cap and connecting hoses.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the 2 . The coolant reservoir Q) is located under the driver
system past the pressure cap and into the recovery seat. The coolant level must be maintained at the
bottle. As engine coolant temperature decreases the " COLD FULL" level indicated on the reservoir.
contracting (cooled) coolant is drawn back from the 3. Position the motorcycle upright on a level surface.
tank past the pressure cap and into the cooling
system. 4. View the coolant level in the reservoir.
Some coolant level drop on new vehicles is normal as (

the system is purging itself of trapped air. Observe
coolant levels often during the break-in period.
Overheating of engine could occur if air is not fully

purged from the cooling system.
Indian Motorcycle 50/ 50 Extended Life Coolant is (
premixed and ready to use. Do not dilute with water.
COO LANT STRENGTH/ TYPE

Test the strength of the coolant using an antifreeze
hydrometer. 5. If the coolant level is below the "COLD FULL" line,
coolant will need to be added to the system.
• A 50/ 50 mixture of e xtended life antifreeze and
6. Remove the driver seat. See Seat Removal I
distilled water will provide the optimum cooling,
Installation, page 3.9.
corrosion protection, and antifreeze protection.
• Do not use tap water, straight antifreeze, or str aight 7. Remove the filler cap G) . Using a funnel, add
w ater in the system. Tap water contains minerals coolant to the filler cap opening until the coolant
and impurities which build up in the system. level in the reservoir is to the "COLD FULL" line.
• Straight water or antifreeze may cause the system to 8. Reinstall the filler cap.
freeze, corrode, or overheat.
9. Reinstall the driver seat. See Seat Removal I
FLUID CAPACITY Installation, page 3.9.
Recommended Anti-Freeze/Coolant:Indian
Motorcycle 50/ 50 Pre-Mixed Extended Life
Antifreeze
(PN 8560214) (Quart)
99261 40 R02 - 20 15 - 2016 Scout Se rvice Manual

2.10
MAINTENANCE
COOLI NG SYSTEM PRESSURE TEST COOLI NG SYSTEM PRESSURE CAP TEST

1. Remove the seat. See Seat Removal I Installation, 1. Remove the seat. See Seat Removal I Installation,
page 3.9. page 3.9.
2. Remove the Fuel Tank. See Fuel Tank Removal, 2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.20. page 5.20.
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 k:Pa) for 4. The cooling system pressure cap relief pressure is
five minutes or longer. If pressure loss is evident 16 psi ( 110 k:Pa). 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.
Coolant may be present at the water pump weep

hole G) due to normal water pump function. Verify
integrity of the water pump seal with a cooling
system pressure test.
I
j
/_ ' .~
I,
·r;y.·j; // I 1
,I f \
.. '""i
------
9926140 R02 - 20 IS - 2016 Scout Service Manual

2.11
MAINTENANCE
COOLING SYSTEM HOSES (
C
COOLING SYSTEM HOSES
1 Hose, Radiator Inlet 5 Hose, Front Head Outlet
2 Hose, Radiator Outlet 6 Hose, Cooler Return
3 Hose, Bypass 7 Hose, Cooler Supply
(
4 Hose, Rear Head Outlet
Cooling System Hoses Inspection

1. Inspect all vehicle coolant hoses for cracks,
deterioration, abrasion or leaks. Replace if
necessary.
(
2. Check tightness and condition of all hose spring
clamps. Replace if necessary.

2.12
MAINTENANCE
RADIATOR INSPECTION/ CLEANI NG

CAUTION
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.
~
( 1 )
\, _,,/
·-~
-~
; .
---~._..--·:-:··:-~::::--; .',(
...
, ---..,
( 4 )
\...._,/
Item Number Description

1 Radiator Cover
2 Upper Radiator Mount
3 Radiator
4 Cooling Fan Assembly
Radiator Inspection and Cleaning

1. Check radiator air passages for restrictions or
damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with low pressure
compressed air or low pressure water.

2.13
MAINTENANCE
COOLANT DRAIN/ FILL (
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 before servicing.
(
Cooling System Drain
/~
Pressure test the cooling system before and after
cooling system service. ,,
( __3,/) '·
(
1. Remove the radiator cover fasteners G) .
Cooling System Fill/Bleeding
,, ......
,/··
.. . ,/
Pressure test before and after servicing the cooling
system.
C
1. Reconnect the coolant return hose to the oil cooler
( 1: , ,
,_j
-:-. . .~~_"'--"--'----=-0--"\ f j f'.
( 11
\...__,,/
assembly.
2. Install the radiator cover.
3. Remove the seat. See Seat Removal I Installation,
page 3.9.
4. Remove the Fuel Tank. SeeFuel Tank Removal,
page 5.20.
5. Remove cooling system pressure cap G) .
2. Slide radiator cover down to disengage posts from 6. Use pinch pliers (commercially available) to pinch
the upper radiator mounts CD . off the coolant line © between the coolant
reservoir and thermostat housing.
3. Remove the coolant return hose G) from the oil

cooler assembly to drain the coolant. 7. Install a cooling system vacuum bleeder
(commercially available) on the pressure cap
opening to create a vacuum in the cooling system.

2.14
MAINTENANCE
8. Using the vacuum bleeder draw in Indian TIRE PRESSURE/ SPECIFICATIONS
1
Motorcycle Extended Life 50/ 50 Engine Coolant to
fill the cooling system.
9. Remove the vacuum bleeder and install the Indian motorcycles are produced using the
pressure cap. designated tires listed below as original equipment.
10. Remove the pinch pliers from the coolant line This includes field testing to ensure stability and
between the reservoir and thermostat housing. superior handling. The use of tires other than original 2
equipment may cause instability. See Chapter 13 for
11. Add Indian Motorcycle Extended Life 50/ 50 Engine
a review of all tire related warnings.
Coolant to the reservoir fill opening CD until the
coolant reservoir CD is half full.
1. Inspect tires for weather checking, cuts, imbedded
12. Install the fuel tank assembly. See Fuel Tank foreign objects, etc.
2. Inspect front and rear wheels for damage.
13. Run the engine until the cooling fan cycles ON and
OFF. 3. Measure tread depth at center of tread.
14. Recheck the coolant level in the reservoir and add 4. Measure in 3-4 places equally spaced around the
to the "COLD FULL" level. tire and record the smallest measurement.
15. Repeat the fill/ bleed procedure until the coolant
level in the reservoir remains at the " COLD FULL"
level. It is dangerous to ride with a worn tire. When a
16. Install the seat. See Seat Removal I Installation, tire reaches the minimum tread depth listed
page 3.9 . below, replace the tire immediately.
IDLE SPEED/ FAST IDLE SPEED Minimum Tread Depth

Front Tire Minimum
.063 in (1.6 mm)
Idle speed is continuously monitored and adjusted Tread Depth
by the ECM.
Rear Tire Minimum
.063 in (1.6 mm)
Tread Depth
Tire Pressure Table (Cold)
Also refer to Manufacturing Information label.
SCOUT
FRONT: Kenda Kruz 36 PSI (248 kPa)
K673F - 130/ 90-16 72H
REAR: Kenda Kruz K673 40 PSI (276 kPa)
- 150/ 80-16 71H
9926140 R02 - 201 S - 2016 Scout Service Manual

2.15
MAINTENANCE
CLUTCH CABLE INSPECTION/ LUBRICATION 3. Remove the jam nut G) that retains the clutch cable
in the lower cable guide. Using an adjustable
wrench, rotate the clutch shaft arm © to release
Control cable casings are lined with a low friction the cable housing from the mounting boss.
sleeve and are factory lubricated for reliable j"' I
operation. Periodic lubrication of cables is not
required and could be detrimental to cable
I I
performance. Only cable ends must be periodically (
inspected and lubricated in accordance with the
Periodic Maintenance Schedule. See Periodic
Maintenance Interval Table, page 2.5.
CAUTION
(
Inspect inner cable for fraying. Do not kink, bend or
twist inner cable or cable casing during removal or
installation.
1. Inspect the clutch cable G)for proper routing,

smooth movement, and damage to the external
casing. 4. Apply a thin coating of all purpose grease to both C
cable ends.
5. Reverse steps 3 - 4 to reinstall clutch cable.
6. Tighten the lower cable guide jam nut to
specification
7. Adjust cable free play. See Clutch Lever Free Play,

page 2.17
2. Inspect the lower cable end CD for damage or

frayed wires.

2.16
MAINTENANCE
CL UTC H LEVER LUBRI CATI ON CLUT CH LEVER FREE PLAY

1. Disconnect clutch cable at primary cover. See l. With handlebars pointing straight ahead, measure
Clutch Cable Inspection I Lubrication, page 2.16. the clutch lever free play at point shown CD
2. Pull cable housing out of lever perch and remove between lever and perch.
barrel from clutch lever. Do not kink cable.
3. Remove the nut CD and push pivot bolt Q) upward
to remove.
cD-{l~ .",- - - -- ----- --.-

~~~~:~: :CJ::·, '-,-.' \
/---- --1.. ~..::,::::..._ ,,,,--··---'
( 1 'i-----'bl
\ .,_,,/
4. Inspect both ends of inner cable for frayed

2. Compare measurement to specification. If
strands. Clean parts and apply moly paste to pivot
adjustment is required, proceed to Step 3 .
bolt and both cable ends.
3. Locate the clutch cable adjuster boot Q) and pull it
5. Assemble lever.
back to expose the jam nut and barrel adjuster.
6. Install cable to lever. Rotate cable back through
slot in perch, and push outer casing back into
perch recess.
7. Install the pivot bolt and torque the nut to
specification.
8. Lubricate and attach lower end of cable to clutch

arm on primary cover.
9. Adjust clutch lever free play. See Clutch Lever
Free Play, page 2.17.
4. Hold cable and loosen the adjuster jam nut.

5. Turn cable adjuster in or out until clutch free play
is correct.
6. Tighten adjuster jam nut to specification.
Clutch Cable Adjuster Jam Nut: 48 in-lbs (5.4 Nm)
7. Slide adjuster boot back over adjuster assembly.

2.17
MAINTENANCE
FRON T BRAKE LE VER INSPECTION FRONT BRAKE LE VER LUBRI CATION (

1. Pull and release the front brake lever. It should 1. Remove the nut CD and pivot bolt (l).
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 2.18.
2. Measure brake lever free play CD. 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.
(
2. Clean p ivot bolt, lever and lever perch.

3. Remove brake lever and apply grease to pivot bolt
(
(l), lever bushing, and pushrod contact surface of
lever G) as shown.
3. Safely elevate the front wheel. Verify wheel rotates

freely without drag or binding when lever is
released.
4. Assemble brake lever.

5. Torque brake lever pivot bolt nut to specification.
BRAKE PEDAL INSPECTION

1. Press and release the brake pedal. It should move
freely and smoothly and return to the rest position
quickly when released.
2. Press brake pedal and check for firm resistance. If
pedal feels spongy or travels too far without
resistance, inspect system for leaks and bleed
brakes. See Brake Bleeding.
9926140 R02 - 20 15- 20 16 Scout Service Manual

2.18
MAINTENANCE
BRAK E PEDAL LU BRICATION
1. Brake Pedal 8. Bolt, Shoulder Pivot

2. Bearing, Brake Pedal Pivot 9. Washer, Wave
3. Footpeg Mount 10. Washer
4. Footpeg 11. Pin, Pivot Footpeg
5. Pad, Brake Pedal 12. Ring, Retaining Spiral
6. Spring, Brake Return 13. Bushing, Pivot Brake Pushrod
7. Screw 14. Screw, Brake Pushrod
Lubricate brake pedal at intervals listed on periodic

maintenance table. See Periodic Maintenance Interval
Table, page 2.5.
1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.

2.19
MAINTENANCE
2. Working on the RH side of the motorcycle, remove 4. Remove brake pedal return spring ®· Remove
(
brake line p clamp bolt CD and foot peg mount brake pushrod pivot bushing ®· Remove the brake
bolts Q). Move foot peg mount/ master cylinder pedal bushing (J) and washer ® ·
assembly so the brake pedal pivot shoulder bolt
can be accessed.
5. Clean off old lubricant and dirt from all parts.

(
6. Apply all-purpose grease to pushrod and pedal
bushings as shown.
It is not necessary to disconnect the brake line from
the master cylinder to perform this procedure.
(
Keep the floorboard I master cylinder assembly in an
upright position at all times to ensure air does not
enter the brake system.
[ Apply Grease
3. Remove the brake pedal pivot shoulder bolt CD

and flat w asher. Remove the pushrod bolt © from (
the brake pedal.
·- ·-- --~··- ··, ... ·::::· -~
7. Install pedal bushing (J) . Assemble pedal, w asher

® , brake pedal pivot shoulder bolt CD and flat (
washer to the foot peg mount.
8. Install pushrod pivot bushing and bolt.
9. Assemble foot peg support to frame. Torque
mounting bolts Q) and p-clamp bolt CD to
specification. SeeFoot Peg Driver Removal I
IO. Depress brake pedal to verify proper operation
and pedal feel. Bleed brakes if necessary. See
Brake Bleeding.

2.20
MAINTENANCE
SHI FT PEDAL IN SPECTION / LU BRICATION 3. IMPORTANT: The shift linkage rod G) must be
1. Check all shift pedal and linkage fasteners to be threaded into each pivot end a minimum of seven
sure they are tight. Torque fasteners to complete turns.
specification. See Shift Pedal Adjustment, page
2.21.
2. Lubricate shift pedal pivot bushing and all pivots
CD with all-purpose lubricant.
4. Tighten jam nuts CD to specification.
SHIFT PEDAL ADJU STMENT CAUTION

1. Loosen jam nuts CD. Do not remove and reposition the shift arm on the
2. Rotate linkage rod Q) until pedal angle is correct. shift shaft to adjust gear shift pedal height. Dots on
shift shaft and shift arm must be aligned for gears to
shift eorrectly.
! 1 }
\_j
9926140 R02 - 20 15 - 20 16 Scout Se rvice Manual

2.21
MAINTENANCE
BRAKE FLUID LEVEL INSPECTION 7. Reinstall reservoir diaphragm and cover and (
torque screws to specification .
.>_ . ,' · IMPORTANT.
The brake fluid level in the reservoir will go down as
brake pads wear. If you notice a constant or sudden Front Master Cylinder Cover Screws: 14 in-lbs (1.6
lowering of the brake fluid level, inspect brake pads Nm)
for wear and brake system for leaks.
(
Front Brake Fluid Inspection Rear Brake Fluid Inspection
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.
/ '1 ,;-/ 9. View fluid level through reservoir sight glass ® ·
:/ The fluid should be clear and at or above the
middle of the sight glass.
2. View front brake fluid levei through sight glass. C

The fluid should be clear and at the middle of the
site glass CD.
3. Wipe area around reservoir cover with a clean
cloth. 10. Wipe area around reservoir cover with a clean
cloth.
4. Wipe brake fluid container with a clean cloth.
11. Wipe brake fluid container with a clean cloth.
5. Remove screws CD, reservoir cover CD and
diaphragm ©. If diaphragm is extended, return it 12. Remove screws ®, reservoir cover (J), and
to the neutral position. diaphragm ®· If diaphragm is extended, return it
to the neutral position.
,'·~~---:~~~~:,:.~-n
, . \::..:./·
'··,....
' - - ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ " " ' - - - - ' - - . . . _ ~ ~ ' " -,-/' /

/
/
6. Carefully add enough DOT 4 brake fluid to bring

level to the upper edge of the sight glass. 13. Carefully add enough DOT 4 brake fluid to bring
level to the upper edge of the sight glass.

2.22
MAINI'ENANCE
14. Install diaphragm and cover. Tighten cover screw s REAR BRAKE PAD IN SPECTION
to specification.
Wear indicator grooves are provided on each rear

Rear Master Cylinder Cover Screws: 14 in-lbs (1.6 brake pad to allow for a visual inspection without pad
Nm) removal. Inspect pads by viewing from the rear of the
motorcycle, directly behind the muffler.
Replace pads if worn to bottom of grooves. See Rear
Brake Pad Replacement, page 14.21.
FRONT BRAK E PAD INSPECTION
the front wheel clamped in a wheel vise.
Wear indicator grooves are provided on each front
brake pad to allow for a visual inspection w ithout pad 2. Viewing the rear brake pads from behind the
removal. Inspect pads by view ing from rear of motorcycle and below the lip of the rear fender,
caliper. locate the wear indicator grooves CD.
Replace pads if worn to bottom of grooves. See Front
Brake Pad Replacement, page 14.21
1. Viewing the front brake pads from the front of the

caliper, locate the wear indicator grooves CD.
2. Wear indicator grooves should be visible on both
inboard and outboard brake pads.
3. Wear indicator grooves should be visible on both

inboard and outboard brake pads.
CRANKCASE VENTI LATION SYSTEM

1. Inspect condition of ventilation hoses CD along the
entire length and at both ends.
CAUTION
Front brake pads should always be replaced as a
complete set. If it is determined that an individual
brake pad has worn past the wear indicator groove,
the front caliper should receive a new pad set. Failure
to replace both front brake pads together may cause
reduced braking performance or brake failure,
resulting in a vehicle crash.
2. Be sure hoses are not restricted, kinked, or

cracked.
3. Replace worn or damaged hoses.

2.23
MAINTENANCE
FUEL TANK VENT INSPECTION (49 STATE)

(
1. Inspect fuel tank vent hose CD in accordance with
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 connections are tight.
EVAPORATIVE EMISSION CONTROL SYSTEM

(CALIFORNIA MODELS)
(
The fuel tank vent line is routed to a vapor canister
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 C
vent and canister purge systems are securely
attached.

2.24
MAINTENANCE
EVAPORATIVE EMISSION CONTROL SYSTEM

(CALIFORNIA MODELS)
_ di~~i) . ,\JI '-

,,,------.\ ~--- " . .
0_c':) - ~~~-??~, / ; ___ , •. ..,-.:::. ·~-·:.' .'!'_ ;·
rl .J. :·J
\\ , . , . . ·,· .Cr':
. '? ~--·:.• "j ! " ' : 1, J
!= · / :
· .. .,,., "-~- ,. -;· . ,": 1~~!\\::: '. _

.-~-:;.
....
. i
>\,.. ,
__
\. ,/
NUMBER PART DESCRIPTION

1 Fuel Tank Vent Hose
2 Evaporative Emissions Vapor Canister
3 Purge Hose (Canister to Purge Valve)
4 Canister Purge Valve
5 Purge Hose (Purge Valve to Throttle Body)
6 Fuel Cap Recess Drain Hose
9926 140 R02 - 2015- 2016 Scout Service Manual

2.25
MAINTENANCE
FUEL SUPPLY HO SE/ FUEL RAI L INSPECTION (

1. The fuel supply hose and fuel rail are located
behind the engine cover on the RH side of the
motorcycle.
2. Inspect fuel supply line CD and fuel rail CD for
deterioration, damage, leakage, or kinked areas.
Inspect fuel supply line-to-fuel rail connection G)
for signs of leakage.
1. Place the motorcycle on the side stand and allow

engine to cool.
page 3.9.
3. Remove the fuel tank. See Fuel Tank Removal, (
page 5.20.
4. Remove air box. SeeAir Box Removal, page 5.17.
3. Replace any components that fail inspection with 5. Disconnect the ignition coil electrical connector.
genuine Indian Motorcycle replacement parts.
6. CD.
Remove the ignition coil fastener
(
7. Remove the ignition coil assembly CD.
The fuel lines exiting fuel pump are subjected to high 8. Using a 6" extension and a 5/ 8" spark plug socket,
pressure. Replace with genuine Indian Motorcycle remove spark plug G).
replacement parts to reduce the possibility of fuel
line failure. Be sure fuel lines are routed properly and
do not come in contact with sharp or hot objects, or
Check gap on replacement spark plug(s). C
anything that may cause wear or damage.
SPARK PLUG INSPECTION / GAP

SPARK PLUG RE MOVAL
HOT COMPONENTS Wear insulated gloves and/ A hot engine can cause serious burns. Allow engine (_
or allow engine and exhaust to cool before to cool or wear protective gloves when removing the
handling these parts. spark plugs.
1. Remove spark plug (s). See Spark Plug Removal,

page 2.26.
The engine should be at room temperature to 2. Inspect electrodes for wear and carbon buildup.
perform this procedure. Look for a sharp outer edge with no rounding or
erosion of the electrodes.
3. Clean with electrical contact cleaner or a glass
bead spark plug cleaner only.
CAUTION
A wire brush or coated abrasive (sandpaper) should
not be used to clean electrodes.
9926 140 R02 - 2015 - 20 16 Scout Service Manual

2.26
MAINTENANCE
4. Measure electrode gap with a wire gauge (D . 7. Install seat assembly. See Seat Removal I
Adjust gap if necessary by carefully bending the Installation, page 3.9
grounding electrode until the specified gap is
achieved.
ENGINE COM PRESS ION TEST
I. Warm engine to operating temperature.
2. Shift transmission into neutral and stop engine.
3 . Remove the seat. SeeSeat Removal I Installation,
page 3.9.
4. Remove the fuel tank. SeeFuel Tank Removal,
page 5.20
5. Remove the air box assembly. See Air Box
Removal, page 5.17.
6. Remove ignition coils. Seeignition Coil Removal I
Spark Plug Type: NGK MR7F
Spark Plug Gap: .030 in (0.8 mm)
SPARK PLUG IN STALLATION

I . Inspect spark plug gap with a wire gauge. If gap
adjustment is necessary, bend ground electrode
carefully using a spark plug gap tool.
Spark Plug Type: NGK MR7F
Spark Plug Gap: .030 in (0.8 mm) 8. Remove the Fuel Pump Relay CD to disable fuel
pump.
2. Apply anti-seize compound sparingly to spark
plug threads , avoiding the bottom 2 - 3 threads.
3. Torque spark plugs to specification.
- : {•)\{•1 * j - 680
STARTER RESISTOR
FAN
20A
CHASSIS
15A
~ : 1 0 6 . 2 i n -~ REL.A y F\.E.. PU.P
15A
8iGfE
20A
• •a .•.
CAUTION
Do not over tighten spark plugs. Damage to the
cylinder head or spark plug may result.
4. Install ignition coil(s). See Ignition Coil Removal I

Installation, page 16.3 .
5. Install air box assembly. See Air Box Installation,
page 5.17 9. Remove spark plug from cylinder to be tested. See
Spark Plug Removal, page 2.26.
6. Install fuel tank assembly. See Fuel Tank
Installation, page 5.25 10. Install compression tester in the spark plug hole
following manufacturers instructions.
9926 140 R02 - 201 5 - 20 16 Scout Service Manual

2.27
MAINTENANCE
11. Crank engine until needle on compression gauge BATTERY (

stops rising (about 5 seconds). This motorcycle is equipped with a maintenance free
battery which is located under the seat. DO NOT
12. Repeat procedure for other cylinder.
remove cell caps or add distilled water to the battery.
Specification - Scout If the battery discharges, refer to Chapter 15 for
STD: 210- 230 psi (1448 - 1586 kPa) diagnostic information.
SERVICE LIMIT: Below 190 psi (1310 kPa)
(
High engine compression may indicate: Battery electrolyte is poisonous. It contains sulfuric
• Carbon deposits in combustion chamber acid. Serious burns can result from contact with skin,
• Engine modification eyes or clothing. Antidote:
• Faulty Gauge External: Flush with water.
Internal: Drink large quantities of water or milk.
Low engine compression may indicate: Follow with milk of magnesia, beaten egg, or
• Slow starter motor cranking speed vegetable oil. Call physician immediately.
• Carbon or foreign material on valve seat Eyes: Flush with water for 15 minutes and get prompt
• Worn or damaged piston and/or piston rings medical attention.
• Leaking exhaust or intake valves Batteries produce explosive gases. Keep sparks,
• Leaking head gasket flame, cigarettes, etc. away. Ventilate when charging
• Valve timing incorrect or using in an enclosed space. Always shield eyes
• Non-OEM camshafts or faulty gauge when working near batteries. KEEP CHILDREN
AWAY FROM BATTERY.
If cylinder compression is below specification,
perform a cylinder leakage test to determine
where the leak is occurring. Follow the instructions CAUTION
provided with the leak-down tester. Whenever removing the battery, disconnect the
negative (black) cable first. When reinstalling the
ENGINE COMPRESSION TEST (WET) battery, connect the negative (black) cable last. l
If a cylinder leakage tester is not available, perform a Do not remove the battery cables while the engine is
wet cylinder compression test. running. Doing so may damage the Electronic
Control Module (ECM).
1. Pour 3-5 cc of clean engine oil into each cylinder Take great care NOT to reverse the battery leads
through spark plug hole. Repeat cylinder when installing the battery.
compression test. See Engine Compression Test,
page 2.27. C
2. If compression increases substantially, inspect
cylinder, piston, and rings. BATTERY INSPECTION
Battery terminals and connections should be kept free
3. If compression does not increase, inspect valves of corrosion. If cleaning is necessary, remove the
and valve seats. corrosion with a stiff wire brush. Wash with a solution
of one tablespoon baking soda to one cup water. Rinse
well with tap water and dry off with clean rags. Coat l
terminals with dielectric grease.
l. Visually inspect the exterior of the battery.
Replace battery if housing is damaged, case is
deformed, or if electrolyte is leaking.
2. To remove corrosion, remove battery from (
motorcycle and wash terminals with water and
baking soda solution. Clean terminals, bolts, and
cable ends with a brass wire brush and apply a
thin film of dielectric grease.
9926140 R02 - 20 IS - 2016 Scout Service Manual l

2.28
MAINTENANCE
3. Measure battery voltage. 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.
CAUTION
Do not remove caps on battery while recharging. Do
not attempt to inspect or add fluid to a maintenance
free battery.
2. Charge battery at 1.8 amps for 5 to 10 hours.
Battery Charging Specification: 1.8 A for 5-10 hours
3. Remove battery from charger and let it sit for 30

minutes or longer.
4. Measure battery voltage with a digital multi-meter.
If battery voltage is lower than 12.5 Vdc, battery
must be recharged again in accordance with step 1
and 2 above.
5. After charging battery and letting it sit for 30
minutes or more, check the battery voltage again.
If battery voltage is still below 12.5 Vdc, replace
battery.
When motorcycle is not used for one ( 1) month or

more, remove battery and store it in a cool, dry area.
Specification: 12.5 Volts DC minimum Inspect voltage monthly and charge according to
above instructions if necessary.
4. If battery voltage is below 12.5 Volts DC, charge it
thoroughly. See Battery Charging, page 2.29.
5. Replace battery if it will not accept a charge. BATTERY STORAG E
When the motorcycle is not used for periods of one
BATTE RY CHARGIN G month or longer the battery should be fully charged
CHARGING NEW BATTERY prior to operation. Store battery in a cool, dry place.
1. Charge the battery at 1.8 amps for 5 to 10 hours. use Battery should be charged monthly using a 12 volt
a straight rate charger (not load sensing or battery battery charger with a maximum charge rate of 1.8
tender type) for the initial charge of a new battery. amp-hr.
CAUTION
Do not attempt to quick charge the battery at any Battery charging can create explosive gasses;
time. keep sparks, flames, cigarettes or anything that
could ignite the gasses away. Provide adequate
2. Remove battery from charger and let battery stand ventilation when charging in an enclosed space.
for 30 minutes or longer. Batteries contain acid that is caustic. Wear
protective clothing and a face shield or protective
3. Measure voltage with a digital multi-meter. If lower eyewear when working with the battery. KEEP
than 12.5 Vdc, battery must be recharged again in OUT OF REACH OF CHILDREN.
accordance with step 1 and 2 above.
minutes or more, check battery voltage again. If BATTERY.R EMOVAL
battery voltage is still below 12.5 Vdc, replace the 1. Remove the seat. See Seat Removal I Installation,
battery. page 3.9.

2.29
(
MAINTENANCE
2. Release fuse panel CD and move off to the side. BATTERY INSTALLATION
1. Install battery into battery box.
2. Install battery hold down bracket and torque
fastener to specification.
3. Connect the positive battery terminal and torque

(
4. Connect the negative battery terminal and torque
3. Disconnect negative battery terminal.
4. Disconnect positive battery terminal.
5. Remove battery hold down bracket fastener CD .
[~ - ·--11u t i'
'QI
5. Install fuse panel.
b,/'""'- 1 ·, , I'
6. Install the seat. See Seat Removal I Installation,
I'
4'::-~
, '1' l k
I
1:,\
•[,\
\ \ I page 3.9.
o 1r· \,\1~
· \&,1 1
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:~ci. '\ ( \ '~~ ,;' (
-) ' l \ \ \b-r.~
ff(/ ' y
. . \ \ V'fr
' · · 1 \ \
/\ .
I~ 1\ ,.Jf.n'
- .W"'
cg, ~:::.. 3~~\
.-----""f;,. \, .I
,v;,t , ,
J
' " ·:.::::...i'l

i, I -/~ .52J \ ' (
In
•
I
i "\.
-~,- /
-::::::-~//
\ \
\ I
·~ \ '\\((1'
6.
(.

2.30
MAINTENANCE
DRIVE BELT INSPECTION 3. If the drive belt or sprocket is being replaced due
to damage, replace belt and both sprockets as a
set if drive system has more than 5000 miles (8000
Inspect drive belt in accordance with Periodic Km) of use.
Maintenance Interval Chart and replace at specified
intervals regardless of belt condition. See Periodic DRIVE BELT SPECIFICATIONS
Maintenance Interval Table, page 2.5.
DRIVE BELT DEFLECTION DATA
DRIVE BELT
WEAR
CONDITION SERVICE
REC OMMEN-
~ M•4•t£?t1:Wf
EXAMPLES DATION
MODEL DEFLECTION FREQUENCY
,~1
External Tooth Replace Belt
,~,
Cracks AT 10 LBS
FORCE
Scout .472" (12 mm) 40-50 Hz
Internal Tooth OK to run, but
,~,
Cracks monitor
condition DRIVE BELT FREQUENCY TENSION DATA
Fuzzy Edge OK to run, but
,~,
Cord monitor 45-50 Hz with Sonic Tension Meter
condition
Hook Wear Replace Belt

DRIVE BELT TENSION
,~, Missing Teeth
Bevel Wear
Replace Belt
OK to run, but
Special Tool: Belt Tension Gauge PV-43532
Do not adjust the belt when wet, or immediately after

riding. Belt must be dry and the drive system must be
at ambient temperature (60-80° F). This is extremely
I~n0cinono gl important for accuracy.
,~,
(Outer Edge monitor
Only) condition
Chipping (Not OK to run, but

Perform this procedure to achieve proper belt
,~,
Serious) monitor
tension and alignment. Belt tension should be set
condition
before performing the alignment procedure.
Stone Damage Belt should be
replaced if
damage is on
the edge of the A drive belt that is not properly tensioned can cause
belt drive line noise and damage the drive belt, causing
possible belt failure and loss of control of the
1. Periodically inspect drive belt for cuts, excessive motorcycle.
wear, foreign substance (oil, grit), missing teeth,
or any other damage.
2. If any damage is found, belt should be replaced.
Care should be taken to be sure the motorcycle will
not tip or fall while elevated. Severe personal injury
Adjust drive belt tension at intervals in accordance or death may occur if the motorcycle tips or falls.
with the Periodic Maintenance Interval Chart. See
Periodic Maintenance Interval Table, page 2.5. 1. Secure motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Shift transmission into NEUTRAL.

2.31
MAINTENANCE
3. ELEVATE rear wheel off the ground when 7. Push up on gauge until 0-ring just touches tool
checking deflection or adjusting the belt. body. See Drive Belt Specifications, page 2.31 for
Find Tight Spot In Belt drive belt deflection specifications.
4. Use the tire valve stem as a reference and perform 8. If belt deflects more than the specified distance
the following Steps: with 10 lbs. of force, tighten the belt. If deflection
is less than specified loosen the belt. See Drive
• Check I record belt deflection at 4 different points, Belt Adjustment, page 2.32.
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
(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 G) in the lower
belt guard. DRIVE BELT ADJUSTMENT
Perform this procedure to achieve proper belt

tension and alignment. Belt tension should be set
before performing the alignment procedure. C
Belt Tension
A rear axle not in alignment can cause drive line

noise and damage the drive belt, causing
possible belt failure and loss of control of the
motorcycle.
• Adjust belt deflection with wheel in this position.

Alignment marks G) and CD are used as a reference (
5. Place tape measure or ruler next to drive belt or for initial wheel alignment. Alignment marks should
use the graduations on lower belt guard for be in approximately the same position on both left
reference. and right sides of wheel.
6. Slide 0-ring on belt tension gauge to the 10 lb.
mark.
• Place belt tension gauge squarely against belt at (_
center and keep it at a 90° angle to the belt surface.
Belt
--~· ~-
._
/Jf ~\
,•. ....' ·\.J,
:
'
\
,-\
id~
~
n c:.~
l1
.... ,,.;.
b\
OK OK 1. Place the motorcycle in an upright position with the

2.32
MAINTENANCE
2. Make note of adjuster locations CD and (J).

3. Raise the rear of the motorcycle so the rear tire can
Drive belt misalignment can cause drive line noise
be freely rotated.
and damage the drive belt, causing possible belt
4. Loosen axle nut G) and retighten to the failure and loss of control of the motorcycle.
ADJUSTMENT SPECIFICATION during the
adjustment procedure.
To minimize change in belt tension, use RIGHT SIDE

adjuster only to make final adjustments to belt
alignment. Be sure to keep axle seated forward
against axle adjusters during this procedure.
7. Rotate the wheel BACKWARD. Tighten RIGHT rear

axle adjuster until belt comes off inside sprocket
flange during backward wheel rotation.
The belt should track to the center of the sprocket

tooth surface when properly aligned. Sprocket teeth
should be visible ori both sides of the drive belt.
Rear Axle Nut (ADJUSTMENT SPECIFICATION) 15

ft-lbs (20.3 Nm)
5. Turn LEFT SIDE adjuster nut © to achieve proper

belt tension. Refer to Drive Belt Tension, page 2.31
\\'
\\'
\I\
I
\ I
;
8. Rotate the wheel in FORWARD direction and verify

that sprocket teeth G) are visible on both sides of
the drive belt.
I
I
,,Ii
//,
I //
J 6. When belt tension is correct, check and adjust final

belt alignment as follows.
Belt Alignment

2.33
(
MAINrENANCE
9. If necessary, loosen the axle nut and RIGHT SIDE 2. Inspect front and rear sprocket teeth for wear or
adjuster until belt moves off the left flange and damage from foreign material.
begins to track down the center of the driven
:i};?:Jif;>f~:I
sprocket flange during forward wheel rotation .
.,. ·-·. ·• - .- · NOTE '· . ·" :·-··, .:
... ·-· . . ' '-. - ...
r, :. ,. \ •, • • ~:;. '•
, ' . .. . . .
It may be necessary to loosen the axle nut and tap
the left end of the axle to ensure it moves forward (
when the adjuster is loosened. The axle nut must be /:'/
retightened to the ADJUSTMENT SPECIFICATION s ,./ .
,,~?.,,.,;
before proceeding.
IO. Rear wheel alignment is satisfactory when the :;- ,

drive belt remains centered on driven sprocket (
during forward and backward wheel rotation.
Sprocket teeth should be visible from both sides of
the drive belt.
11. Verify that drive belt tension is still within
":iiil\?rcil/.~, "\
specification. Refer toDrive Belt Tension, page 3. Closely inspect drive belt condition.
2.31.
12. Tighten rear axle nut to FINAL Specification FUSE REPLACEMENT
Fuses and relays are located in the fuse box under the
seat.
Rear Axle Nut (FINAL TIGHTENING)65 ft-lbs (88.0 I. Remove the seat. See Seat Removal I Installation,
Nm) page 3.9.
2. Release the retainer CD and slide the fuse box
13. Pump rear brake pedal several times to reset brake rearward.
pad distance.
'\Y \
14. Verify wheel rotates smoothly and freely without
drag when brake pedal is released:
;-\!
SPROCKET INSPECTION C
Drive belt and sprocket service life are maximized

and drive line noise minimized by proper cleaning.
Cleaning interval is approximately every tire change,
or more often if operated in dirty, dusty, or high
debris environments.
Inspection
I. Clean the drive belt and front and rear sprockets
,/
with a mild mixture of dish soap and warm water.
Rinse and dry thoroughly.
9926140 R02 - 2015 - 2016 Scout Service Manual l

2.34
MAINTENANCE
3. Release the fuse box cover clips CD and remove 5. Turn ignition switch ON.
cover.
6. Set headlight to HIGH beam.
7. Compare the position of headlight beam on the
wall to the illustration below and adj ust if
necessary.
2 5 ft. (7 .6 m)
/ 7.5 in. ('.9.0 cm)
Headlight Bulb
Center Height
4. If any fuse is blown, turn off main switch. Install HEADLIGHT AIM ADJU STMENT
new fuse of specified amperage. Turn on switches 1. To adjust the headlight vertically, loosen the
and see if system operates correctly. Repeat fuse
headlight housing mount fastener CD and pivot the
failure indicates an electrical problem.
headlight housing up or down as required. To
CAUTION adjust the headlight horizontally, loosen the
headlight mounting bolt CD and pivot the headlight
Do not use fuses of a higher amperage rating than side-to-side as required.
what is specified.
If the correctly rated fuse continues to blow,
something is wrong and needs to be corrected.
Substituting a higher amperage fuse can lead to
extensive electrical system and vehicle damage.
HEADLIGHT AIM IN SPECTION

Adjust headlight aim when there is a change in load
(rider, cargo, accessories , etc.) or after suspension
adjustment.
ALL MODELS: With the headlight sw itched 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 w hen centered straight
ahead at 25 feet (7.62 m).
Follow all steps below to ensure accurate aim SIDE-S TAND INSP ECTION
inspection. 1. Support the motorcycle in an upright position with
1. Check and adjust the tire pressure. See Tire the front wheel clamped in a wheel vise .
Pressure I Specifications, page 2.15.
..) 2. Verify suspension ride height is set correctly. See

Rear Shock Preload Inspection, page 2.38.
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.

2.35
MAINTENANCE
2. Inspect side-stand spring for damage or loss of 2. Remove side-stand pivot bolt G) using a 6 mm hex (
tension. Verify the side-stand returns to fully wrench while holding the nut CD with a 15 mm
retracted position. wrench.
3. Inspect side-stand for smooth movement. 3. Grasp side-stand firmly and move it to the UP
position.
4. Inspect side-stand pivot bolt nut for proper torque .
4. Pull side-stand rearward against spring tension
until mounting flange on side-stand is clear of the
mounting boss on the frame.
5. Relax tension and remove spring.
5. Replace side-stand if it is bent. Do not attempt to 6. Installation: Attach spring to side-stand.
straighten side-stand. (
7. Lightly grease side-stand mounting boss on frame
and the shouldered portion of the pivot bolt.
SIDE-STAND REMOVAL/ INSTALLATION
8. Place loose end of spring through hole in frame
rail.
The side-stand spring is under tension. Wear eye and 9. With side-stand in the retracted position (up), pull
face protection when removing and installing the stand rearward against spring tension until the
spring and side-stand. Be sure the vehicle is properly mounting flange on the side-stand drops onto the
secured before you begin. mounting boss on the frame.
10. Swing side-stand to the extended position to align
1. Side-stand will be moved between the UP bolt hole and install bolt and nut.
(retracted) and DOWN (extended) position during
removal and installation. Be sure vehicle is 11. Torque to specification and wipe off any excess
properly secured. grease. C
12. Cycle the side-stand to be sure it moves freely,

(
and returns to the fully retracted position.
(_

2.36
MAINTENANCE
STEERING HEAD/ FRO NT WHEEL INSPECTION SWING ARM IN SPECTION
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. Sit astride the motorcycle. Compress the rear

suspension several times and check for smooth
Be sure control cables, hoses and wiring are not and quiet operation.
interfering with handle bar rotation. 2. Secure motorcycle with rear wheel elevated.
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 CD . Inspect for worn bearings and linkages
inspect for smooth, free movement. Point front by moving the wheel side-to-side CD.
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.
....,,
c'4i:,<;\,;:Y" "' . ~- .,:-·--
4. If movement is detected, determine if movement is

at axle area G) or swing arm pivot area ©. Refer to
wheel bearing and swing arm bearing
replacement.
3. Rotate front wheel and inspect for smooth rotation
of front wheel bearings. If roughness or unusual
sounds are present, replace front wheel bearings.
See Chapter 11.
4. Turn handle bars full right or left and hold against
the fork stop. Attempt to move front wheel side-to-
side. If movement is observed, inspect front axle,
wheel, and bearings. See Chapter 11.
5. Rotate rear wheel and inspect for smooth rotation

of rear wheel bearings. If roughness or unusual
sounds are detected, inspect rear wheel bearings,
belt tension and alignment, and brake pads.

2.37
MAINTENANCE
6. Inspect rear shock for leakage and all rear REAR SHOCK PRELOAD ADJUSTMENT
suspension components for damage or loose 1. Place the motorcycle in an upright position with C
fasteners. the front wheel clamped in a wheel vise.
7. Inspect suspension pivots and shock mounts for 2. Using shock spanner wrench (PV-46993) loosen
radial movement in all pivot joints. If a joint has the lock nut G) by turning it counter-clockwise (as
radial movement, remove rear shock absorber and viewed from the top of the shock) .
inspect suspension pivot linkage. See Chapter 12.
3. Spray a light lubricant on the adjuster nut where it
8. Replace any worn or damaged parts. contacts the spring.
9. Verify axle nut is tight. 4. Adjust shock preload by rotating the adjuster nut
-·{•l,(•11, _ clockwise (as viewed from the top of the shock) to

INCREASE preload (firm) or counter-clockwise to
DECREASE preload (softer).
~Nut:65ft-l~
C
REAR SHOCK PRELOAD INSPECTION
Periodically inspect rear shock preload. For the most
\
comfortable ride and proper ground clearance, adjust
preload if ride height is out of specification.
1. Verify that tire pressure is at specification. See Tire
Pressure I Specifications, page 2.15.
··-, .·
2. Load the motorcycle with all intended cargo.
3. Determine shock preload G) by measuring from
the upper shock mount bolt center to lower shock
mount bolt.
~ttt)>}.,:\,,?',~7f}1~il (
5.
"'
Recheck the preload measurement after adjusting.
6. Tighten the lock nut securely against the adjuster
nut.
(.
4. Adjust preload as needed to achieve suspension

sag indicated in the table below. See (Rear Shock
Preload Adjustment) for adjustment procedure.
SHOCK PRELOAD LENGTH

Scout 282 mm (from shock
mount bolts center-to- (
center)

2.38
MAINTENANCE
VALVE CLEARAN CE IN SPECTION plugs. Torque spark plugs to specification. See

Spark Plug Installation, page 2.27 .
I
page 3.9 . 13. Inspect the valve cover seal and replace if
2. Remove the fuel tank. See Fuel Tank Removal, page necessary.
5.20. 14. Install NEW isolators on the valve cover bolts.
3. Remove air box. SeeAir Box Removal, page 5.17. Install the valve cover and the three T40 bolts. 2
Torque cover bolts to specification. SeeValve Cover
4. Remove thermostat housing cover. See Thermostat Installation, page 7.23
Housing Cover Removal I Installation, page 3.12.
15. Install the ignition coil. See Ignition Coil Removal I
5. Remove valve covers. SeeValve Cover Removal, Installation, page 16.3.
page 7.23.
16. Install the air box . See Air Box Installation, page
6. Remove spark plugs. 5.17.
7. Remove flywheel access cover. 17. Install the fuel tank. See Fuel Tank Installation,
8. Rotate the engine CCW (from flywheel side) until page 5.25.
the earn lobes G) are facing away from valves being 18. Install the seat. See Seat Removal I Installation,
inspected. page 3.9.
VALVE CLEARANCE ADJU STMENT

Procedure to adjust valve clearance as part of sched-
uled maintenance.
Consult the Periodic Maintenance Interval Table for

maintenance intervals.
1. If any of the valve clearance measurements are out

of specification, remove the camshaft carriers and
camshafts and proceed with this procedure.
Intake Camshaft - PN 3022484
Exhaust Camshaft - PN 1204693
9. Measure the valve clearance at location CD with a

feeler gauge.
Intake Valve Clearance (cold): 0.006 in (0.152 mm)
Exhaust Valve Clearance (cold): 0.008 in (0.203 mm)
2. Remove the valve tappet from a valve that was out

of specification.
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.
3. Record the 3 digit number on the bottom of the

l O. If the valve clearance is out of specification,
tappet CD.
proceed to "Valve Clearance Adjustment". See
Valve Clearance Adjustment , page 2.39.
11. Repeat steps 8 - 10 on each of the eight valves.
12. If previously removed, apply anti-seize compound
to the spark plug threads and reinstall the spark

2.39
(
MAINrENANCE
C
4. Reference the valve clearance measurement
recorded for that valve, along with the 3-digit
tappet number.
5. Refer to the appropriate tappet selection matrix to
select the proper tappet. See Intake Valve Lash -
Tappet Selection Matrix, page 7.37orExhaust Valve
Lash - Tappet Selection Matrix, page 7 .38.
6. Install the proper tappet.
Lubricate the outer portion of the valve tappet upon (

installation.
7. Repeat steps 2 - 6 until all necessary valves have

been adjusted.
8. Reinstall the camshafts and camshaft carriers and
tighten the bolts evenly to specification. r
9. Measure and confirm that valve clearance is now

within specification for each valve.
10. If valve clearance is not within specification, repeat
this procedure.

2.40
FRAME / BODY
CHAPTER3
FRAME/BODY
GENERAL INFORMATION . .. . ........................................................................... 3.2
SERVICE NOTES . . .... . ......... .. ....... . •......•............ ... ... . ..• . .. . . . . ..... .. ......•........ . 3 .2
SPECIAL TOOLS .............. . .... ....... ........ .......... ... ... .. .. . . ... .. ... ..• .. ............ . ..... 3.2
TORQUE SPECIFICATIONS ............. . ............. .. .. ... . .. . . .... . . ... .. . .......... . ............. . 3.2
ASSEMBLY VIEWS .. . ... . . .. .. . ....... ...... . .... .. ... ... .. .. ·.... . ..... .. .. ; . .. . ....... ..... . . . .. .. . .. . . .. 3.3
FENDERS I SEAT . .. ..... ... . ............ .... ... . .. .. ... . .... ... .... ... . . . . . . ... . .. . . ...... . .. . ..... . .. 3.3
FRAME . ..... . . ... ... . ...... . ..... .. .. . ........ .. • ....... . ............ . .. . . . . .... ...................... 3.4
FOOT PEGS ..... .. . .. ... .. .... . . .. .. ..... ... .. .. ..............•. . ..... .. ............. . ........... .. ... 3 .6
BODY I FRAME SERVICE .. .. . . ........ . . .... .. ................ . .. ..... .. .. .. .. .. .. .. . . .. . ... . .. .. ... .. . . 3.7
FOOT PEG DRIVER REMOVAL I INSTALLATION .. ... .... .. .. . . . ....... . ... .. . . . . ... ... . . ....... . ...... 3.7
LEFT FOOT PEG .. .... . .. .. .... ... ........ .. ... ..... . ..... . . .• .. ... .. .. . ... . .. . . . ... .... .. ...... .. . 3.7
RIGHT FOOT PEG . ....... . .. ... ... . . . .. ..... ........ . . .. .. .. . . .. ........ . ....... . . .. . . . .... . . . .. . 3. 7
FOOT PEGS PASSENGER REMOVAL I INSTALLATION .. . ... ... . . . ............. . . .. . .. .... . ... ... ... . .. 3.8
SEAT REMOVAL I INSTALLATION .. .. .. . .... . ..... . . . . .. .... .. . ......... ...... .. ... ... ...... . ... ... . .. 3.9
FRONT FENDER REMOVAL . .. . . . .... .. .. . ........... . .. ..... . .... .... . .. ....... ... . ....... .. . . . . ... . . . 3 .9
FRONT FENDER INSTALLATION . .. . • ... .... .. . . . ..... . .. .. .... . .. . ... . .. . . .. . .. ...... . .... .. ... .... . . 3.10
REAR FENDER REMOVAL ......... . .. . .•.... . .... . . . .... . ... . . .... ... .... .. . . . . . . .. . .. .. .... . . . . ... . . 3.10
REAR FENDER INSTALLATION ... . .... . .. . ...............•......•. .. ... . ... •. .. . .. •.... . . ............ 3 .11
INSTRUMENT PANEL REMOVAL I INSTALLATION ... . .. .... .. ... .. . . .. .... . . . .. .. .... . ...... . . . ...... 3.11
IGNITION SIDE COVER REMOVAL I INSTALLATION . ... . . . . ............. ... . .. .. ... . .. .. .. .... ...... 3 .11
THERMOSTAT HOUSING COVER REMOVAL I INSTALLATION .... .. •.. .. .. . . . . ... . . . .. ..... . •. . . .... . 3 . 12
FRAME REMOVAL I INSTALLATION . . .. ...... . ...... . . .... .. . . . .......... ... . .. . . . . ............... .. . 3 . 12
~[)26140 R02 - 2015 - 2016 Scout Service Manual

3.1
FRAME/BODY
GENERAL INFORMATION
SERVICE NOTES TORQUE SPECIFICATIONS
This section covers the removal and installation of
frame and body components, assemblies and systems. Torque Specifications
Pay close attention to assembly procedures and torque
specifications. DESCRIPTION TORQUE
SPECIFICATIONS
Cables, hoses and tie straps that have been removed
during disassembly must be · replaced per factory Ignition Side Cover Screws, 96 in-lbs (10 Nm)
(
standards during assembly. Caution should be used (Qty. 3)
when tightening body panels. Any deformation on the
panel around the screw is an indication that the screw Instrument Panel Screw, 22 ft-lbs (29 .8 Nm)
is too tight. Do not over tighten body components in (Qty.4)
order to avoid damage. Screw - M8 x 1.25 x 16 19 ft-lbs (25.7 Nm)
(QTY.2), Backbone Bracket
SPECIAL TOOLS to Front Frame
C
TOOL DESCRIPTION PART NUMBER Screw, Frame Backbone to 35 ft-lbs (47.4 Nm)
Front Frame- MIO x 1.5 x
PV-49955 Body Panel Tool Kit 145 (QTY.2) , Backbone to
Front Frame
Bosch Automotive Service Solutions: 1-800-345-
2233 or https: //polaris.service-solutions.com/ Screw, Footpeg Driver - 35 ft-lbs (47 .5 Nm)
MIO x 1.50 x 35 (QTY.2)
Screw, Front Fender - M8 x 18 ft-lbs (24 .4 Nm)
1.25 x 50 (QTY.4)
Screw - Ml2 x 1.75 x 95 51 ft-lbs (69 .1 Nm)
(QTY.2), Front Frame to
Engine
Screw - MIO x 1.50 x 30 35 ft-lbs (47.4 Nm) (
(QTY.4) , Mid Cast Frame to
Backbone
Screw - Ml2 x 1.75 x 250 51 ft-lbs (69.1 Nm)
(QTY.2), Mid Frame to
Engine
Screw, Footpeg Passenger - 19 ft-lbs (25.7 Nm) (
M6 x 1.0 x 10 (QTY.I)
Screw, Rear Fender - M8 x 18 ft-lbs (24.4 Nm)
1.25 x 20 (QTY.4
Screw - MIO x 1.50 x 25 35 ft-lbs (47.4 Nm)
(QTY.4) , Rear Subframe to
Midframe (.
Screw, Seat Mount - M8 x 18 ft-lbs (24.4 Nm)
1.25 x 16 (QTY. I)
Shift Rod, Bolt 7 ft-lbs (9.5 Nm)
Swingarm Pivot Tube 5 ft-lbs (6.7 Nm)
Thermostat Housing Cover, 96 in-lbs (10.0 Nm)
Screws (Qty.3)

3.2
FRAME/BODY
ASSEMBLY VIEWS
FENDERS/ SEAT
NUMBER PART DESCRIPTION TORQUE

1 Screw, Front Fender - MS x 1.25 x 50 (QTY.4) 18 ft-lbs (24.4 Nm)
2 Screw, Seat - MS x 1.25 x 16 (QTY. l) 18 ft-lbs (24.4 Nm)
3 Screw, Rear Fender - MS x 1.25 x 20 (QTY.4) 18 ft-lbs (24.4 Nm)

3.3
FRAME/BODY
FRAME
9926140 R02 - 2015

- · Manual
- 2016 Scout Service
3.4
FRAME/BODY
NUM- PART DESCRIPTION TORQUE(IF TORQUE SEQUENCE

BER APPLICABLE)
CD Backbone, Frame Weld - -
CD Backbone, Frame Weld - -
CD Pivot, Swingarm 5 ft-lbs (6. 7 Nm) 3rd
© Frame, Subframe Rear - -
® Spacer - 280D x 131D x 12.5 - -
© Frame, Mid LH - -
(j) Frame, Mid RH - -
® Frame, Front - -
® Foam, Air Box Frame - -
Bolt, Swing arm Pivot - M 16 x 1. 50
@)
x340
- -
Screw - MlO x 1.50 x 25 (QTY.4), 35 ft-lbs (47.4 Nm)

® 4th
Rear Subframe to Midframe
Screw- MS x 1.25 x 16 (QTY.2), 13th (Right)
@ 19 ft-lbs (25 .7 Nm)
Backbone Bracket to Front Frame 14th (Left)
Screw- Ml2 x 1.75 x 250 (QTY.2), 1st (Lower)
® 51 ft-lbs (69 . 1 Nm)
Mid Frame to Engine 2nd (Upper)
Screw, Frame Backbone to Front
@ Frame- MlO x 1.5 x 145 (QTY.2), 35 ft-lbs (47.4 Nm) -
Backbone to Front Frame
Screw - Ml2 x 1.75 x 95 (QTY.2), 5th (Left)
® 51 ft-lbs (69.1 Nm)
Front Frame to Engine 6th (Right)
7th (Left Front)
Screw - MIO x 1.50 x 30 (QTY.4), 8th (Left Rear)
® 35 ft-lbs (47.4 Nm)
Mid Cast Frame to Backbone 9th (Right Front)
10th (Right Rear)
Nut - MlO x 1.50 (QTY.2), 11th (Right Front)
® Backbone to Front Frame
- 12th (Right Rear)
@ Nut - Ml2 x 1.75 (QTY.3) - -

3.5
FRAME/BODY
FOOT PEGS
~~
r
~2 ~t:
/~1,1H
i . '.,;;)
'-,,,' 7
,, /1
.. C
~ ~Qi '/ ',, __
""' .' ,.f/

/
... r
V l. .-. / .:
:
·;.:_/ !
'
..
~r;,
, ,I;·
· ,,.:, ·
.
~.? ·""'" /
: ·~~ ' ,
~ . . ._,..~
C
(;3•,i
'
J
\.....,_/
(
NUMBER PART DESCRIPTION TORQUE
1 Screw, Footpeg Passenger - MS x 1.25 x 20 (QTY.2) 19 ft-lbs (25. 7 Nm)
2 Screw, Footpeg Driver - MlO x 1.50 x 35 (QTY.2) 35 ft-lbs (47.5 Nm)
3 Screw, M6 x 1.0 x 10 (QTY. l) 84 in-lbs (9.5 Nm)
4 Shoulder Screw (QTY.2) 50 ft-lbs (68 Nm)
C.

3.6
FRAME/BODY
BODY/ FRAME SERVICE

FOOT PEG DRIVER REMOVAL/ INSTALLATION RIGHT FOOT PEG
LEFT FOOT PEG 1. Remove bolt CD retaining the master cylinder clevis
1. Remove Shift Rod Bolt CD from Shift Rod G). G) to pedal.
2. Remove two bolts G) securing foot peg bracket to 2. Remove two Master Cylinder Bolts G).
frame.
3. Remove two bolts © securing foot peg bracket to

3. INSTALLATION is performed by reversing the frame.
removal procedure.
4. Torque driver foot peg bracket bolts to
specification.
Driver Foot Peg Bolts: 35 ft-lbs (47 .5 Nm)

Shift Rod Bolt: 7 ft-lbs (9.5 Nm)
4. INSTALLATION is performed by reversing the

removal procedure.

3.7
FRAME/BODY
5. Torque driver foot peg bolts to specification. FOOT PEGS PASSENGER REMOVAL/
INSTALLATION
r
TORQUE
Driver Foot Peg Bolts: 35 ft-lbs (47 .5 Nm)
Foot Peg Master Cylinder Bolts: 84 in-lbs (9.5 Nm)
Master Cylinder Clevis Bolt: 84 in-lbs (9.5 Nm)
1. Remove bolts CD securing foot peg bracket to
frame. C
2. Remove foot peg I bracket as an assembly.
/ C
':{"-
, ._
'
:
/ :
.,,.,:. ,..._,"
., .,.~. ','
.{~·'
.,. .. ·
·<..
/
/
/
3. INSTALLATION is performed by reversing the (

removal procedure.
4. Torque passenger foot peg bracket bolts CD to
specification.
3.8 9926 140 R02 -2015 - 2016 Scout Service Manual

FRAME/BODY
SEAT REMOVAL / INSTALLATION FRONT FE NDER REMOVAL

1. Lift up on the seat front to disengage the front of Motorcycle should be parked on a level surface rest-
the seat from the frame post. ing on the side stand.
CAUTION
Use care not to scratch or damage painted surfaces
during fender removal and I or installation.
l . Remove two fender mount bolts from each fork

slider leg.
'.\\}
:A•~ .... ·::
-~/,/
2. Lift the seat and pull rearward to disengage the

seat from the mount holding the back of the seat to /· I
the frame .
/
/
/
/
'·· v~./f , ! .~"
'\,.{/
" ~' ,\,:
!.< :i
' _/};)Ji/-!
2. Stand in front of the motorcycle facing the front
fender and squeeze the sides together w hile
" rolling" the fender out from between the fork
legs.
·,
\
. '·
removal procedure.
Once fender has been removed from the motor-

cycle, make sure the fender is stored safely until it
is reinstalled.
99 26140 R02 - 20 15- 20 16 Scout Se rvice Manual

3.9
FRAME/BODY
FRONT FE NDER IN STALLATION REAR FEND ER REMOVAL

(
Motorcycle should be parked on a level surface rest- 1. Remove seat. See Seat Removal I Installation, page
ing on the side stand. 3.9
CAUTION 2. Remove two bolts CD and fender washers 0 from

both sides of the fender.
1. Gently squeeze the sides of the front fender and

"roll" the fender into position between the fork
legs so the bolt holes line up.
'
:\
\
3. Locate the rear lighting harness connector CD and C

disconnect.
2. Install the two bolts on each side of the fender and

torque to specification. (
,,'-:..........
·'\,:--,,__
·. \\ ~
~:~:-
. ·,s_~\:l
····-·-···~':.· ...-;
(
/
: ..... ···;} .
/
/ .... ~
···. _.' . ! ,. 4. Lift the fender off of the motorcycle .
CAUTION
f:'?_
.J_.-,)~_:_?f~_:.-.> r / ' ~ ~ '\\; C
/:2' ~.. . :'
,,,,.....
·
·r /.,.;-
,\
,
r- ·. . >
_.l..1I,: _;<?!,
1
·~ ;.·_., ,..1.'_,;1.. i ~~, ((
Be careful not to damage painted surfaces.
3 . Turn the handlebar all the way to the left and right
to verify proper operation and freedom of
movement.

3.10
FRAME/BODY
REAR FENDER IN STALLATION 2. Lift instrument panel and disconnect the single
multi-plug connector(D.
CAUTION
1. Route the rear harness along the rear fender and

secure with cable ties.
2. Place the rear fender assembly onto the
motorcycle so the bolt holes line up and install
screws and(Dfender washersCDto finger tightness.
3. Plug the rear harness lighting connector G) into
the chassis harness.
4. Torque fender screws to specification.

removal procedure.
5. Install seat. See Seat Removal I Installation, page
3.9
INSTRUMENT PANEL REMOVAL/ INSTALLATION

1. Remove four handle bar screws securing the
instrument panel to the handle bars. IGNITION SIDE COVER REMOVAL /
INSTALLATION
1. Remove ignition side cover fasteners CD.
...
· ····· -·· . .- .... -.. ~ -.
···- ... ... ,.,...,,,,
',,~
2. Remove ignition side cover (D.

3. Installation is reverse of removal and torque
fasteners to specification.

3.11
FRAME/BODY
7. Remove passenger foot pegs (if equipped) . See (

Foot Pegs Passenger Removal I Installation, page
3.8.
8. Remove the head pipe assembly. See Head Pipe
Removal, page 5.14.
THER MOSTAT HO US IN G COVER RE MOVAL/ 9. Support the engine with a platform jack.
INSTALLATIO N C
1. Remove the thermostat housing cover fasteners CD.
10.Remove the re ar fender. SeeRear Fender Removal ,

page 3.10.
11. Remove the rear swingarm. See Swingarm
Removal, page 12.17.
12.Remove any electrical harness clips to the frame.
2. Remove the thermostat housing cover Q). 13. Remove the rear subframe fasteners CD and
subframe assembly.
3. Installation is reverse of removal. C
4. Torque fasteners to specification.
- 1(•>;(•)·1 -
~in-lbs(lO ~
FRAM E RE MOVAL / INSTALLATION
·-···-...
C:,:~!-
(
or death could occur if the motorcycle tips or falls.
14. Remove the RH and LH mid cast frame fasteners Q).
REMOVAL
1. Place the motorcycle in an upright position with the
2. Remove the seat assembly. See Seat Removal I
3. Disconnect the negative cable from the battery.
4. Remove the fuel tank. See Fuel Tank Removal, page
5.20.
5. Remove the battery box. See Battery Box Removal,
page 15.12.
6. Remove the driver foot controls. SeeFoot Peg
Driver Removal I Installation, page 3.7.
9926140 R02 - 20 15 - 2016 Scout Service Manual

3.12
FRAME/BODY
15. Remove front triple clamps and forks. See Triple 1. Thread the swing arm pivot G) completely into the
Clamp Removal, page 11.26. RH mid frame ®·
16.Remove radiator assembly. See Radiator Removal I
17. Remove the fasteners G) holding the RH and LH
backbone to the front frame.
2. Assemble RH mid frame ®, LH midframe (J),

spacers ® on the engine with mounting bolts ® to
hand tightness.
18.Remove the lower fasteners © holding the front
frame to the vehicle and remove front frame.
INSTALLATION
3. Assemble the rear subframe @) to the midcast
. " frames.
Frame fasteners must be torqued in sequence. See
Torque Specifications, page 3.2.

3.13
FRAME/BODY
4. Install the airbox if previously removed. See Air 8. Torque fasteners to specification. See Frame, page
Box Removal, page 5 .17. 3.4. r
5. Install RH frame backbone ® and LH frame TORQUE
backbone @ on the midcast frames.
Front Frame Lower Fasteners: 51 ± 6 ft-lbs (69 ± 8
Nm)Backbone Fasteners: 35 ± 4 ft-lbs (47 ± 5Nm)
Main Frame Fasteners: 51 ± 6 ft-lbs (69 ± 8 Nm)Rear
Subframe Fasteners: 35 ± 4 ft-lbs (47 ± 5Nm) (
9. Torque swingarm pivot@ outward (clockwise) to 5

ft-lbs ( 6.7 Nm) to seat tube against LH midcast
frame.
(
6. Position the spacer ® between the front frame
assembly @ and engine case.
10. Install swingarm assembly. SeeSwingarm

11. Install rear fender. See Rear Fender Installation,
page 3. 11.
12. Install the radiator assembly. See Radiator Removal C
I Installation, page 4.22.
13. Install the triple clamps. SeeTriple Clamp
Installation I Steering Head · Bearing Adjustment,
page 11.27.
7. Install the front frame assembly @ to the frame 14. Install the forks. SeeFront Fork Installation, page
backbones and engine case. 11.25.
15. Install the head pipe assembly. SeeHead Pipe
16. Install mufflers. See Muffler Installation, page 5. 13.
17. Install the driver foot controls. See Foot Peg Driver
Removal I Installation, page 3. 7
18. Install passenger foot pegs if equipped. See
Footpeg Passenger Removal I Installation, page
3.8Foot Pegs Passenger Removal I Installation,
page 3.8.
19. Install battery box. SeeBattery Box Installation,
page 15.12.
20. Install the fuel tank. SeeFuel Tank Installation, page
5 .25.
21. Connect battery cables.

3.14
FRAME/BODY
22. Install seat assembly. See Seat Removal I


3.15
FRAME/BODY
NOTES C
('

3.16
LUBRICATION I COOLING
CHAPTER4
GENERAL INFORMATION . ... .... .... . .. . .. . .. .. .......... .. ....... . ..... . ................ .... .......... 4.2
SERV1CE NOTES .. . ............... ... ......... .. .......... ... . .... .......... . .... . . . .. . ............... 4.2
TROUBLESHOOTING .............. . ............. . . . ........... . ............. . ..................... .... 4.2
SPECIAL TOOLS . .... . ...... ..... ... .. .... . .... . . . ...... . . ..... ................ . .......... .. ........... 4.2
TORQUE SPECIF1CATIONS ... ...... .. ........ . ... . ... . ....... ........ ....... . ................... . ... . . 4. 3
SERV1CE SPECIF1CATIONS ............................................ . .... ... .... ....... . . . ... . . .. . . 4.3
ASSEMBLY VIEWS ........... . . .. . .. .... . .. . ... . ........ . .... . ........... .... .................. . . . ....... . 4.5
COOLING SYSTEM ... . .......................... . .......... . ..... . .... . . . . . . . ......... .. ... . .......... 4.5
COOLANT FLOW DIAGRAM .. . .. . . . . .. .... . ............ ..... . . .... . .............. . ........ . . .. ...... . . 4.6
WATER PUMP . . . . .. ......... . .. .. ........... . .. .. .... . . . . . . . .... .. .................. .. . .. ........... . . 4.7
LUBRICATION SYSTEM ....................... . ......... ... .... .. ..... . .. . ......................... .. .. 4.8
OIL FLOW DIAGRAM .... ...... . . ............................ . ....... .. .... . .... .. ...... . . . .. . ..... . .. 4.11
OIL PRESSURE INSPECTION . .. . .... . ..... ..... ..... .. .. . ..... . ........ .. ......... .. . . . . ... .... . . . . .... 4.12
OIL PRESSURE .. . ............ . ..... . ....... . ...... .... ... ... .. . . . ...... . .... . .. . ... . ............... . . 4.12
OIL PUMP SERVICE ..................... .. .... .. ........ .... .. ... ............... . ... . ....... . . . ....... . . 4.13
SCAVENGE OIL PUMP REMOVAL ... . .... . ....... . .. . .... . .. . ............... .. ............... . ... . ... 4.13
SCAVENGE OIL PUMP INSTALLATION ... . . ... . .. ...... . ... . . ... .. .. ..... ...... .. ........ .. ... ... . ... 4.14
PRESSURE OIL PUMP REMOVAL .... . .......... ... ...... . ..... ... ..... . . . ... .. . .. . .. . ... .. . ........... 4.14
PRESSURE LUBRICATION OIL PUMP INSTALLATION .. .. . .................. . ..... ... ...... .. . .. .. .. . . 4.15
OIL COOLER SERVICE ... ... ... .. . .... . .... . ... . ................... .. . .... ...... . ................... . . . 4.17
OIL COOLER REMOVAL . ..... . ... .. . ..... .. . ... .. . .. . . ............. . ................................. 4.17
OIL COOLER INSPECTION . . . ..... ... . .. . . . .. ... .......... .... ....... . . . ... . . . ...... . ........ . . . . . ... 4.17
OIL COOLER INSTALLATION .. .. .... . ..... . . . .. . . . . .. ............ . .............. . ........ .... ........ 4.17
COOLING SYSTEM SERVICE .. . . . ... . ..... . .............. . ........ .. .. . . ... .. .... . .. . ...... .......... . . 4.19
COOLANT STRENGTH I TYPE ... .. .. .. ........................ . . . . . . . . . ..... .. .................. ... .. 4.19
COOLING SYSTEM PRESSURE TEST ... ........ .... . . . . ..... . ...... . . ... . ... ..... ... ........ . ...... ... 4.19
COOLING SYSTEM PRESSURE CAP TEST . . ... .... .. .. . .. . ... .. ... .... . ... . .. . ... .. ................... 4.20
COOLANT DRAIN I FILL ................. . ............. ... . . . ... .. . ... ... .. ... . . . . .. . . ... . .. ........ .. 4.20
COOLANT F1LL I BLEEDING .................... . ... ... ..... . ................ ... .. .. .......... . ...... 4.22
RADIATOR REMOVAL I INSTALLATION ... ....... ..... ...... . .. ..................... .. ............ .. . 4.22
WATER PUMP ... .... . .... .... ..... .. ... ......... ....... .. . ... .. . ... . ... ..... . ........... ...... . . . . ... 4.23
THERMOSTAT . .............. . ....... . .. .. ........ ..... ................... . .............. . . ....... . .. . 4.26
COOLANT TEMPERATURE SENSOR .. . .. ... . .... . . .. .. .. . . ... . . .. ............. . ........... .. .. . ...... 4.27
TROUBLESHOOTING .......... .... ................. . ........... . .. . .... . ..... . .............. ..... .... 4.28
9926140 R02 - 20 15 - 20 16 Scout Service Manual

4.1
GENERAL INFORMATION
(
SERVICE NOTES TROUBLESHOOTING
The Scout uses a semi-dry sump lubrication system.
The engine oil is housed in a separate chamber within LOW OIL PRESSURE HIGH OIL PRESSURE
the engine cases CD as shown in the image below. Incorrect oil being used Incorrect oil being used
or low oil level
Engine temp above test Additives added to oil to
temperature range increase viscosity C
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
C
SPECIAL TOOLS
The engine has two separate oil pumps, a scavenge
pump CD and pressure (lubrication) pump G). The TOOL DESCRIPTION PART NUMBER
scavenge pump has two sets of internal gerotors. One
Oil Pressure Gauge PV-43531
set scavenges oil from the right side of the engine
crankcase and the second set from the left side. The
Bosch Automotive Service Solutions: 1-800-345- C
scavenge pump supplies oil to fill the oil tank area CD
2233 or https:// polaris.service-solutions.com/
of the engine. The oiling system pressure relief valve
is located inside the pressure oil pump.
To access the scavenge oil pump, the stator cover must

be removed. To access the pressure pump, remove the
right engine cover. Before disassembly, review the
troubleshooting charts located in this chapter.
If the engine is making irregular noises that appear to
be coming from rotating parts, check the lubrication
side oil pressure. Check the oil pressure before
engine disassembly, and recheck the oil pressure after
a repair.

4.2
TORQUE SPECIFICATIO NS
PART DESCRIPTION TORQUE SPECIFICATION
Oil Drain Plugs - Scavenge and Oil Tank 15 ft-lbs (20.0 Nm)
Oil Filter (Apply oil to filter seal) 115 in-lbs (13 Nm) or approximately 3/ 4 to I full turn
after seal contacts the filter mount sealing surface
Oil Cooler Spigot 22 ft-lbs (30.0 Nm)
Lubrication Oil Pickup Screen to Crankcase 88 in-lbs (10.0 Nm)
Oil Pressure Sensor 88 in-lbs (10.0 Nm) Apply sealer to threads
Scavenge Oil Pump to Crankcase 88 in-lbs (10.0 Nm)
Lubrication Oil Pump to Crankcase 88 in-lbs (10 .0 Nm)
Lubrication Oil Tube to Oil Pump 88 in-lbs (10.0 Nm)
Oil Scavenge Inlet Screens 88 in-lbs (10.0 Nm)
Oil Scavenge Tube to Oil Pump 88 in-lbs (10.0 Nm)
SERVICE SPECIFICATIO NS
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 Chapter 2.
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 Chapter 2.
Recommended Engine Oil if Indian Indian Motorcycle Synthetic Not Applicable
Motorcycle l 5W60 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

4.3
OIL PUMP CLEARANCES (SCAVENGE)

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) C
OIL PUMP CLEARANCES (FEED)
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 "-.0059" (.080 mm - .150 .007'' (.200 mm

mm)
COOLING SYSTEM SPECIFICATIONS

ITEM DESCRIPTION SPECIFICATION I CAPACITY
Capacity Engine Coolant I Extended Life Anti-Freeze 50/ 50 System 2.77 Qts (2.63 Ltrs) I
Antifreeze Premixed (Yellow) Recovery Bottle .16 Qt (.15 Ltrs)
Thermostat Opening Temperature 180 Degrees F (82 Degrees C)
Cooling System Pressure Cap Relief Pressure 16 PSI
COOLING FAN OPERATION
CONDITION APPROXIMATE RESISTANCE TEMPERATURE
OHMSQ
Engine Protection Misfire 1200 240.8 Degrees F (116 Degrees C)
Coolant Hot Lamp (On Solid) 1400 233.6 Degrees F (112 Degrees C) C
Cooling Fan On 2000 204.8 Degrees F (96 Degrees C)
Cooling Fan Off 2100 203.0 Degrees F (95 Degrees C)
Room Temperature 25000 68 Degrees F (20 Degrees C)
(.

4.4
ASSEMBLY VIEWS
COOLING SYSTEM
NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

1 Filler, Funnel Coolant -
2 Tank, Coolant Surge -
3 Hose, Coolant Radiator Inlet -
4 Hose, Coolant Oil Cooler Inlet -
5 Fan, Cooling Assy -
6 Hose, Coolant Radiator Outlet -

7 Radiator, Assy -

4.5
COOLANT FLOW DIAGRAM C

Cooling System Flow Thermostat Closed (Bypass)
Cooling System Flow Thermostat Open
·... .. ................. •.," '

4.6
WATE R PUM P
Water Pump Assembly
.,,
.-~-·
NUMBER DESCRIPTION TORQUE
1 SCREW, SOCHD M5Xl2 -

2,3 GEAR, WATER PUMP DRIVEN with PIN -
4 BEARING,NEEDLE -
5 SHAFT, WATER PUMP -
6 BEARING, ROLLER -
7 NUT, SPECIAL Ml4xl.5 13.3 ft lbs (18 Nm)
8 SEAL, SHAFT -
9 SEAL, SHAFT WATER -
10 IMPELLER, WATER PUMP 24.8 in lbs (2.8 Nm)

4.7
r
~UBRICATION SYSTEM
ressure Lubricat·ion System Assemblyv·1ew
9926140 R02 - 2015 - 2016 scout Service Manual

4.8

1 Screw, Oil Pump Mounting- M6 x 1.0 x 15 (QTY.3) 7 ft-lbs (10 Nm)
2 Screw, Oil Pump Gear 7 ft-lbs (10 Nm)
3 Washer, Oil Pump Gear -

4 Gear, Oil Pump -
5 Oil Pump Assembly (Pressure) -
6 Screw- M6 x 1.0 x 12 7 ft-lbs (10 Nm)
7 Tube, Oil Pressure Inlet -
8 Seal, Oil Pressure Inlet Tube (QTY 2) -
9 Screw, Dipstick Adapter 7 ft-lbs (10 Nm)
10 Dipstick , Engine Oil Level 7 ft-lbs (10 Nm)

11 Adapter, Engine Oil Dipstick -
12 Seal, Engine Oil Adapter -
13 Seal, Oil Pump Pickup -
14 Screen, Oil Pump Pickup -
15 Screw, Oil Pump Pickup Screen 7 ft-lbs (10 Nm)
16 Filter, Engine Oil 6 ft-lbs (8 Nm) or Approximately

3/ 4 turn after sealing ring has
contacted the filter adapter.
17 Spigot, Oil Cooler 22 ft-lbs (30 Nm)
18 Cooler, Engine Oil -

19 Switch, Engine Oil Pressure 7 ft-lbs (10 Nm)
20 Cooling Jet, Piston Rear -

21 Screw, Piston Cooling Jet 5ft-lbs (7 Nm)
22 Cooling Jet , Piston Front -

23 Screw, Piston Cooling Jet 5ft-lbs (7 Nm)

4.9
Scavenge Lubrication System Assembly View

1 Screw, Oil Pump Mounting- M6 x 1.0 x 15 (QTY.3) 88 in-lbs (10.0 Nm)
2 Pump, Engine Oil Scavenge -
3 Tube, Scavenge Oil Return -
4 Screw, Scavenge Oil Return Tube 88 in-lbs (10.0 Nm)
5 Screw, Scavenge Pump Mount 88 in-lbs (10.0 Nm)
6 Oil Drain Plug 15 ft-lbs (20 .0 Nm)
7 Washer, Oil Drain Plug Sealing -
8 Screen, Inlet Scavenge Engine Oil -
9 Screw, Inlet Scavenge Screen 88 in-lbs (10.0 Nm)
'
10 Screw, Inlet Scavenge Screen 88 in-lbs (10.0 Nm)
11 Screen, Inlet Scavenge Engine Oil -

4.10
OIL FLOW DIAGRAM

-······-···-···-·····-··-··------·- ....... ____________________ ···-·----- - - -·-·-··--------------------·-··---· ,.
·------------·-·--···------
LEGEND
Supply t
Drainback Return
Rear Cylinder
Intake/Exhaust
Camshafts
Left Connecting
Rod Bearing
t i
t
Transmission Input Left Piston Cooler Rear Camshaft
I Shaft/Bearings Jet Chain Tens ioner
i
~ Left Crankshaft
Main Bearing
~~~~.~--r~-~ Starter One Way

Transmission
Output Shaft/
Camshaft
r~
r
Gear Drives haft
Bearings
I Oil I
-~~
Lubrication Oil i Oi l Filter Main Oil Gallery
Pump
-·--1 Cooler l !
Pressure I - - - - - ··········-~····
Regulating
Valve T
Right Crankshaft
Main Bearing
i Right Piston Oil Pressure Front Camshaft

Cooler Jet Switch Chain Tensioner
Right Connecting
Rod Bearing
i
l I
Front Cylinder
t II
Intake/Exhaust
Camshafts i
Lubrication Oil
.........
_J__ I
I
!
.............. ,: ____
............................... ......_.._,_,,_,_,, ___..._..... .
····- ··l ____
Pump Pickup
Screen/Tube r----------1
I I Right Side RIGHT SIDE
I I Drilled Crankcase
I Scavenge Pump I Crankcase Oi l Inlet (Front) ENGINE
Oil Passage
I Right Gerotor I Scavenge Screen OIL SUMP
I I
I I
Crankcase Oil Scavenge Oil
L----------1
Scavenge Oil Pump
Reservior
L_:tumTube r----------1
I I
I I
I Scavenge Pump I Left Side LEFT SIDE (Rear)
I Lett Gerotor I Scavenge Inlet
Crankcase Oil Inlet ENGI NE OIL
I I Tube
I I Scavenge Screen SUMP
L----------1

4.11
OIL PR ESS UR E INSPECTION

OIL PRESSURE
CAUTION
Use caution when working around hot engine oil.
1. Start the engine and run until operating

temperature is reached.
2. Turn the engine OFF.
3. Remove oil pressure sensor CD.
4. Install oil pressure gauge.

5. Use the dipstick to check the engine oil level and
add recommended oil, if necessary.
6. Start engine and check oil pressure at 3000 rpm.
7. Compare reading to oil system specifications.
8. If oil pressure is outside of specification, refer to
troubleshootingTroubleshooting, page 4.2.
9. Once testing is completed, clean threads with (
Loctite Primer N, and apply thread sealant to the
oil pressure switch threads and torque to
specification.

4.12
OIL PUMP SERVI CE

SCAV ENGE OI L PUMP REMOVAL 7. Remove the stator cover fasteners ® and stator
1. Drain cooling system. Coolant Drain I Fill, page cover assembly CD.
2.14
2. Remove the left side ignition cover fasteners CD
and cover CD.
::y,
/
8. Remove the scavenge inlet tube fastener (!) and

scavenge oil pump fasteners ® ·
3. Disconnect the radiator outlet hose CD from the

fitting on the stator cover.
9. Remove scavenge oil pump assembly ®·

10. Remove and discard the 0-ring on both sides @) .
4. Disconnect coolant bypass return hose © from the
stator cover.
5. Remove the crankshaft position sensor CPS. See
Crankshaft Position Sensor Test/Replace.
6. Disconnect the stator electrical connector.

4.13
SCAVENGE OIL PUMP INSTALLATION PRESSURE OIL PUMP REMOVAL

1. Install a new o-ring G) on the inlet tube.
1. Remove exhaust head pipe. SeeHead Pipe
Removal, page 5.14.
2. Disconnect clutch cable from engine clutch lever.
SeeClutch Cable Removal I Installation, page
11.12.
3. Remove primary cover fasteners G) and cover
assembly CD.
2. Install the oil pump CD into the crankcase and

loosely install bolt © securing the snorkel tube to
the LH crankcase. C
3. Align bolt holes and install oil pump bolts CD and
torque to specification.
4. Remove primary drive cover fasteners CD, seal ®

and cover assembly ©.
4. Torque inlet tube bolt to specification.
5. Install engine stator cover. SeeStator Cover (

Installation, page 9 .19.
6. Verify engine oil pressure after assembly. See Oil
Pressure, page 4.12.
5. Remove pressure pump pickup tube fastener ©,

gear fastener (J), washer ® and three mounting
bolts®·

4.14
PRESSURE LUBRICATION OIL PUMP

INSTALLATION
1. Assemble gear shield @ and gear © onto
lubrication pump @.
6. Remove pressure pump @ and inlet tube ®

assembly from engine.
~-
( 14 )> ,
2. Lubricate new inlet tube seals @) with engine oil
..
1
/'- and install the seals on the inlet tube®·
3. Assemble the inlet tube to the pump and torque
screw to specification.
-- i
,,,,- ·\ / ' \ ( '\
( 11 ) ( 12 '\ 13 ) 4. Install the lubrication pressure pump assembly into
\. .._/ \...._':J '-.-./ the right crankcase with pump mounting screws®
and pickup tube screw©. Torque fasteners to
specification.
7. Separate inlet tube ® from pressure pump @ and
discard inlet tube seals @).
8. Separate gear shield@ from oil pump gear®·

4.15
C
5. Install the oil pump gear screw 0) and washer ®
onto pump shaft. Torque fastener to specification.
6. Install the primary drive cover assembly. See

Primary Drive Cover Installation, page 9.7.
9926140 R02 - 20 I 5 - 2016 Scout Service Manual

4.16
OIL COOLER SERVICE

OI L COOLER REMOVAL OIL COOLER IN SPECTION
1. NOTE: Scout Sixty is not equipped with an oil 1. Inspect cooler, lines and all connection for leaks.
cooler. Drain the cooling system. See Coolant
Drain I Fill, page 2. 14. 2. Inspect coolant lines for proper routing. Replace if
there is any sign of abrasion or damage.
2. Remove the horn assembly. See Horn Removal I
Installation, page 17.12. 3. Inspect cooler surface for kinks or debris.
4. Inspect cooler mounting fastener for proper
3. Disconnect the supply coolant hose CD at the oil torque.
cooler.
5. Replace any damaged components.
OIL COOLER IN STALLATION

Inspect the oil cooler sealing surfaces/ seals for dam-
age and replace if necessary.
1. Install the oil cooler assembly CD on the engine so
the locating tang CD is positioned in the engine
case re cess.
4. Place an oil pan beneath the oil filter adapter to

catch any oil that drains out of the cooler assembly
upon removal.
5. Remove oil filter assembly.
6. Hold the oil cooler assembly CD from turning to
prevent distorting the locating tang G) and remove
the oil cooler mounting spigot ©.
2. Prevent the oil cooler assembly from spinning

when installing the oil cooler adapter spigot G)
and torque spigot to specification.
3 . Install new oil filter.

4. Connect the supply and return coolant lines to the
oil cooler.
5. Install the horn assembly. See Horn Removal I
6. Install the radiator cover.
7. Fill and bleed the cooling system. See Coolant
Drain I Fill, page 2 .14.
It may be necessary to hold the oil cooler assembly 8. Check engine oil level. See Engine Oil Level
from turning to assist with removal oil cooler Check, page 2.8.
mounting spigot.
9. Run the engine to cycle oil through the oil cooler
7. Remove the oil cooler assembly from the vehicle . and check oil level. Top off if necessary.

4.17
10. Check for engine oil or coolant leaks.

C

4. 18
COOLING SYSTEM SERVICE

COOLANT STRENGTH/ TYPE
Test the strength of the coolant using an antifreeze
hydrometer. Never remove pressure cap when engine is warm or
• A 50/50 mixture of extended life antifreeze and serious burns may result. Allow the engine and
distilled water will provide the optimum cooling, cooling system to cool before servicing.
corrosion protection, and antifreeze protection.
• Do not use tap water, straight antifreeze, or straight
water in the system. Tap water contains minerals 3. Remove the cooling system pressure cap and test
and impurities which build up in the system. using a cooling system pressure tester.
• Straight water or antifreeze may cause the system to (Commercially available).
freeze, corrode, or overheat. 4. The system must retain 11-14 psi (75-95 kPa) for
FLUID CAP.A.CITY five minutes or longer. If pressure loss is evident
within five minutes, check the radiator, all cooling
Recom.m.ended Anti-Freeze/Coolant:Indian system hoses, hose clamps and water pump for
Motorcycle 50/50 Pre-Mixed Extended Life leakage.
Antifreeze
(PN 8560214) (Quart)
hole G) due to normal water pump function. Verify
COOLI NG SYSTEM PRESSURE TEST system pressure test.
page 3.9.
2. Remove the Fuel Tank. See Fuel Tank Removal,
page 5.20.

4.19
l
COOLING SYSTEM PRESSURE CAP TEST

page 3 .9.
2. Remove the Fuel Tank. See Fuel Tank Removal, serious burns may result. Allow the engine and
page 5.20. cooling system to cool before servicing.
3. Remove the cooling system pressure cap and test (

using a cooling system pressure tester.
(Commercially available).
4. The cooling system pressure cap relief pressure is
16 psi (110 kPa). Replace cap if it does not hold the
required specification pressure.
COOLANT DRAIN/ FILL

serious burns may result. Allow the engine and (
Cooling System Drain
Pressure test the cooling system before and after

cooling system service.
1. Remove the radiator cover fasteners G) .
2. Slide radiator cover down to disengage posts from

the upper radiator mounts CD .
(_

4.20
6. Use pinch pliers (commercially available) to pinch

off the coolant line © between the coolant
reservoir and thermostat housing.
3. Remove the coolant return hose (I) from the oil ' / .' \ ..J,.
cooler assembly to drain the coolant. ·· /
7. Install a cooling system vacuum bleeder

(commercially available) on the pressure cap
opening to create a vacuum in the cooling system.
8. Using the vacuum bleeder draw in Indian
Motorcycle Extended Life 50/ 50 Engine Coolant to
fill the cooling system.
9. Remove the vacuum bleeder and install the
pressure cap.
10. Remove the pinch pliers from the coolant line
between the reservoir and thermostat housing.
11. Add Indian Motorcycle Extended Life 50/ 50 Engine
Coolant to the reservoir fill opening (I) until the
coolant reservoir (I) is half full .
Cooling System Fill/Bleeding 12. Install the fuel tank assembly. See Fuel Tank
13. Run the engine until the cooling fan cycles ON and
Pressure test before and after servicing the cooling OFF.
system. 14. Recheck the coolant level in the reservoir and add
to the "COLD FULL" level.
15. Repeat the fill/ bleed procedure until the coolant
1. Reconnect the coolant return hose to the oil cooler level in the reservoir remains at the "COLD FULL"
assembly. level.
2 . Install the radiator cover. 16. Install the seat. See Seat Removal I Installation,
3. Remove the seat. See Seat Removal I Installation, page 3.9.
page 3.9.
J 4. Remove the Fuel Tank. SeeFuel Tank Removal,
page 5.20.
5. Remove cooling system pressure cap CD .

4.21
l
COOLANT FILL/ BLEE DING 13.Install seat. See Seat Removal I Installation, page
3.9.
1. Remove seat assembly. See Seat Removal I
2. Remove fuel tank assembly. See Fuel Tank RADIATOR REMOVAL / IN STALLATION
Removal, page 5.20.
3. Remove the pressure cap CD.
Never remove pressure cap when engine is warm or C
I. Place the motorcycle on the side stand and rotate

the handlebars to the full left lock position.
2. Drain the cooling system. See Coolant Drain I Fill,
page 4.20.
3. Remove radiator cover fasteners CD from both
sides.
4. Add coolant to top of filler neck CD

5. Install a commercially available vacuum bleeder to
I
i
remove air from the cooling system.

6. Remove vacuum bleeder.
7. Add coolant bring level to top of the filler neck.
8. Install the pressure cap.
9. Add coolant to the filler funnel G) until the coolant
is visible in the surge tank ©.
(
10. Install the fuel tank. See Fuel Tank Installation,

page 5.25.
11 . Run engine to increase coolant temperature until
the cooling fan cycles on and off.
12. Check coolant level in the surge tank and add as 5. Remove the radiator mount fasteners G).
required.

4.22
3. Remove the Ignition Cover fasteners CD and remove

the Ignition Cover Q).
( l.
\
\
6. Disconnect the cooling fan electrical connector.

7. Remove the radiator inlet and outlet hoses.
8. Remove the coolant return hose froin the radiator. 4. Disconnect the radiator outlet hose G) at the left
9. Remove the radiator and store in a location to engine cover.
prevent damage.
10. Reverse removal procedure for installation.
11. Fill cooling system. See Coolant Fill I Bleeding,
page 4.22
WATER PU MP
Water Pump Seal Removal and Installation

hole due to normal water pump function. Verify
system pressure test.
1. Drain cooling system. See Coolant Drain I Fill, 5. Disconnect the bypass hose © from the left engine
page 4.20. cover.
2. Remove Crankshaft Position Sensor from the stator 6. Disconnect the stator harness connector.
cover. See Crankshaft Position Sensor, Test I
Replace , page 5.42.

4.23
7. Remove the stator cover fasteners ® and stator 9. Remove the water pump seal assembly ® with a
cover©. hooked tool or equivalent taking care to not
damage the water pump shaft or engine case.
8. Remove water pump impeller (J)
10. Clean the water pump seal bore and inspect the
seal bore surfaces for scoring or damage.
11. Install new water pump seal ® in engine case by
hand. Thread water pump seal installation tool PF- C
51608 @) on the water pump shaft.
(.

4.24
12. Use the wrench flats@ to hold the water pump seal 4. Align the new water pump shaft oil seal in the
installation tool @) from turning while turning the engine case and insert with light pressure.
tool wrench hex® to seat the seal in the bore.
5. Use a suitable driver to install the seal so the outer

13. Reverse the removal procedure to reassemble. face is flush with the step 0 on the engine case.
Water Pump Shaft Oil Seal
1. Remove water pump seal. Refer to Water Pump
Seal Removal and Installation.
2. Remove water pump shaft oil seal CD with a hooked
tool or equivalent taking care to not damage water
pump shaft or engine case.
Do not damage the engine case or sealing surfaces
6. Install new water pump seal. Refer to Water Pump

Seal Removal and Installation.
3. Clean the water pump oil seal bore and inspect the
seal bore surfaces for scoring or damage.

4.25
THER MO STAT (
:·· - ., . . A ... ' ·.,. _, ..... ;, ~~: >,< . .
-:,. · ·....
.. , '
_.. WARNING
. . . ·.: .,-a .•. ,,,;
(
1. Place motorcycle on the side stand.
2. Remove seat. SeeSeat Removal I Installation, page
3.9.
3. Remove fuel tank assembly. SeeFuel Tank Removal,
page 5.20.
4. Remove right thermostat housing cover G). See
Thermostat Housing Cover Removal I Installation,
8. Remove the thermostat assembly ®·
page 3.12
9. Reverse removal procedure for installation.

page 4.20. 10. Fill and bleed the cooling system. SeeCoolant
Drain I Fill, page 4.20.
6. Disconnect the radiator inlet hose Q) and overflow
reservoir hose G) from the thermostat housing.
(.
7. Remove thermostat housing fasteners © and

thermostat housing ® ·
9926140 R02 · 2015 · 2016 Scout Service Manual

4.26
LUBRICATIO N /COOLING
COOLAN T TE MPERAT . ~-------

1. Drain . URE SE NSOR
coolmg
2 page 4.20 . s
ystem. See C oolant D .
. Remove . . . mm I Fill
3 Side C over
igruhon swit
Removal IIc h side
. . cove<. Se . '
. Remove ignif nstallahon, pag 3e Igrution .
-
racket f as teners
_ _ _.:.....:.:..::1:0:'.n~s~wi~tc:h~~b;~~~stei CD
e .11.
""·0------ J ///
'
/' .
! • r--· --- --
)_~~~ 2
V
-Si·~
3j ·7 ·--, ..
7·,:;:;;-~·-~i\;~~~~&~", ,! < ) (\ 1 ~
\ 'Tl I'!,
/ .
·- ,;t-..,,, Ii I
l
,v
\ J "1_,,J, ;,,•;:"'
t;:- ,-,.
,{
u~ ·~ ..,
' "l>°-
- \~· _ \~
/
__.
___', " " : : -
~
~
,,.~~...-'.A V,1
: W.fb ,·);:). ' 1 F~~1- ,)JI/) ' •.-, ,4
-0 "• · ,<, I V ~ ·- C11S, ,:,, '.___ -
,:V \ ci !l'_,, ! ..<-::- r,
~
,,, ).J / - V'. ' / - , ~- - : ~ ~ - (], l<:(, . - "
r·\ \y\, \ -.V\~r~-\

... ~ · ·-;;\!,11
1~ /;/j
tjl)
·-· I,1 I;/1/1 -~ y,.;,r"
.. --·
1
~>-
~~-
I
I"' ·. \ C,/ D ·f 'N I ._ • ,J ,. ,.--- ,.-'
>\ \
-1\ ',.
\ \ /"'°/ (!j-,
l._,,i' k /
:,
,;;-,f'-'!/',;·-.J.-,f/
1"' :I , l f{::;{f,-l
·0.' .. ,-•, ~-
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'Cif" . _ I ~ ~ \y'{
)if/ /'"'. _/ ______~J:>T"i
Li;- I ""J..
--'---=..,__
= ··-/ :iv-' \' ' ,. '•-· '-((l;
., . d.] ..
4. D' --- ! ---- -·-/ ,,..--
1sconnect the i . . . r ~ ' :IJ /
CD and removegmhon th switch e 1ectrical

assembly (j) e ignition . connecto,
s. o·,sconnect .th sw,tch b
,acket
~-,:-----
stator ho usmg.
. e coolant b ypass hose ©
-------------~4~ JfL.rro,m the
~
~-.:::~
\\ • "·I \-·-
·-L'
\ \
\\ \
-
\ ~
'
t:"~
( I
- - ' ..' .~'-mF'J,f:~-:--
-~~ ;,.r=-\0 .~,~·<.
';yfF' I,)~ 1 4 "',;~-
'<.
r::
·-,
V, ;. / ' _;]'l" ~A \
\ · /:--.;t?¥·'' ~ ·,
I
1;
"*" '·
!!. ~
J/' ·h°"\'
I
1
.' (! .
8.
t
r
~' , ' UJ J• - ""

,:~\ \~ ''fE::'':;.,\£/ / ,;//'\ 1
-
. "- -~ y
,
)/! 3( < -· /\ 4 \/(.)):_.1't\'f:! .

' "'< ' ..'l
. ·, ,,.,. \\ .
t:.;~\'\ ~~'.~~:~i,./ 7 \ \ ·,;A !r 1· r~ ..{. P/-Y \\M //

@:i· \ \\> \ \ .~, y
\!A1~-!~l ;,·.,'::(1 mv· 1
•f.., / ' :/1
'/ , ' Ir'
I
\ \V,",. .\
I;!\!,,' ~,- -j I Y'\ o/7' -"(, rh-! ,,I 1j J
~~\ / !~ ~
~\\..x ~. \ ,r·
,. ! , 1
\ir,.J;,,\ \_,_ \ \ ~,·-reii- · sY.. '"'·. !. !//!(!'):/!

~.,:,l
\ffi\lli,
\l'i';;.:;;:M .i
J\ \ \ · · /.' · · ~-
\ - ', . '{' - ,_, .,:/ \ ; L,,(;,Y'iJJ
y? J
,,w . '
"'-:-:.,..
1
1 ! ....
--'-r-L:1-- · /.:/,~-
,.r·
~~ .'~ \\/'i
/.1. .
6. D' - ,.""1 ~~-'
,sconnect th ' I I r'
cylinde, heade. coolant outlet h ose CD from th e rear
,I
9926140 R0 -::::~---------
· - 2016 Srcout Servi ceManual
. 2 -_2015
4.27
TROUBLESHOOTING
Overheating
(
• Low coolant level

• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked in (
radiator, lines, pump, or water jacket, accident
damage)
• Engine running lean (fuel system restriction)
• Fuel pump output weak
• Water pump failure/ Loose impeller
• Engine Coolant Temperature Sensor failure
• Electrical malfunction
• Cooling fan inoperative or turning too slowly
• Low oil level
• Faulty hot lamp circuit
• Thermostat stuck closed or not opening completely
Temperature Too Low

• Thermostat stuck open
C
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal
• Worn pump shaft or pump shaft bearing
(.

4.28
FUEL DELIVERY I EFI I EXHAUST
CHAPTERS
GENERAL INFORMATION ........ .... ... ...... ........ ................ ....... ........... ... ............. 5.3
SERVICE NOTES . .. . .. ... ... .............. ... . ... . ....... .......... . .............. ....... .. . . ... ...... 5.3
SPECIAL TOOLS ... .... ........... ....... .. ............... ............. .. ... .............. ..... ... ..... 5.4
SERVICE SPECIFICATIONS .. .. .. ........ .... ... ..... ........ ...... ... ............ ...... ...... ...... .. 5.4
TORQUE SPECIFICATIONS .. .... .. ........ ..... .... .......... .............. . ........ ......... ... .. ... . 5.4
SERVICE PRECAUTIONS ............ . .. .. .. ....... .... ..... . ........... .. .... ...... ... .. ............ ... . 5.5
EFI SYSTEM PRECAUTIONS ......................................... .. ............. . .............. .. .. 5.5
ASSEMBLY VIEWS ........... .......... .... .... .. ......................................................... 5.6
FUEL LINE ROUTING (49 STATE MODELS) ........................ . ................................... 5.6
FUEL LINE ROUTING (CA) ........ . . .. . . ..... ..... . .............................. . ................. . . . 5.7
FUEL SYSTEM ... . . .. ............ . .. . ................ .. . ....... .. .. .. .. .... .. ................. .. ....... 5.8
FUEL TANK . ... . ........ ................. .. . . • . .. ... .... . ... .. ..................... .. . ............. ... . 5.9
AIR BOX .... ........ . . ............. . ... .. ..... .. ..... ....... . . ..... . . .. ........ .. .... .... ........... . . 5.10
SENSORS - POWERTRAIN MANAGEMENT .. ... .... . .. . . . . .............. .. . .. . ... .. . . . . .. ..... .. .... . 5.11
EXHAUST SYSTEM ................................................................................... 5.12
EXHAUST SERVICE .. . ... .. ... ... .. ....... . .. ... .... .. ........ .... ......... .. . ... .... ...... .. . ........ .. 5.13
MUFFLER REMOVAL .. . ... ......... ... ..... ..... ... . .. . ... ...... ..................... .. . .......... ... 5.13
MUFFLER INSTALLATION . .. ...... ........ ...... ....... .......... . ..... .... ..... ..... .. . ... .. . .... .. . 5.13
HEAD PIPE REMOVAL . ..... ..... ... . . .. ... . . .. . ..... ......... ....... .. . . . ...... ....... . . ............. 5 .14
HEAD PIPE INSTALLATION ........................................ ... ....... . ... . .... ... ....... . .... . 5 .15
AIR CLEANER SERVICE . . . . ... . ......... ... . .... .. . .. ............. . . . .. .. . ..... . . .. . .. ... .. ..... . .. .... 5.17
AIR BOX REMOVAL . . .. . . ........ ... .......... .. .. ........ ..... . ... .. ...... ... .... .. . .. ...... ... ... . .. 5.17
AIR BOX INSTALLATION .... ... .. ... . .. .. . .... . . ...... .. ............................... . . . . ...... ... .. 5.17
FUEL DELIVERY SERVICE ......... ........ ..... ........ . . . ... .. ...... . ...... . ........ .. . .... . . . ........ 5.19
INTAKE MANIFOLD REMOVAL I INSTALLATION .............. . ... .. ... .. ...... .... . . .. ... ........... 5.19
FUEL PUMP PRESSURE INSPECTION .......................... ... .. . . .. . .. ... ... ...... .. .... .... .... . 5.19
FUEL SYSTEM DEPRESSURIZATION .... .... .. .. ... ..... . ........................................ .. ... 5.20
FUEL TANK REMOVAL ................... . ............... ... . ...... . ..... . .. .. ........ . ......... ..... 5.20
FUEL PUMP REMOVAL .. . .................. .... .. . ......................... ............. ............. 5.21
FUEL FILTER REPLACEMENT ................... . ........................ . .. .. . .... ...... ............ . 5.23
FUEL TANK VENT INSPECTION .......... ...... .... ....... ... . .. ... . ....... .. . ....... ...... .... ..... . 5.23
FUEL PUMP INSTALLATION .......... .. . .......... .. . . .. ......... ...... . . ...... .... . . . .. .. .. ......... 5.23
FUEL TANK INSTALLATION ....................................... . . .. . .... ....... ...... . ... .... ... .. 5.25
FUEL LEVEL SENSOR RESISTANCE TEST .... ... .... .... . . .. ... ..... . .. ............. .... . ... .. . .. .. ... 5.26
FUEL PUMP SUPPLY VOLTAGE TEST ... .. ... ........... . .................. . .......................... 5.27
FUEL PUMP CURRENT DRAW TEST .. ... .................... .. ............. ........ .... . . . .. ... .. .... . 5.27
PRIMING THE FUEL SYSTEM ......................................................................... 5.28
EFI SERVICE ............... .. .. .... ....... ........ ..... ...... ........ .. . . ............. . .... .... .......... 5.29
FUEL INJECTION SYSTEM - OVERVIEW OF OPERATION ..... ..... ..... ..... ............ .. ...... . .. .. 5.29
ECM CONNECTOR MAP .................. ... . ..... ......... . . .. ...... .. .. .................... .... ... 5.30
DIAGNOSTIC TROUBLE CODES .. ..... ...... ............ ....... . ... ...... ... .. ..... . ..... ..... ....... 5.31
SENSOR DIAGNOSTICS .......... .. .. ... ...................................................... .. . .... 5.38

5.1
(
ECM PINOUT TESTING .................................................................................... 5.38

C
ECM CONNECTOR REMOVAL ... . ......... . ........................ . .. . .................... . . .. .......... 5.38
ECM REMOVAL I INSTALLATION ....... ... . . ...... ... ... . ................................................ 5.39
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) REPLACEMENT . . ........... . ........ 5.39
COOLANT TEMPERATURE SENSOR, TEST I REPLACE ............ . ................................... . ... 5.40
FUEL INJECTOR REMOVAL I INSTALLATION ........ . ..................................................... 5.41
(
FUEL INJECTOR RESISTANCE TEST ................................................................ . ...... 5.41
CRANKSHAFT POSITION SENSOR, TEST I REPLACE ....... . .... .. ...... .. . . ........... . ............ .. .... 5.42
THROTTLE BODY (ETC) REMOVAL I INSTALLATION ............ ·... .. . . ......... . ... . ........ .. ........... 5.42
LOAD I TIP OVER MODULE ....................................................... . .......... .. ........... 5 .43
DIGITAL WRENCH ... ..... ....... ............... ....... . . .. . ...... .. ... ... . ... ......... ... ..... . ............. 5.44
DIGIT.AL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW . . ........... .... ..... . ... .... ................... 5.44
DIAGNOSTIC SOFTWARE VERSION .... . . ... ... . ................................... . .. . .......... .. ....... 5.44
ECM REPLACEMENT ............. . .... ... .. . ............................. . ..................... . . .. ....... 5.44
GUIDED DIAGNOSTIC AVAILABLE ... . ...... .. . . .................................................. .. .. . ... 5.44
DIGIT.AL WRENCH COMMUNICATION ERRORS .. ... . ......... . .... .. .. . . . . . . .. .. . . . . ......... . . . .. . ...... 5.44
DIGIT.AL WRENCH DIAGNOSTIC CONNECTOR .. .... . .. . .. .................................. . .. . . .. .. . . .. 5.44
DIGIT.AL WRENCH SERIAL NUMBER LOCATION .... . .. .. . .... .................. . ................... . ..... 5.45
C
DIGIT.AL WRENCH VERSION AND UPDATE ID ........... . . ... .. . ............... .. . . ............... . . . ... . 5.45
DIGIT.AL WRENCH UPDATES .......... . ... .. .. .. ............. .. .......................... .... . .. ... . ...... 5.45
DIGIT.AL WRENCH FEATURE MAP ........ .. ........................ .. . ..... . .. ............................ 5.47
ENGINE CONTROLLER REPROGRAMMING (REFLASH) ........ ..... .. . . ...... . . . . .. . .. . . ........ ..... . ... 5.48
TROUBLESHOOTING ..... . . . . .. . . ................... ... .. ... .. .. ... . ..... . .......... .. .... .... ...... .. .. .. . . 5.50 (
FUEL SYSTEM TROUBLESHOOTING PART 1 ............. . .. .. ......................... .. ......... .. . .. .. .. 5 .50
FUEL SYSTEM TROUBLESHOOTING PART 2 . ..... .. ................................... . ................... 5.51
FUEL SYSTEM TROUBLESHOOTING PART 3 . ................. . ................. . .. .. .............. . . .. .. . . 5.52
FUEL SYSTEM TROUBLESHOOTING PART 4 .................................................... . .......... 5.53

5.2
GENERAL INFORMATIO N
SERVI CE NOTES
Many hazards are present when working on or around
the fuel injection system. Read and pay close attention The battery should always be disconnected before
to the following warnings and cautions when working working on the fuel system.
on any component in this section.
When replacing fuel lines, always use genuine Indian
Motorcycle replacement parts. This will ensure top
Gasoline is extremely flammable and is explosive performance, function and durability.
under certain conditions. Work in a well ventilated Fuel lines remain under pressure at all times. Use
area. Open flames, sparks and cigarettes must be caution when disconnecting lines for service.
kept away from gasoline. Disconnect the fuel pump electrical connector to
disable fuel pump and crank engine to release
pressure. Always depressurize the fuel system prior to
service.
Careless handing of the control cables can result in Cover the fuel hose connections with a clean,
twisting or bending of the cables. This can cause the absorbent towel to minimize spillage while
cables to stick or bind, resulting in loss of vehicle disconnecting.
control. Don't overlook the basics while troubleshooting
the fuel system:
• Except where noted, views of connectors are from
WIRE side of the connector.
The engine exhaust from this product contains • A battery in a low state of charge can cause
chemicals known to cause cancer, birth defects or problems. Be sure battery is in good condition and
othe! reproductive harm. fully charged.
• Air leaks in intake tract I air box - check fo r air leaks
and repair to avoid misdiagnosing the EFI system.
• Contaminated or improper fuel.
The engine and exhaust system become very hot • Restricted fuel flow I filters (low fuel pressure).
during operation and remains hot for a period of time • Fuel tank vent line pinched or obstructed.
after the engine is shut off. Wear insulated protection • Faulty spark plug(s).
for hands and arms or wait until the engine and • Corroded, disconnected, or incorrectly connected
exhaust system have cooled before performing wiring.
service work. • Poor ground connections - be sure all grounds are
clean and tight.
• Exhaust system restriction or improper e xhaust.
• Engine mechanical condition.
Always stop the engine and refuel outdoors or in a

well ventilated area.
If you get gasoline in your eyes or if you swallow

gasoline, see your doctor immediately. Never try to
syphon gasoline using mouth suction.
Never start the engine or let it run in an enclosed

area. Engine exhaust fumes are poisonous and can
cause loss of consciousness and death in a short time.

5.3
SPECIAL TOOLS TORQUE SPECIFICATIONS

C
TOOL DESCRIPTION PART NUMBER DESCRIPTION TORQUE
SPECIFICATION
Electrical Tester Kit PV-43536
Air Box Cover 84 in-lbs (9.5 Nm)
Fuel Pressure Adapter PV-48656
Air Filter Element 62 in-lbs (7.0 Nm)
Fuel Pressure Gauge PU-43506-A
Air Filter Retainer Plate 31 in-lbs (3.5 Nm)
Relay Bypass PU-49466
Smartlink Module Kit PU-47471 CTS 70 in-lbs (8.0 Nm)
USB to Serial Adapter PU-50621 Console Panel Screws 84 in-lbs (9.5 Nm)
CPS 88.5 in-lbs (10.0 Nm)
2233 or https://polaris.service-solutions.com/ Evaporative Emissions 84 in-lbs (9.5 Nm)
Canister
SERVICE SPECIFICATIONS Fuel Filter Screws 12 in-lbs (1.4 Nm)
ITEM SPECIFICATIONS Fuel Pump Nut 24 in-lbs (2.7 Nm)
Fuel Pump Pressure 3.51 BAR (350 kPa) (51 psi) Fuel Tank Screw 18 ft-lbs (24.4 Nm)
C
Idle Speed 800 rpm ± 50rpm Gear position Switch 43 in-lbs (4.9 Nm)
Fuel Pump Amp Draw 12 ft-lbs (16.2 Nm)
3-5Amps Head Pipe Nuts
(Normal Operation)
Muffler Hanger Bolts 19 ft-lbs (25.7 Nm)
Recommended
91 Octane Minimum
Octane Muffler Clamps 40 ft-lbs (54.2 Nm) (
Injector Resistance 11.4 - 12.6 Ohms Ignition Coil 84 in-lbs (9.5 Nm)
Oil Pressure Switch 88 in-lbs (10.0 Nm)
Oxygen Sensor 14 ft-lbs (19 .0 Nm)
Rear Head Pipe Hanger 18 ft-lbs (24.4 Nm) C
Side Stand Switch 43 in-lbs (4.9 Nm)
Throttle Body 88.5 in-lbs (10 Nm)
TMAP 62 in-lbs (7.0 Nm)
Wheel Speed Sensor 96 in-lbs (10.8 Nm) (
Worm Drive Exhaust 31 in-lbs (3 .5 Nm)
Clamps

5.4
SERVICE PRECAUTIONS
EFI SYSTEM PRECAUTIONS
While electronic fuel injection is durable and

reliable, the components can be damaged or
problems may occur if the following precautions are Do not touch ECM connector pins
not taken.
Anti-static wrist strap PV-43541
It is not advisable to "jump start" the machine with
another battery. Although problems are unlikely to
occur if everything is done carefully, the electrical
component could be damaged. Some tests require probing of the ECM wiring
harness connector. Do not touch or probe the
Never disconnect the battery while the engine is exposed pins on the ECM. Static electricity from your
running. body or the meter can easily damage the ECM.
When connecting and disconnecting the battery
cables refer to Chapter 15 for complete battery Always use the proper adapter from the Connector
connection and charging information. See Battery Test Adapter Kit when probing the terminals. Most of
Installation, page 15.11. the connectors are sealed and cannot be back probed.
Make sure that the ignition is powered down before Be extremely careful not damage the connectors by
connecting and disconnecting connections. Best forcing meter probes into the connectors.
practice is to disconnect the battery before connecting
or disconnecting the electrical connections.
Fuses and circuit breakers protect critical electrical
components and circuits. Never replace the fuse with a Use proper tNl ad•pters on connedOf pins
larger value fuse or "jumper" the fuse with wire,

aluminum foil or any other means. Always investigate Connector test adapter kit PV-43526
the cause of the problem and repair before replacing Poor connections are the most common cause of
the fuse. Electronic Fuel Injection malfunctions. Inspect
connector and wiring connections carefully during
troubleshooting.
The ECM and sensors are sensitive pieces of

electronic equipment. Dropping or hitting them may
cause irreparable damage.
Carefully inspect the connections of the failed circuit
before doing any other troubleshooting steps. Wire
terminals should be corrosion free and fully seated
into the connectors. Connector should snap together
and lock.
Static electricity can damage the electronic controllers

beyond repair. The human body can easily store
enough static electricity to damage sensitive
electronic components. Before working with any
components of the Fuel Injection system, ground
yourself to dissipate any static charge. Also take care
not to touch any of terminal pins on the ECM.

5.5
ASSEMBLY VIEWS
FUEL LINE ROUTING (49 STATE MODELS) C
C
CD Fuel Supply Line (Pump to Fuel Rail)
CD Vapor Vent Line, Upper (from tank)

Drain Line, Fuel Cap (from fuel cap recess) (.
CD
© Vapor Vent Line, Lower (to atmosphere)

5.6
FUEL LIN E ROUTIN G (CA)

G) Evaporative Emissions Canister
Q) Vapor Supply Line, Lower (from canister)
G) Canister Purge Valve
© Vapor Vent Line, Lower (to canister)
G) Vapor Supply Line , Upper (to tank)
® Vapor Ve nt Line , Upper (from tank)
(j) Fuel Supply Line (Pump to Fuel Rail)

5.7
(
FUEL SYSTEM
('
C
CD Screw, Evaporative Emissions Canister - MS x 1.0 x 16 (QTY.2) 7 ft-lbs (9.5 Nm)
CD Evaporative Emissions Canister (CA Models ONLY) -

G) Purge Line (CA Models ONLY) -
C
© Purge Valve (CA Models ONLY) -
® Screw, Fuel Pump-M5 x 0.8x 16 (QTY.IO) 43 in-lbs (4.8 Nm)
© Fuel Pump -
9926 140 R02 - 2015 - 2016 Scout Service Manual

5.8
FUEL TANK
CD Screw, Fuel Cap- M5 x 0.8 x 25 (QTY.4) 43 in-lbs (4.8 Nm)
(I) Fuel Cap -

G) Adapter, Vent -
© Isolator, Tank -
® Fuel Pump -
® Screw, Fuel Pump 43 in-lbs (4.8 Nm)
CD Assembly, Tank Mount -

® Screw, Fuel Tank - M8 x 1.25 x 16 (QTY.4) 18 ft-lbs (24.4 Nm)
Screw, Tank Mount Assembly-MS x 1.0 x 10
® 7 ft-lbs (9.5 Nm)
(QTY.4)
.)

5.9
AIR BOX (
CD Screw, Air Filter 24 in-lbs (2.7 Nm)
0) Filter, Air -
G) Airbox Assembly -
(
© Hose, Breather Engine -
® Clamp, Worm Drive -
® Seal, Airbox Frame -
(.

5.10
SENSORS - POWERTRAIN MANAGEMENT

,,;-, ·
(\.___g'j /~
!\ 10 /1~·-
'-......./, 8 .
I 1 /--.....
'----11\ 11 \),~
'--·'\_7 /)
NUMBER SENSOR I LOCATION TORQUE (IF APPLICABLE)

G) TMAP - (Temperature I Manifold Absolute Pressure) Sensor 25 in-lbs (2.8 Nm)
CD Ignition coils 89 in-lbs (10 Nm)

G) ECM (Engine Control Module) -
Fuse Box
© NOTE: Master 40 Amp Fuse located behind battery box -
® Fuel Injectors -
© Canister Purge Valve (CA models only) -
CD Oil Pressure Switch 89 in-lbs (10 Nm)
® Gear Position Switch 25 in-lbs (2.8 Nm)
® Oxygen Sensor, Rear 14 ft-lbs (19.0 Nm)

@) Side Stand Switch 60 in-lbs (6.8 Nm)
® CPS (Crank Position Sensor) 89 in-lbs (10 Nm)

@ Oxygen Sensor, Front 14 ft-lbs (19.0 Nm)
® Vehicle Speed Sensor 89 in-lbs (10 Nm)
® CTS (Coolant Temperature Sensor) 17 ft-lbs (22.5 Nm)

ABS (Anti-Lock Brake) Module - INTERNATIONAL -
® MODELS ONLY
@ Load I Tip Over Module - Located below battery box. -

5.11
(
EXHAUST SYSTEM
C
(
CD Nut, Muffler Hanger - MS x 1.25 C 10 (QTY. l) 19 ft-lbs (25.7 Nm)
CD Clamp, Exhaust (QTY.3) 40 ft-lbs (54.2 Nm)
CD Bolt, Muffler Hanger - MS x 1.25 x 20 (QTY.3) 19 ft-lbs (25.7 Nm)

C
© Nut-Ml6 x 1.5 (QTY.l) 50 ft-lbs (67 .8 Nm)
® Nut - MS x 1.25 (QTY.4) 12 ft-lbs (16.3 Nm)
® Oxygen Sensor (QTY.2) 14 ft-lbs (19.0 Nm)

5.12
EXHAU ST SERVI CE
MU FFLE R REMOVAL 3. Remove the Bottom Muffler Bolt and Nut © . Loosen
lower muffler clamp & remove muffler.
(• ( '·, /
/
Engine and e xhaust components get hot and remain (· \ /
!'" \
hot for a period of time after the engine is stopped.
Wear insulated protective clothing or wait for
components to cool sufficiently before working on
the machine.
1. Remove upper muffler Support Bolts G) located on

the back side of mufflers.
, .---,"
! '
MUFFLER INSTALLATION
1. Slide the Bottom Muffler into position so Bolt CD
and Nut © can be installed. Slide Bottom Muffler
51
Clamp onto Head Pipe. Hand tighten.
! '
2. Loosen the upper Muffler Clamp CD between the

head pipe and upper muffler. Remove Upper
Muffler.
2. Slide the Top Muffler into position. Install Top

Muffler Support Bolts G). Slide Upper Muffler
Clamp onto Head Pipe. Hand tighten.
~~ ~- "-<_"'
',"''-

5.13
3. Torque Top and Bottom Support Bolts to 3. Cut zip tie located underneath radiator and
specification. disconnect front Oxygen Sensor (I). C
4. Torque upper and lower Muffler Clamps 0 to

specification. C
/
<:;_
4. Remove two Rear Head Pipe Nuts G).
HEAD PIPE REMOVAL

1. Remove mufflers. SeeMuffler Removal, page 5.13.
2. Disconnect rear Oxygen Sensor (D.
5. Loosen Front to Rear Head Pipe Clamp ©.

5.14
6. Remove two Front Head Pipe Nuts®· HEAD PIPE INSTALLATION

l . Install new exhaust Gaskets (j) on front and rear
exhaust tube.
7. Remove head pipe to bracket fastener ®·
2. Connect Front Oxygen Sensor Q).
/
' ··
;
/ /\
.. .0"';
....../ .
;
8. Remove rear exhaust tube from engine bolts first,

then swing the Head Pipe assembly forward
allowing room to remove front Head Pipe from the
engine.
9. Remove old exhaust Gaskets (j) from front and rear Install new zip tie securing Front Exhaust Sensor to
exhaust tube. frame
3. Install Front Head Pipe to engine and secure Head

Pipe Nuts ® ·
99261 40 R02 - 20 IS - 2016 Scout Service Manual

5.15
(
4. Install Rear Head Pipe to engine and secure with 7. Install head pipe to bracket fastener ®·
two Head Pipe Nuts G).
(
' '
'
(
- '
5. Connect Rear Oxygen Sensor G). 8. Torque fittings to specifications.

~\ \ ~ ...
r.:
TORQUE
·1.. \\\ (:) / ;/. ·:
Head Pipe Nuts: 12 ft lbs (16.2 Nm)
"•!·';:., ..... -·
. ,...:.,, Muffler Clamps: 40 ft-lbs (54.2 Nm)
'~) ·
Head Pipe to Bracket Screw: 12 ft lbs (16.2 Nm)
.,. ~.:;,/''. ,--
(
6. Tighten Front to Read Head Pipe clamp©.

5.16
AIR CLEANER SERVICE

AIR BOX REMOVAL
1. Secure motorcycle in an upright position and place
a suitable jack under engine.
.'.',»: ;
~\-~/
'/
,/ J~/
7. Disconnect the breather hoses © from the air box
fitting and lift the back of the air box to remove
from throttle body.
2. Remove seat. See Seat Removal. Seat Removal I
......~~
Installation, page 3.9 ·...................,.·
3. Remove fuel tank. See Fuel Tank Removal. Fuel

Tank Removal, page 5.20
4. Remove frame tube to mid-casting bolts G), two
nuts CD and bolt CD retaining the right frame tube
©.
'·>(_':;~:~<->\}?--"''
~...';St./ . :s.~~:., .
.,.~,,
'· (:::
\/ - ~~ 1:)r·.
AIR BOX INSTALLATIO N
l. Connect the breather hoses © to the air box fitting
,/ . ¥¢:{c?;.,=.~~;s;j} I
;
and slide the front of the air box in place.
5. Remove both frame tubes.

6. Loosen the air inlet boot clamp ®·

S.17
2. Tighten the clamp ~ securing the air box to the air

inlet boot. C
. /
/
/
) ..
j
1. ,"' .
3. Install both frame tubes.

4. Install the frame Tube to Mid-Cast Bolts(D, two nuts
G) and Bracket bolt CD retaining the right frame
tube ©. Torque Fasteners to Specification.
,<:~,::~7? J:S}}) ·:· ·

,."-);F. /.
(
:. f :
:rif>(J,::fr ·· ·
·,· /
/
I
TORQUE
Frame Tube to Mid-Cast/ Frame Fasteners CD and G) :
35 ft lbs (47 .4 Nm)
Frame Tube Brack et to Frame Fastener CD:
19 ft lbs (25.7 Nm)
5. Install fuel tank. See Fuel Tank Installation, page

5.25.
3.9.
l.

5.18
FUEL DELIVERY SERVI CE

INTAK E MANI FOLD RE MOVAL/ INSTALLATION
1. Place a suitable jack under motorcycle frame/
engine.
FUEL PUMP PRESS UR E INSPECTION
Gasoline is extremely flammable. Work in a well

ventilated area. Open flames, sparks and cigarettes
must be kept away from gasoline. KEEP GASOLIN'E
OUT OF THE REACH OF CHILDREN!
CAUTION
Wear safety glasses or a face shield when working
around the fuel system to protect your eyes.
2. Remove the seat. SeeSeat Removal I Installation, 1. Depressurize fuel system and disconnect fuel line
page 3.9 at fuel rail . SeeFuel System Depressurization, page
3. Remove the fuel tank. See Fuel Tank Removal, 5.20.
page 5.20. 2. Install fuel pressure gauge PU-43506-A and fuel
4. Remove the air box and throttle body assembly. pressure gauge adapter PV-48656.
See Air Box Removal, page 5.17. 3. Start engine and record fuel pressure (or press the
5. Remove the fuel injectors and fuel rail assembly. power switch ON and cycle the Engine Stop switch
See Fuel Injector Removal I Installation, page 5.41. to read pressure w hen pump cycles for 2-3
seconds) .
6. Loosen the two clamps CD securing the intake
manifold to the rubber boots at the front and rear Minimum Fuel pressure
cylinders. 3 .51 BAR (35 1 kPa) (51 psi)
' ;
\;ip{'~~jf
//': l\ _J~ ' < ' ,
7. Remove the two bolts securing the intake boots to

the cylinder head,
removal procedure.
9. Torque the intake manifold clamps and boots to
specification.

5.19
4. Turn ignition switch off. Disconnect gauge adapter 2. Squeeze both release buttons (one on each side of
and re-connect fuel line (Fuel Tank Installation, fitting) and hold. Gently slide fitting straight off
page 5.25). fuel rail.
nJEL PRESSURE TROUBLESHOOTING

FUEL PRESSURE TOO FUEL PRESSURE TOO
LOW: INSPECT HIGH: INSPECT
('
* Low fuel level (add * Plugged fuel return
fuel) (in tank on pressure
* Pump not running regulator)
(Fuel pump or circuit * Pressure regulator
malfunction) malfunction (located
* Restricted fitting, fuel on pump) .
supply line, or gauge (
adapter hose
* Fuel line kinked or
restricted (from tank
fitting to rail)
* Fuel line leaking 3. Cover fuel fittings to keep debris out.
(leaking air in or fuel
out) FUEL TANK REMOVAL
* Vent restriction
* Plugged fuel pickup
filter (located in fuel
tank) Allow engine and exhaust to cool completely before
* Pressure regulator disconnecting fuel line or removing tank. Protect fuel
malfunction (located on tank finish when removing, storing, and installing
pump) tank. (
*Fuel pump malfunction
(Pump should run for Be prepared to place the fuel tank in a secure location
about 2-3 seconds the with a drain pan positioned to catch any fuel that may
instant that the key leak or drip from disconnected hoses or fittings.
switch and Engine Stop 1. Remove seat. See Seat Removal I Installation, page
switch are turned ON. 3.9.
2. Remove the fuel tank filler pad.
FUEL SYSTEM DEPRESS URI ZATION
Allow engine and exhaust to cool completely before

disconnecting fuel line or removing tank. Wear eye
protection.
1. Wrap a clean shop towel around fuel line fitting CD.

5.20
3. Remove the four bolts CD at the rear of the fuel 6. Support the tank and disconnect fuel pump
tank. electrical connector.
7. Wrap a shop towel around the fuel fitting and
\
disconnect the fuel supply line connector from the
fuel pump by squeezing release tabs on both sides
of the fitting.
8. Install Special Tool PV-50567 Fuel Tank Fitting Plug
onto the fuel pump fitting to the protect the fitting
', /=- :i__I_ j i- J and prevent fuel from seeping out of the tank.
........_._,.._. ,,
-~~
4. Disconnect the fuel tank vent line CD and fuel cap

recess drain line CD at the rear of fuel tank.
9. Lift the rear of the fuel tank and slide rearward to

release from the front isolators.
.7
-- , , ~
5. Place the handlebars in the straight ahead

position. Place a protective cloth on front of the
fuel tank to prevent damage. Lift the rear of the
tank approximately 2". to access the fuel supply
line connector and fuel pump electrical connector IO. Lift the fuel tank off the motorcycle and place on a
CD. suitable flat surface to prevent tank damage.
FUEL PUMP REMOVAL
Replace all mounting screws and pump seal 0-ring

any time pump is removed for service or fuel filter
maintenance. Do not kink or bend fuel pickup hose
upon removal. Review gasoline warnings outlined in
the beginning of this chapter.

5.21
CAUTION 4. Remove fuel pump bolts G).

('
Be careful when performing this procedure to avoid
damaging the fuel pump, electrical wiring, or hoses.
Always inspect wires and hoses closely for damage
after removing the fuel pump.
1. Remove the fuel tank. SeeFuel Tank Removal,

page 5 .20. (
2. Disconnect fuel vent/ drain hoses (D .
5. Lift the fuel pump assembly and carefully remove

from fuel tank.
-.,,,,;=~~.,<1
\.__
'')
/
_,.~·~#!:~
,,):
3. Remove tank mount assembly by removing four

bolts Q).
(
,,,., ·

5.22
f'UEL FILTER REPLACE MENT 8. Install new filter I motor cage assembly to the
pump assembly.
9. Reinstall the retaining ring and seat with a small
The fuel filter element should be replaced every
deep well socket.
25,000 miles (40,234 km).
10. Remove seal from outlet of fuel pump and replace
Removal with new seal.
1. Remove fuel pump from the fuel tank. See Fuel 11 . Install the pump cage onto the flange assembly. Be
Pump Removal, page 5.21. careful not to severely bend or kink wire exiting
the thermistor.
2. Insert a small screwdriver and gently pry the
retaining tabs CD to release it from the snap detent 12. Connect the fuel pump connector.
on both sides of the pump cage. 13. Install the pump assembly into the fuel tank.
f'UEL TANK VENT INSPECTIO N

1. Refer to Chapter 2 for tank vent inspection and
hose routing information. See Fuel Tank Vent
Inspection (49 State) , page 2.24.
f'UEL PUMP IN STAL LATION

1. Install fuel pump assembly into bottom of gas tank.
Insert fuel filter © first before pushing the rest of
the fuel pump into fuel tank. Verify the filter is
positioned correctly in the tank cavity before
installing the pump bolts.
3. Slide the pump and filter assembly CD to release it

from the flange assembly.
4. Disconnect the fuel pump electrical connector CD.
5. Remove the filter element retaining ring ©.
6. Insert a large flat blade screwdriver and pry near

the filter tee fitting to separate the filter element
assembly from the pump motor. Use caution not to
break or permanently deform the plastic.
7. Remove the filter element and seal. Remove motor
from remaining assembly.

5.23
2. Install fuel pump bolts CD and tighten to 3. Install tank mount assembly using four bolts CD.
specification following the torque sequence Torque to specification.
shown.
Fuel Tank Mount Assembly Bolts: 7 ft-lbs (9.5 Nm)

(
4. Connect fuel vent/ drain hoses (j).
,,..,,..- ...'<
--,,,=-.,,.-'-~( 1 )
,_/
C
...,_..-
~
~·-~. ---·
.) .....................!
5. Install the fuel tank. See Fuel Tank Installation,

page 5.25
6. Prime the fuel system and verify fuel pump
operation. See Priming the Fuel System, page
5.28.

5.24
FUEL DELNERY I EFI I EXHAUST
FUEL TANK INSTALLATIO N 6. Connect the fuel tank vent line CD and the fuel cap
1. Secure the handlebars in the straight ahead recess drain line G). Install rubber tank filler panel
position. prior to fully lowering the rear of the tank.
2. Apply alcohol, soapy water solution, or rubber
lubricant to the isolators and carefully lower the
fuel tank onto the tank isolators.
7. Install the fuel tank mounting bolts G) and torque

to specification.
3. Remove Special Tool PV-50567 Fuel Tank Fitting

Plug from the fuel pump.
4. Connect the fuel supply line to the fuel pump ©

and fuel pump electrical connector ® to the fuel
tank.
5. Verify the fuel line is routed and slide tank forward

until fully seated on forward isolators.

5.25
(
FUEL LEVEL SENSOR RESISTANCE TEST 3. On the fuel pump side of the connector, measure
OVERVIEW OF OPERATION: The fuel level sensor is resistance across the sensor and compare to the
located inside the fuel tank on the fuel pump table.
assemblyG).
ID COLOR ASSIGN-
MENT
1 White Fuel Pump(-)
The sensor is a thermistor with inverse temperature 2 Yellow Fuel Pump ( +)
characteristics (as temperature increases, sensor
resistance decreases). When the fuel level falls below 3 Black Thermistor (-)
the sensor, temperature increases, lowering the
resistance to provide a ground path for the Low Fuel 4 Red Thermistor ( +)
lamp bulb which is powered when the ignition key is
on. The lamp will start to glow dimly when the fuel
SENSOR APPROXIMATE
level falls below the sensor, and will brighten as the
TEMPERATURE RESISTANCE LIMITS (
fuel level continues to fall (low resistance).
With fuel tank empty and key ON the lamp will take 23°C 1000 ± 15% Q
approximately 30 seconds to 1 minute to reach full 50° C 190 ± 15 % Q
intensity (depending upon temperature). The sensor
can be tested using a digital multimeter. Resistance
readings obtained with tank installed will be in
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 Fuel Pump Removal,
page 5.21.
2. Set multimeter to measure resistance. Attach
suitable test probe adaptors to meter leads (from
kit PV-43526).

5.26
FUEL PUMP SUPPLY VO LTAGE TEST FU EL PUMP CURR ENT DRAW TEST
Before performing this test, verify that battery is fully
charged and in good operating condition.
1. Remove the seat assembly. See Seat Removal I Fuel pump current draw is an indicator of pump
Installation, page 3.9. condition. Perform draw test if fuel pump operation is
suspect, or if fuel pump fuse is found open (blown).
2. Remove the fuel tank assembly. See Fuel Tank
Removal, page 5.20Fuel Tank Removal.
3. Disconnect the fuel pump I level sensor electrical
connector. When meter leads are inserted the pump will run,
and current draw will be displayed on the meter,
4. Connect meter across terminals 2 & 4 on the wire even with key and stop switch off. Fuel tank must be
harness side of connector. completely installed and have enough fuel in it to
cover the fuel pickup screens for an accurate test.
FUELSND-2 BIGDG . 2 0 6 BKffiU-
F PPWR-2 VT/YE N D2-3 B K - 1. Remove the seat. See Seat Removal I Installation,
page 3.9
FUE L- PU MP 2. Remove fuse box cover CD.

P IN FUNCTIO N
1 F UEL LEV EL SENSO R SI GNA L RETURN
2 FUEL PUM P GRO UND
3 FUE L SEN DER OUTPUT
4 FU EL PUMP PO WER
5. Turn the ignition switch to the "ON" position to

power up the motorcycle electrical system.
6. Turn Engine Stop switch to RUN and read DC
voltage on meter when switch is first turned on.
Voltage reading should be close to battery voltage
for 2-3 seconds after switching Engine Stop switch
to RUN.
7. If low or no voltage is delivered to the fuel pump,
verify ground wire (Pin 2, BK/DG) has good 3. Remove Fuel Pump Relay Q) by pulling straight
continuity to battery (-) post. upward.
r
8. If ground is OK, check Gray wire from fuel pump
relay terminal B4 to ECM Pin # 142 . The Gray wire
receives a momentary ground from the ECM (for ( ~ - - - - - - -68
- .0.-. _ _ _F_A_N_. - -CH
- -A
-. SSIS
- .--,'
2-3 seconds) and activates the fuel pump relay
w hich supplies power to the pump on the VT/YE tf\
~~
I STARTER RESISTOR
RELAY RJa.. PLU>
'2.0A
fNGl,.IE
15A
J-EADUGHT
wire. ' 15A 20A , 15A
9. Trace both power and ground circuits to

determine fault if battery voltage is not present for (/ 1-EADUGHT ~ ENGN:: CO~ ,
2-3 seconds after ignition switch and STOP I RUN

switch are turned on. 1 ---~""'':___r ~ REU~ ~~ ·
10. When a CPS signal is received by the ECM
(engine is cranking or running) the ECM maintains
the ground on Pin # 142 (Gray wire), keeping the ',, II , 2) 11
1
I~
pump powered.
4. Set meter to DC Amps. Be sure red meter lead is in
the lOA jack, and black meter lead is in common
(-) jack.

5.27
5. Insert red meter lead in pin socket B5 (7) and PR IMING THE FUEL SYSTEM
black meter lead in pin socket A4 (4) of relay Prime procedure should be performed:
block. • 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.
1. Fill the fuel tank.
2. Turn Engine Stop switch OFF.
3. Turn the ignition switch to ON.
4. Turn stop switch to RUN.
5. 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.
6. Read fuel pump current draw on meter and
compare to specification. 8. WAIT approximately 10 seconds.
7. Inspect fuel pump circuit wiring or replace fuel 9. Repeat Steps 4-8 about 4 times to complete the C
pump if current draw exceeds specification. priming procedure.
SPECIFICATION: Fuel Pump Current Draw

M aximum: 6 DC Am.ps
Fuel level in tank must be high enough to submerge
pickup screen on fuel pump.
(
l.
992 6 140 R02 - 2015 - 20 16 Scout Service Manual

5.28
EFI SERVICE
FUEL INJECTIO N SYSTEM - OVERVI EW OF switch is turned ON to pressurize the system for start-
OPERATION up.
The Electronic 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 is controlled by the ECM. Pulse duration determines
adjacent to the battery box. It is programmed to the amount of fuel delivered to the engine (longer
provide the correct fuel/ air mixture and ignition cycles = more fuel). The ECM selects the correct fuel
timing 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
circuits of the electrical and fuel delivery systems. (AFR). The ECM calculates an injection time based on
the measured airflow and desired AFR.
An Electronic Throttle Control (ETC) system takes the
place of a conventional, cable-operated throttle body. Although TMAP and engine RPM are the most
The ETC controls throttle blade angle and provides influential inputs for selecting a map reference point,
rate-of-change feedback to the ECM. the ECM also evaluates feedback from minor sensors
in the system, to obtain a 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 I 58
PSI). The fuel pump cycles " ON" for 2-3 seconds w hen The locations of sensors and other EFI system related
the motorcycle is powered up and the Engine Stop components are outlined in this chapter. See Sensors -
Powertrain Management, page 5.11.

5.29
ECM CONNECTOR MAP (
490000000056 490000000056
37000000 00000048 37000000 00000048
25 000000 00000036 25 000000 00000036
13 000000 00000024 13 00000000000024
100000000000012 1 00000000000012
C
ECM 1 ECM2
(
l
PIN COLOR FUNCTION PIN COLOR FUNCTION
ECMl ECM2
l - NOT USED 1 BK CPS NEGATIVE SIGNAL
2 - NOT USED 2 GY/DB FRONT HEATED 02 SENSO R SIGNAL 2
3 YE/ BK PPS 2 RETURN 3 OG/YE TPS 1 OlITPUT
4 BN/ GN TMAPSENSORRETURN 4 BN/YE TIPOVER SENSOR SIGNAL RETURN
5 BN/WH TPS SIGNAL RETURN 5 BG/WH REAR HEATED 02 SENSOR RETURN 2
6 WH/ BK PPS I RETURN 6 BK/BU FUEL LEVEL SENSOR SIGNAL RETURN
7 YE/WH START SWITCH OlITPUT (TO ECM) 7 BG REAR HEATED 02 SENSOR RETURN 1
8 VT/ OG RIGHI' TURN SIGNAL SWITCH OlITPUT 8 OG/ BK ENGINE COOLANT TEMP SENSOR RETURN
(TOECM)
9 - NOT USED 9 - NOT USED
10 - NOT USED 10 WHIRD PPS 1 - +5 VOLT REF
11 YEIGN PPS 2 OlITPUT 11 - NOT USED
12 - N OT USED 12 DB LEFT FRONT TS LAMP OlITPUT

5.30
PIN COLOR FUN CTION PIN COLOR FUNCTION

ECMl ECM2
13 - NOT USED 13 RD CPS SIGNAL POSITIVE
15 GY/BK ENGINE RELAY CNTL 15 OG/DB ENGINE COOLANT TEMP SENSOR SIGNAL OUTPUT
16 PK ECM SWITCHED POWER INPUT 16 - NOT USED
17 - NOT USED 17 BK/YE BRAKE PRESSURE SWITCH OUTPUT (TO ECM)
18 - NOT USED 18 OGIWH TIPOVER SENSOR SIGNAL
19 DB/YE CLUTCH SWT OUTPUT (TO ECM) 19 OG/ BN TMAP SENSOR SIGNAL OUTPUT
20 VTIWH LEFI' TURN SIGNAL SWITCH OUTPUT (TO 20 VT/RD TPS 2 SIGNAL
ECM)
21 WH/GN PPS SIGNAL l OUTPUT 21 - NOT USED
23 RD/BK RUN I STOP SWITCH (ECM INPU'I) 23 BN/PK TMAP SENSOR B+ POWER
24 YE/VT FRONT BRK SWT OUTPUT (TO ECM) 24 DB/RD RJGHT FRONT TS LAMP OUTPUT
25 YE/RD PPS 2 - 5 VOLT REF 25 NOT USED
26 BNIGN TIPOVER SNR - 5 VOLT REF 26 - NOT USED
27 - NOT USED 27 OGIDG TMAP INTAKE AIR TEMP SENSOR SIGNAL OUTPUT
30 - NOT USED 30 GY/RD REAR HEATED 02 SENSOR OUTPUT 1
31 BK/OG COOLING FAN RELAY CONTROL 31 - NOT USED
32 YE CAN HIGH 32 DGI BN VEHICLE SPEED SENSOR OUTPUT
33 - NOT USED 33 BK/PK NEUTRAL SWITCH OUTPUT (TO ECM)
34 - NOT USED 34 NOT USED
35 - NOT USED 35 DB/BK CANISTER PURGE VALVE (CPV) CONTROL
36 - NOT USED 36 DB LEFT REAR TS LAMP GROUND OUTPUT
38 BN/DB TPS - +3.3 VOLT REF 38 NOT USED
39 - NOT USED 39 GYIYE FRONT HEATED 02 SENSOR CONTROL 2
40 DG/DB HEADLIGHT RELAY CONTROL 40 SECONDARY AIR GROUND OUTPUT
41 WHIYE STARTER SOLENOID RELAY CNTL 41 - NOT USED
42 GY FUEL PUMP RELAY CNTL 42 - NOT USED
43 - NOT USED 43 WH/GY FRONT FUEL INJECTOR DRJVER 2
44 DG CAN LOW 44 WH/DB REAR FUEL INJECTOR DRJVER l
45 - NOT USED 45 NOT USED
46 - NOT USED 46 GYIWH REAR HEATED 02 SENSOR CONTROL I
47 - NOT USED 47 BK/WH ECM ELECTRONIC GROUND
48 - NOT USED 48 DB/ RD RJGHT REAR TS LAMP GROUND OUTPUT
50 - NOT USED 50 BK/WH ECMGROUND 1
51 PK/DB STOP LAMP POWER OUTPUT 51 PK/RD ETC MOTOR(+)
52 - NOT USED 52 YE ETC MOTOR(-)
53 BK/WH ECMGROUND2 53 - NOT USED
54 BKIWH ECMGROUND3 54 WH FRONT COIL SIGNAL 2
55 VT/PK ECM SWITCHED POWER 3 55 - NOT USED
56 VT-PK ECM SWITCHED PWR 2 56 WH REAR COIL SIGNAL 1
DIAGNO STIC TROUB LE COD ES

CODE SPN FMI COMPONENT CONDITION MIL
POl23 3 Voltage Too High ON
POl 22 51 4 Throttle Position Sensor l Voltage Too Low ON
P0121 2 Signal Out of Range (Not Plausible) ON

5.31

(
Pll23 0 Voltage Above Critical Level ON
Pll22 1 Voltage Below Critical Level ON
P0120 10 Abnormal Rate of Change ON
Pll20 13 Calibration I Adaption Failure ON
P0500 ON
0 Vehicle Speed Too High
Cl057 ON
P0502 1 Vehicle Speed Too Low ON
P0503 ON
2 Data Erratic or Intermittent (or Missing)
Cl058 84 Vehicle Speed Signal ON
P050 1 8 Sensor Frequency Outside Normal Range ON
Pl60A 9 Abnormal Update Rate ON
Cl069 ON
19 Received Vehicle Speed has error
Pl06B ON
P0463 3 Voltage Too High ON
P0462 4 Voltage Too Low ON
Pl462 96 16 Fuel Level Signal Above Normal Operating Range ON
Pl463 18 Below Normal Operating Range ON
P0461 2 Signal Fault ON
Pl527 3 Pressure Too High ON
Pl526 98 4 Engine Oil Level Sensor Switch Pressure Too Low ON
P250F 17 Oil Level Low OFF
Manifold Absolute Pressure
P0106 102 2
Sensor
Signal Out of Range ON C
Pll06 7 Pneumatic Fault ON
105 Intake Air Temperature Sensor
P01 14 10 Abnormal Rate of Change ON
POl ll 2 Signal Out of Range ON C
POl 18 3 Voltage Too High ON
POl 17 4 Voltage Too Low ON
P0116 2 Signal Out of Range ON
110 Engine Temperature Sensor
P0217 16 Temperature Too High OFF
Pl217 0 Engine Overheat Shutdown OFF
Pl 116 15 Temperature Above Normal Range OFF
P0128 17 Temperature Too Low ON
P0563 OFF
3 Voltage Too High
Cl063 ON
P0562 OFF
4 Voltage Too Low
Cl064 System Power (Battery Potential ON
Pl562 168 I Power Input) Voltage Above Critical Level ON
0
Pl564 16 Voltage Above Warning Level ON
Pl563 l Voltage Below Critical Level ON
Pl565 18 Voltage Below Warning Level OFF
P0219 0 Speed Exceeded Max Limit ON
Cl059 190 0 Engine Speed Engine Speed Too High OFF
Cl060 1 Engine Speed Too Low OFF

5.32

Cl061 2 Data Erratic or Intermittent (or Missing) OFF
Pl219 7 CV'T Threshold Exceeded ON
Pl21C 31 Error in Engine Speed Computation ON
Cl066 19 Received Engine Speed has Error OFF
523 Gear Sensor Signal
Pl914 9 Abnormal Update Rate ON
P0914 2 Signal Fault ON
P0704 598 2 Clutch Switch Signal Signal Fault ON
Pl602 628 12 ECUMemory EEPROM Read I Write Failure ON
P0336 8 Circuit Fault ON
636 Crankshaft Position Sensor
P0335 2 Plausibility Fault ON
P0261 5 Driver Circuit Open/ Grounded ON
P0262 651 3 Injector I (Front) Driver Circuit Short to B+ ON
Pl262 4 Driver Circuit Grounded ON
P0264 5 Driver Circuit Open/ Grounded ON
P0265 652 3 Injector 2 (Rear) Driver Circuit Short to B+ ON
P0615 5 Driver Circuit Open/Grounded ON
P0617 677 3 Starter Solenoid Driver Circuit Driver Circuit Short to B+ ON
P0616 4 Driver Circuit Grounded ON
P0327 731 4 Knock Sensor I Voltage Too Low ON
Cl030 5 Open/ Short ON
904 Wheel Speed Sensor (Front)
Cl031 2 Input Abnormal I Signal Failure ON
CI03D 2 Plausibility Fault ON
Cll3D 3 Short to B+ ON
Cl23D 4 Open/Short to GND ON
907 Wheel Speed Sensor (Rear)
Cl036 5 Open/Short ON
Cl33D 8 Abnormal Frequency ON
Cl43D 14 Incorrect Sensor I Improper Mounting ON
Cl045 1023 5 Trip Sudden Decelerations Open I Short ON
Pl481 5 Driver Circuit Open/Grounded ON
Pl482 1071 3 Fan Relay Driver Driver Circuit Short to B+ ON
Pl353 1268 3 Ignition Coil Primary Driver I Driver Circuit Short to B+ ON
Pl354 1269 3 Ignition Coil Primary Driver 2 Driver Circuit Short to B+ ON
P0232 1347 3 Fuel Pump Driver Circuit Driver Circuit Short to B+ ON
Pl714 5 Driver Circuit Open/ Grounded OFF
Left Tum Indicator Driver
Pl715 2367 3 Driver Circuit Short to B+ OFF
Circuit
Pl716 4 Driver Circuit Grounded OFF
Pl710 5 Driver Circuit Open/Grounded OFF
Right Tum Indicator Driver
Pl71 l 2369 3 Driver Circuit Short to B+ OFF
Circuit
Pl712 4 Driver Circuit Grounded OFF
POl30 3056 2 Oxygen Sensor I (Front) Signal Fault ON

5.33

('
Pll3A 12 Bad Component ON
POl32 3 Voltage High ON
POl31 4 Voltage Low ON
Pl6A2 3 Voltage Too High ON
Pl6Al 4 Voltage Too Low ON
Pl6A3 0 Voltage Above Critical Level ON (
3597 ECU Output Supply Voltage I
Pl6A5 16 Voltage Above Warning Level ON
Pl6A6 I Voltage Below Critical Level ON
Pl6A7 18 Voltage Below Warning Level ON
Pl6A9 3 Voltage Too High ON
Pl6A8 4 Voltage Too Low ON
Pl6AA 0 Voltage Above Critical Level ON (
3598 ECU Output Supply Voltage 2
Pl6AB 16 Voltage Above Warning Level ON
Pl6AC I Voltage Below Critical Level ON
Pl6AD 18 Voltage Below Warning Level ON
Pl7AA 3 Voltage Too High ON
Pl7AB 4 Voltage Too Low ON
Pl7AC 0 Voltage Above Critical Level ON C
3599 ECU Output Supply Voltage 3
Pl7AD 16 Voltage Above Warning Level ON
Pl7AE I Voltage Below Critical Level ON
Pl7AF 18 Voltage Below Warning Level ON
ETC Accelerator Position
Pll35 65613 2 Sensor Outputs I & 2 Correlation Fault ON
Correlation C
Pl223 0 Voltage Above Critical Level ON
Pl222 520198 I Throttle Position Sensor 2 Voltage Below Critical Level ON
P022 1 2 Signal Out of Range (Not Plausible) ON
P0220 10 Abnormal Rate of Change ON C
Pl220 13 Calibration I Adaption Failure ON
Pl81C 31 Condition Exists (engine disabled due to extended ON
520267 Kickstand Switch kickstand)
Pl501 2 Signal Fault ON
Pl503 3 Voltage High ON
520200 Tipover Sensor
Pl502 4 Voltage Low ON
Pl504 14 Condition Exists (tip over condition detected) ON
P0443 520202 3 Canister Purge Valve Driver Circuit Short to B+ ON
POl71 17 System Too Lean I (Front) (Pre) ON
520204
POl72 15 System Too Rich I (Front) (Pre) ON
Fuel Correction
POl74 17 System Too Lean 2 (Rear) (Post) ON
520205
POl75 15 System Too Rich 2 (Rear) (Post) ON
Pl611 5 Driver Circuit Open/ Grounded ON
Pl614 520208 3 Chassis/Ace Relay Driver Circuit Short to B+ ON
P l613 4 Driver C ircuit Grounded ON
POl35 2 Oxygen Sensor Heater I (pre) Plausibility Fault ON
520209 (front)

5.34
CODE SPN FMI C OMPONENT CONDITION MIL

P0032 3 Driver Circuit Short to B+ ON
P0141 2 Plausibility Fault ON
P0036 5 Oxygen Sensor Heater 2 (post) Driver Circuit Open/Grounded ON
520210 (rear)
P0038 3 Driver Circuit Short to B+ ON
P0037 4 Driver Circuit G rounded ON
CI022 520250 7 ABS Pulsar (front) COG Chip ON
C l023 52025 1 7 ABS Pulsar (rear) COG Chip ON
CI024 520252 5 ABS Solenoid (RR!) Open / Short ON
C l 025 520253 5 ABS Solenoid (RRO) Open / Short ON
Cl026 520254 5 ABS Solenoid (m) Open/ Short ON
Cl027 520255 5 ABS Sole noid (FFO) Open/ Short ON
Cl028 520256 5 ABS Solenoid (RF1) Open/ Short ON
Cl029 520257 5 ABS Solenoid (RFO) Open/Short ON
Cl032 520258 II ABS Actuator (front) Whe e l Lock (orVSS failure) ABS On ON
Cl 03A 5203 13 II ABS Actuator (front) Wheel Lock (or VSS failure) ABS Off ON
C l 033 520259 II ABS Actuator (rear) Wheel Lock (or VSS failure) ABS On ON
Cl03B 520314 II ABS Actuator (rear) Wheel Lock (or VSS failure) ABS Off ON
C0020 8 Motor Lock ON
Cl 020 5202 60 3 ABS Motor Off Stick ON
Cl02 1 4 On Stick ON
C I034 52026 1 7 ABS Fail Safe Relay On/ Off Stick ON
C l 038 4 Drop ON
520262 ABS Source Voltage
Cl039 3 Raise ON
CI040 520263 31 ABS Tire Irregular Tire Size ON
Cl041 520264 12 ABS ECU ECU Error ON
Cl042 520265 7 ABS Module Incomplete Evacuation and Fill ON
Accelerator Position/Brake
PISOA 520275 31 Condition Exists ON
Position Interaction
P0227 91 4 Accelerator Position I Voltage Too Low ON
P0225 2 Not Plausible ON
Pl 228 3 Voltage Too High ON
Pl 227 29 4 Accelerator Position 2 Voltage Too Low ON
Pl225 2 Not Plausible ON
PISOB 12 Throttle Position Sensor ( I or 2 Neither Position Sensor Passed Test ON
520276 Indeterminable)
PISOC 2 Position Sensor Correlation Fault (One okay, one failed) ON
PISOD 3 Maximum ON
PISOE 4 Minimum ON
Pl5 1A 2 Throttle Body Control - Power Not Plausible ON
520277 Stage
P ISIB 8 Signal Error ON
Pl53F 31 Deactivated power stages due to 5V sensor supply error ON
31 Throttle Body Control - Return Condition Exists
PI SI C 520278 Spring C heck Failed ON
31 Throttle Body Control - Condition Exists

P ISID 520279 Adaption Aborted ON
31 Throttle Body Control - Limp Condition Exists

PISI E 520280 ON
Horne Position Check Failed
31 Throttle Body Control - Condition Exists
PI SA 52028 1 Mechanical Stop Adaptation ON
Failure
Pl52B 520282 31 Throttle Body Control Condition Exists ON

5.35
C

Pl52C 3 Maximum ON r
Pl52D 520283 4 Throttle Body Control Minimum ON
Pl52F 2 Outside of Pedal Range (Level I) ON
Pl52E 31 Throttle Body Control - Position Condition Exists ON
520284
Deviation Fault
Pl53E 2 Brake Switch (I or 2 Brake Switch Correlation Fault ON
520285 Indeterminable)
(
Pl540 520286 31 ECU Monitoring Error Condition Exists ON
Pl541 520287 31 ECU Monitoring Error (Level 3) Condition Exists ON
Pl542 31 ECU Monitoring of Injection Condition Exists ON
520288 Cut Off(Level !)
Pl543 31 ECU Monitoring of Injection Condition Exists ON
520289 Cut Off(Level 2)
Pl544 31 Controller Option Settings not Condition Exists ON (
520290 Programmed
Cl075 5 Open Circuit I Short to B+ ON
520291 Left Fog Lamp
Cl076 6 Grounded Circuit ON
CI078 5 Open Circuit I Short to B+ ON
520292 Right Fog Lamp
Pl53D 527 31 Cruise Control Panel Switches Switch/Switches Stuck ON (
Pl590 596 31 Cruise Control Enable Switch Switch Stuck ON
Pl591 31 Cruise Control Set/Decel Switch Stuck ON
599
Switch
Pl592 31 Cruise Control Resume/Acee! Switch Stuck ON
601
Switch
Cl07B 5 Open Circuit I Short to B+ ON
2350 Low Beam Lamp
Cl07C 6 Grounded Circuit ON
Cl07E 5 Open Circuit I Short to B+ ON
2348 High Beam Lamp
Cl07F 6 Grounded Circuit ON
Cl22A 5 Open Circuit I Short to B+ ON
520293 Horn
Cl22B 6 Grounded Circuit ON
Pl075 5 Open Circuit ON
Pl076 524083 3 Secondary Air Control Valve Shorted to Battery ON C
Pl077 4 Shorted to Ground ON
520294 Windshield Motor Driver
C!223 6 Grounded Circuit ON
Cl225 520295 2 Windshield Motor Switch Both inputs are closed ON
Cll25 520296 12 Accelerometer Bad Component ON
Cl512 524046 31 Start Button Switch Stuck ON
Cl530 520297 31 System On Button Switch Stuck ON
520298 Heated Grips
520299 Power Lock Motor
C!083 12 Battery Voltage too Low (Replace) OFF
Cl084 520300 17 Tire Pressure Sensor (Front) Pressure to Low OFF
CI085 9 Abnormal Update Rate OFF
Cl088 12 Battery Voltage too Low (Replace) OFF
C!089 520302 17 Tire Pressure Sensor (Rear) Pressure to Low OFF
C!090 9 Abnormal Update Rate OFF
Pl633 520304 12 Key Fob Battery Voltage too Low (Replace) OFF

5.36
CODE SPN FMI COMPONENT CONDITION M IL

Pl530 31 Throttle Body Control - Condition Exists ON
520305 requested throttle angle not
plausib le
P l537 31 EC U Fault - Hardware Condition Exists ON
520311 Disruption
Cl229 520312 31 Power Lock Motor Switch Switch Stuck ON
Pl 594 520320 3 Brake Light Shorted to Battery ON
P l595 4 Shorted to Ground ON
P l 597 52032 1 3 Tail Light Shorted to Battery ON
P l 598 4 Shorted to Ground ON
Pl 599 3 Voltage Too High ON
P !59A 520322 4 Front Brake Switch Voltage Too Low ON
P l59B 2 Signal Fault ON
Pl59C 3 Voltage Too High ON
Pl59D 520323 4 Rear Brake Switch Voltage Too Low ON
P l59 E 2 Signal Fault ON
Ul405 31 Cruise Control Input Message Counter not incremented ON
524080
Counter
U0405 524079 31 Cruise Control Input Checksum Checksum does not match ON
Pl062 5582 9 ~tatic Roll Angle Abnormal Update Rate ON
Pl063 520329 9 Op erator Switch Status (pOSS!) Abnormal Update Rate ON
P l064 13 Out of Calibration ON
520330 Immobilizer
Pl06A 9 Abnormal Update Rate ON
Pl327 3 Voltage Too High ON
520331 Knock Sensor Positive Line
Pl328 4 Voltage Too Low ON
P l 32A 3 Voltage Too High ON
520332 Knock Sensor Negative Line
P l32B 4 Voltage Too Low ON
Pl"l36 2 Signal Fault ON
P ll39 12 Bad Component ON
520333 Oxygen Sensor (Pre) (BANK 2)
P ll37 3 Voltage High ON
P ll38 4 Voltage Low ON
ECU Monitoring (Pedal Map
P l545 520336 31 Mismatch) Condition Exists ON
P2279 520338 31 Gross Air Leak Condition Exists ON

Data Valid But Above Normal Operating Range - Least
P l l 6C 15 Severe Level (System Too Rich) ON
520342 Idle Fuel Correction Bank 1
P l 160 17 ON
Severe Level (System Too Lean)
Pll6E 15 ON
Severe Level (System Too Rich)
520343 Idle Fuel Correction Bank 2
Data Valid But Below Normal Operating Range - Least
Pll6F 17 ON
P0170 15 Severe Level (System Too Rich) ON
Adaptive Fue l Correction Bank
520344
1 Data Valid But Below Normal Operating Range - Least
Pll70 17 ON
Data Valid But Below Normal Operating Range - Least
P0173 15 Severe Leve l (System Too Rich) ON
Adaptive Fuel Correction Bank
520345
2 Data Valid But Be low Normal Operating Range - Least
Pll 73 17 ON
Upstream 02 Sensor Signals
Pl416 52036 31 Condition Exits ON
Swapped

5.37
SENSO R DIAGNO STICS • FJ.ways use the appropriate test connector from the
If a sensor fails or reads outside a "normal" range, a Electrical Connector Test Adapter Kit (PV-43526) or
"pre-programmed" (default) value is substituted by an appropriate test probe that will not damage
the ECM until sensor reading returns to normal. (expand) the connector pin socket.
Sensor values can be viewed in Digital Wrench on the • DO NOT attempt to use standard meter probes or
"Sensor Data Grid Or Graphs" screen. Since the other devices to probe connector pin sockets as this
sensor reading may either be actual feedback from could expand a terminal socket or damage the
the sensor OR a default value set by the ECM in the connector, create a problem where none existed
event of a fault in the sensor or wiring, it is important before , and complicate the diagnostic process.
to verify the condition of the sensor. • Sensor tests on the following pages can often be
performed at the sensor connector itself or at the
The Malfunction Indicator Light (MIL) may or may not ECM connector based on accessibility of the
illuminate to alert the rider of a possible problem, (
connector or wiring.
depending on which system fault has occurred. The • If a sensor tests within the specified range (OK),
first step following illumination of the MIL is to perform then test the circuit wiring. This usually originates at
a visual inspection to see if a cause can be the ECM connectors, but may include other
determined. connections.
Connect Digital Wrench to see what codes are present
in memory, and focus your diagnostics on that sensor
and the related wiring for that circuit. Refer to wiring ECM CONN ECTOR REMOVAL
diagrams and system break-out diagrams to narrow a 1. To disconnect the two 56-pin ECM connectors:
problem search. • Locate the ECM connectors G) .
If multiple codes are set, refer to the wiring diagram
and focus your efforts on wiring and connections
common to each of the sensors, such as a power
supply or common ground. Multiple sensor failure is ;
extremely unlikely. ·;;;.-:,....,,.-;-,. ....• -·· "\
....·.~ ' \
Many sensor tests described in this section are ZQ_~}', .,. ; ______... _.... .. ,... r
performed at the ECM wire connector. This method . ,.-·-
ensures that the data from a sensor is reaching the
ECM. Sensor tests can be performed at the sensor if ..., ..
easily accessible, but the wiring between the sensor (
and the two 56-pin ECM connectors should always be
closely e x amined and the path between the sensor
and ECM verified if the sensor itself passes the test.
Poor or corroded connections are the most common
cause of system faults. FJ.ways check the integrity of
the male pins and female receptacles of the • Remove the panduit strap securing the connector
connectors in the affected circuit. These may include lock lever (if equipped).
the sensor connector, the ECM connector, and any • Slide the lock lever toward the rear of the vehicle
wiring between the two, such as jumper harnesses until connector is disengaged from the ECM.
where applicable. • Lift the connector straight off of the ECM.
EC M PINOUT TESTI NG ECM Connector Installation

2. Carefully align the ECM connector straight with
the flange on the ECM. (Do not tip or rotate the
Tests in this section may require reading resistance connector into the ECM).
and voltages at ECM connector. Once ECM
connector has been removed from the ECM: 3. Gently apply straight inward pressure on the
connector while sliding the lock lever back toward
the connector until the lever stops and the
• Do not touch pins on ECM. Static electricity from connector is fully seated.
your body can damage the ECM.
• Do not attempt to perform tests on the ECM unit .

5.38
4. Secure a new panduit strap CD around the ECM

rear connector lock lever and harness .
....y;
:: .fl'- ,r ···
![ i ·~
!!I- .
-~ \.
tr]
\ . ·,
Air passing through the intake is measured by the

TMAP and relayed to the ECM. These signals,
comprised of separate air temperature and manifold
absolute pressure readings, are processed by the
ECM and compared to its programming for
EC M REMOVAL/ IN STALLATION determining the fuel and ignition requirements during
1. Remove the battery box. See Battery Box Removal, operation. The TMAP sensor provides the ECM with
page 15.12. engine load data.
2. Disconnect the ECM connectors. See ECM TMAP Sensor Test
Connector Removal, page 5.38. The TMAP sensor is a non-serviceable item. If it 1s
3. Remove the ECM CD from the 4 posts securing it to faulty, it must be replaced
the frame.
This sensor should only be tested using Digital

Wrench Diagnostic Software.
TMAP Sensor Replacement

l. Remove the ignition coil assembly and associated
bracket. See Ignition Coil Removal I Installation,
page 16.3.
2. Disconnect vehicle harness from TMAP sensor.
3. Remove TMAP sensor screw CD and remove sensor
from the intake manifold.
4. Reverse the removal procedure to install.
TE MPERATURE MANIFOLD ABSOLUTE

PRESSURESENSOR(TMAP)REPLACEMENT
Operation Overview
Mounted on the intake manifold, the TMAP sensor CD
performs two functions in one unit.

removal procedure.

5.39
5. Torque TMAP sensor screw to specification.
COOLANT TEMPERATURE SENSOR. TEST/

REPLACE
CHT TEST OVERVIEW

INDICATES INSPECT LOCATION
Voltage received at ECM from CTS Resistance readings through sensor and wiring at ECM Under rear
sensor is outside of parameters. 2 connector (ECM disconnected). This will test will cylinder
inspect the wiring, connectors, and CHT sensor intake port.
resistance.
1. Disconnect ECM #2 connector. See ECM 5. If resistance is out of specified range, disconnect
(
Connector Removal, page 5.38. sensor and measure the resistance through each
wire from ECM connector to the sensor connector.
2. Attach test lead adapters to meter leads.
Resistance should be less than 1 Ohm (good
3. Set multimeter to measure resistance. continuity).
4. Measure resistance between pin 208 and pin 215 6. If Step 5 continuity is good, measure the resistance
of the ECM #2 connector and compare to through the sensor and compare to specification.
specification. See ECM Connector MAP, page 5.30.
METER TEST SPECIFICATIONS (±10%)

COMPONENT
SETTING CONNECTIONS
COOLANT TEMPERATURE 30.5 K Ohms+/ - 13%@ 25° C (77° F)
OHMS Pin #208 to #215
SENSOR

5.40
FUEL INJ ECTOR REMOVAL / IN STAL LATION 12. Install the injector retainer CD onto the injector G)
1. Remove the seat assembly. SeeSeat Removal I as illustrated.
Installation, page 3 .9
2. Remove fuel tank. See Fuel Tank Removal, page
5.20.
3. Remove the air box. See Air Box Removal, page
5.17 .
4. Remove the ignition coil(s) assembly. See Ignition
Coil Removal I Installation, page 16.3.
5. Disconnect electrical connectors from fuel
injectors.
6. Remove fuel rail screws G) . '
'
13. Insert the assembled injector into the fuel rail © .

14. Install the fuel rail assembly to the engine.
15. Install and torque the fuel injector screws to
specification.
Fuel Injector Retaining Screw s: 88.5 in-lbs (10.0 Nm)
7. If still attache d , disconnect the fuel supply line

FU EL INJ ECTOR RES ISTANCE TES T
from the fuel rail quick connect.
8. Lift fuel rail off injectors to remove it. Cover Take note of front and rear fuel injector harness
injector ends and fuel r ail quick connect with connectors before disconnecting them.
plastic wrap rail to prevent contamination.
9. Clean the area around injectors with compressed The fuel injectors are non-serviceable. If diagnosis
air to prevent foreign material from entering the indicates a problem with either injector, test the
engine. Pull injectors out of cylinder heads , resistance of the fuel injector (s) by measuring
keeping them in order (front and rear) for between the two pin terminals G).
assembly.
10. INSTALLATION is the reverse of the removal
procedure.
11. Install new o-ring on each fuel injector and
lubricate with engine oil.

5.41
Fuel Injector Resistance Specification: 2. Disconnect the CPS sensor from the vehicle
(
11.4 .Q - 12.6 .Q harness and release flying lead from plastic darts
and cable ties.
3. Remove the screw G) securing the CPS sensor to
CRANKSHAFT POSITION SENSOR. TEST/ the engine case and remove sensor.
REPLACE
Crankshaft Position Sensor CPS Test
1. Locate the CPS connector G) under the Belt Guard,

and disconnect .
...;'--1 _,.,. ,~ ....?.C> / ,. ; i;_ :..,<)'/ .--··<f1\,.J, - • ""· ~·- -:::-(. . ' ';-;-•
....-·t ·: : ,(,. •' ,. ,I'/ ,.,I /s.'. . :,i ':.P · , .. ' "~
# ,,., ,A ' I , }(
) .;'\, .'
' . . ';"",_ . .fl ·.i\ A/ '
;;_j/.'.f?f/// '"'~. ' C
.....::'' -'
1/$"•< ·'' ' . ,•a, ,/ ,. . /~': J/' :;,,_, ,:, ,,.- ' 4. Installation is performed by reversing the
C
~~:Ji1~~/ ~~
removal procedure.
Apply rubber lubricant to the CPS sensor o-ring to

2. Connect an olunmeter between the pin terminals ease installation.
Q) and compare resistance readings to
specification below. 5. Torque the CPS retaining screw to specification.
Crankshaft Position Sensor Retaining Screw: 88.S in-

lbs (10.0 Nm)
C
THROTTLE BOOY (ETC) REMOVAL/

INSTALLATION
I. Remove seat assembly. See Seat Removal I
2. Remove fuel tank. See Fuel Tank Removal, page
5.20
3. Remove air box assembly. See Air Box Removal,
page 5.17.
3. If resistance is correct, check to see that the sensor
is mounted properly and that the tone wheel has 4. Disconnect the electronic throttle body connector.
not been damaged and is securely mounted to the
crankshaft assembly.
Crankshaft Position Sensor: 860 Ohm.s @ 20°C (68°F)
CPS Replacement
1. Remove regulator I rectifier assembly and bracket.
See Rectifier I Regulator Replacement, page 15.30.

5.42
5. Remove four electronic throttle body fasteners G) .

Ii#'
6. Remove electronic throttle control CD and replace

gasket G) .
7. Reverse procedure for installation.
8. Torque the throttle body fasteners to specification.
LOAD/ TIP OVER MODULE
, ''. );,~~;;.?~.y
~·;( ,:.
The Load I Tip Over Module G) adds load to standard

high-current hand control switches for terminal
cleaning and to provide ECM interface signal
integrity. The Tip Over Sensor incorporated into this
module interrupts the ignition/fuel supply which
prevents engine operation after a tip over event.
See Chapter 17 Chassis Electrical for additional
information.
J

5.43
DIGITAL WRENCH
DI GITAL WRENCH DIAGNO STIC SOFTWARE DIGITAL WRENCH COMMUNICATION ERRORS
OVERVIEW If you experience problems connecting to a vehicle or
any other Digital Wrench related problem, visit the
Digital Wrench Knowledge Base for the most current
Refer to Section 2, 3 and 4 in the Instruction Manual troubleshooting information, FAQs, downloads and
provided in the Digital Wrench Diagnostic Kit to software updates at: http://polaris.diagsys.com/.
install the Digital Wrench diagnostic software on your
computer.
.___._..;..; ·
The Digital Wrench diagnostic software · allows the ·~
'""'l:--•M,~••~
technician to perform the following tests and

observations:
• View or clear trouble codes Knowl'e dge Base C
• Analyze real-time engine data
• Reflash ECU calibration files •Main
• Perform guided diagnostic procedures •Procedures & Solutions
• Create customer service account records • Errors a n d
• Perform output state control tests (some models) Troubleshootin g
•Fr equently Asked
Questions
DIAGNOSTIC SOFTWARE VERSION
Alw ays use the most current version of the Digital
Wrench software to ensure you have the latest updates
or enhancements. New reprogramming files and DIGITAL WR ENCH DIAGNO STIC CONN ECTOR
guided diagnostic procedures are added to these The diagnostic connector G) is located behind the
updates as they become available. battery.
(
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 C
provided in Digital Wrench.
GUIDED DIAGNOSTIC AVAILABLE

Guided diagnostics are available within Digital
Wrench for most supported Diagnostic Trouble Codes
(DTCs). That is, any fault that will turn on the 'Check
Engine ' indicator.
In addition, guided diagnostics are also available for Follow these steps to connect the diagnostic interface
many other electrical sub systems. cable to the vehicle:
Diagnostic procedures are added to subsequent 1. Assemble the SmartLink Module and attach the PC
versions of Digital Wrench as they become available. Interface Cable to your laptop.
Check your release version often and upgrade when
available to be sure you are using the most current 2. Unplug the Digital Wrench connector from it's
software available. protective receptacle.
3. Connect the Vehicle Interface Cable to the Digital
Wrench diagnostic connector.
4. Press the ON button to power up the motorcycle
electrical system and switch the STOP I RUN
switch to the RUN position.

5.44
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. .r-<"':Jc~>---· --.~ - ..... _. .
!""~ -"""'!-~ . - - 1..~
- - --- ~~:.J.t:Ti!r~~~-~.:J£::
6. Once connected, proceed with using Digital ,...- "' '*-w.· r:- - 1t-...~ ·
;g-... .... l ! ·: }· e - :.! •·-·,..•--·..,"'
Wrench. "
DIGITAL WRENCH SERIAL NUMBER LOCATION ,-.-.. - .-~

Open the configuration screen by clicking on the
wrench icon. The serial number is located on the right
side of the screen.
·"
.. ·· ···················································•·•·•·•···••·•····
Digital Wrench Update
3. If a newer update is available, it should be

downloaded before using Digital Wrench.
Always operate with the latest update.
DIGITAL WRENCH UPDATES

Updates are released for Digital Wrench via the
DIGITAL WRE NCH VERSION AND UPDATE ID Internet at: http:/ /polaris. diagsys. com. The Digital
Knowing what Digital Wrench version and update is Wrench website can also be accessed through the
installed will help determine which updates are dealer website at: www.polarisdealers.com.
required.
Only authorized Indian Motorcycle dealers and

Versions and updates are subject to change. distributors can access the dealer website.
1. 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.
O ,itffifiM', M, > -,-.--- ... ·. 0 PCLARJS'
3. Click on Digital Wrench Updates.
_.::t ::u::
t-. t==
'21'--
~-----
j; ii" - -
' u-
~1.,ot,''·""'"'1,ou,U.","1.•t':-
I~ "fu. . ,.,. .,_l>'l f.ltl(".,* )O POLARIS £ ,.:t.
Version · --··""·:..,-..
. ,,.,,....._,...,
r:~= ~----
~---·-
,-,.....r.:- - '\........;
~ ~ - -Y•.•• ~
IE5.1: I . t:; I
Fr,-.::t:, _ J
'...___--. - _-_-_-_-_..... ----·--·-·---------··-·----~·-·-----~--- ~
..
4. The Digital Wrench portal website should appear

in a new web browser.

5.45
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.
Do not "run" or "open" the file from where they are.

Select "save" and download them to your PC before
running the install. C
==- -· 8. When the update is complete, the version shown
on the right side of the Digital Wrench start-up
screen should match the update you just
i - - - - - - - - - - -- - - ------ .._ ._.;; downloaded.
Digital Wrench Update M·iffliMM','N,A, •
11
-• •• di.. . .......@ POLARIS'
··--
• (.7.'i; s:m:;
. _,._...
·A - -
·!IJ!--
.1' ·--
,
•Q -
~ b Wt:-••U,~ .\ ~ ?11,T(:, , •
~ , , . _ < " ~ i'«""'-''4U.Tt-..1
You must already have the current version installed

before adding an update. Updates will not install if Version
you are using an older version loaded on your PC. C
6. If the update file date listed is newer than your
current version and update, download the file.
~::.~ ·,."·~~=:-~~~~~ ·~;0~
"'~- .. c-- - ~ C.,,..-·t< _,,, __ ,
B,i~-.-c ~~~- _:~~~-- ~='.
.. ~--.. : I- ~-C :.! -,· .,.. . ,..,, • ._ • ._ •
Versions and updates are subject to change.

5.46
DIGITAL WRENCH FEATURE MAP
Digital Wrench Enter cust omer and vehicle
Open the ASSERT ASK Form t~ l information and view ECU

Identification
Enter I Edit I Change

Vehicle Information.
Enter / Edit I Change Vehicle
Information
E _ . ..,,,,
Open the ASSERT
~ ~:_,::;_::j Quick Start ASK Form.
II Current Work Ord er
l r Ne w Work Order Perform specialized testing
IL Select E xisti ng Order and adjustment functions
service reports.
f· 0 Veh icle Home Page
~.~ V eh icle Se lection

;~-"
~
l
:iJr" Customer Information
$ fi_. Product Utilities

I
If System_ Configurat ion
i Smartlink Setup
I
!~ S oftware Reg istration
Di gital Wrench Help
Ir System Help
Ir Dig ital V\/rench Horne Page
j ~ Digital W rench Knc,wledge Base
i
L O E xit Open the Software
Configuration Screen .
Set up data capture and record
functio ns
Run The Help System
View informati on from the

main ECU Sensors
Prints the current scr~en as ~ -
This is the most viewed screen. View .,.....,,,,-.;o-'111

a formatted prmto ut.W
sensor and ECU information in a grid.
meter. or chart format.
View. or clear trouble codes in the

Engine Controller memory
Load the Vehicle Home Page

Global Training
OW 1PG 102&:J?~

5.47
ENGINE CONTROLLER REPROGRAMMING • KNOW THE PROCESS: If you are not familiar with the
(RE FLASH) entire reprogramming process, review the HELP
Process Overview section of the diagnostic software before you
The reprogramming feature is in the Special Tests attempt reprogramming. Click on the ? on the tool
menu on the Digital Wrench screen. Start Digital bar or press Fl 1. The information in the on-line help
Wrench and click on the Special Tests menu icon (red is the most current and complete information
tool box). A technician should be familiar with the available. This should be your first step until you are
process and with computer operation in general familiar with the process. (
before attempting to reprogram an ECM. • COMMUNICATION PROBLEMS: If you have had
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 alone until complete.
Failure to follow the reprogramming instructions Reprogramming (Reflash) Procedure:

completely and correctly can result in an engine that If you are not familiar with the reprogramming
does not run! Replacement ECMs are programmed process, review the "Reprogramming (Reflash) Tips"
as "no-start" and require a reflash for them to work. before you begin. Follow the on-screen instructions as
you progress through the steps. If you encounter a
Reprogramming (Reflash) Tips: problem, always check the On-Line help for current
tips and information.
BATTERY VOLTAGE: The majority of problems with
reprogramming can be attributed to a low battery. 1. Verify the most current update has been
Be sure the battery voltage (no load) is at least 13 downloaded and loaded into Digital Wrench.
volts and at least 12.5 volts with the key 'ON'. 2. Connect SmartLink Module cables to PC and
Connect a battery charger if necessary to bring vehicle.
voltage level above minimum. Fully charge the
battery before you attempt to reprogram. 3. Open the Digital Wrench program.
r:
DEDICATED LAPTOP: Best results are obtained 4. Select the model year, product line and vehicle
using a laptop computer that is "dedicated to Digital
description by selecting the "Change Vehicle
Wrench". A laptop that is used by a variety of Type" icon.
people and in several applications around the
dealership is more likely to cause a reprogramming 5. Select the "Special Tests" icon.
problem than one dedicated to Digital Wrench
6. Select "Engine Controller Reprogramming". C
diagnostics only.
OBTAINING THE LATEST UPDATE: Reprogramming 7. Select the file you want to load into the ECU then
updates are provided periodically and contain the click the "Continue" icon to proceed to the
most recent calibrations. Integrity Check and obtain a Request Code.
CLOSE NON-ESSENTIAL PROGRAMS: It is
recommended that you DO NOT install non-essential
programs on a Service Department laptop. Camera
detection software, Virus Scanners, Tool Bars, etc.
may clog up memory if running in the background
and make it harder for the diagnostic software to
operate.

5.48
8. Copy (CTRL +C) the Request Code that will be

required on the dealer website in the next step.
DO NOT CLOSE Digital Wrench or the Request
Code will be invalid .
.All characters are letters; there are no numbers in a

request code.
Request Codes and Authorization Keys must be

entered EXACTLY as they appear on the screen.
9. Go to www. polarisdealers. com and click on

"Reflash Authorization" from the "Service and
Warranty" drop-down menu.
10. Enter or paste (CTRL +V) the Request Code into
the box.
11. 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.
12. An "Authorization Key" will appear in the upper
left corner of the screen. Copy (CTRL+C) this key
exactly as it appears.
13. Enter or paste (CTRL+V) the Authorization Key in
the box located on the Digital Wrench screen.
Click the 'Continue' button and follow instructions
provided on the screen to complete
reprogramming procedure.
14. At this point the reflash process will begin. Do not
touch the vehicle or PC during the process.
15. Once the ECU reprogramming procedure is
complete, click the 'Finish' button on the screen.
Verify the reflash was a success by starting the
vehicle.

5.49
TRO UBLESHOOTING (
FUEL SYSTEM TRO UBLES HO OTI NG PART 1
PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED
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 I Replace
Fuel pump not working Test I Replace
Fuel pressure regulator Test I Replace C
Faulty fuel pump relay Inspect I Repair
Open wiring I connector Inspect I Repair
Faulty connection at ECM
Excessively rich or Fuel pump Test I Replace
lean fuel mixture Fuel pressure regulator Test I Replace
Crank Position Sensor Test I Replace
Low Battery Test I Replace
C
TMAP sensor Test I Replace
CHT sensor Test I Replace
Fuel Injector Test I 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 !AC system
lean fuel mixture Air restriction in !AC Inspect !AC hoses and
Fuel Pump fittings
Fuel injector I Fuel Rail Inspect fuel pressure C
obstructed or leaking Replace
Air Filter Replace
Wrong Fuel I Old Fuel Inspect I Replace
Crank Position Sensor Inspect I Replace
Poor Running in Higher Air intake restriction Air filter Inspect
RPM Range Oil Overfilled Ignition Coil(s) I plug Refer to ignition section.
Ignition problems wires Charge or replace
Low Battery Voltage Battery Unplug connections - inspect
Loose, corroded, or ECM and wiring harness Inspect cylinder head &
wet connector(s) Valve springs, valve, valves
Valve train problems head

5.50
FUEL SYSTE M TROUBLESHOOTING PART 2

Engine Stalls Fuel Pump Problem Low battery voltage Battery/ Charging system
Faulty fuel pump Check fuel pressure
No signal from ECM Repair Wiring
Wiring problem Repair/ Chk Pump Relay
Excessive rich or lean TMAP Sensor Repair I Replace
fuel/ air mixture Plugged fuel filter Replace
Fuel pump (pressure) Test I Replace
Fuel pressure regulator Test I Replace Pump Assembly
Vacuum leak Repair I Replace hoses
Wiring problem Repair
Air Filter Replace
Low battery voltage Ck battery & charging system
Control Circuit/ Fuel pressure regulator Test Pressure I Replace
Sensors not TPS Test I Replace
functioning correctly Engine speed sensor Test I Replace
Fuel pump relay Test I Replace
Rotor Inspect I Install correctly
Fuse Replace
ECMRelay Replace
Low battery voltage ECM Inspect Charging system
Valve train problems Refer to chapter 7
or Compression low
Backfiring Low Battery Voltage Battery Refer to battery section
Ignition Problem Spark plug fouled, poor Replace plugs I diagnose
Air leaks wire connection for Inspect wiring connections
Restricted air intake or ignition or fuel injection, Disconnect and check pin
throttle body loose pin in multi-pin connections
connector for ECM or Seal intake or exhaust leaks
wiring harness Clean air inlet tract and throttle
Inlet and Exhaust body
Intake tract I Throttle
body

5.51
FUEL SYSTEM TROUBLESHOOTING PART 3

Poor Running in upper Control Circuit/ CPS Test I Replace
rpm ranges Sensors not ETC Test I Replace
functioning correctly Air temperature sensor Test I Replace
Manifold Absolute Test I Replace
Pressure sensor Repair/Replace (
Intermittent wiring Test I Replace
I connector problem ECM
Fuel delivery incorrect Plugged or kinked fuel Repair/ Replace
and/ or vent hoses Test I Replace
Fuel pump Test Pressure I Replace
Fuel regulator Test I Replace (
Fuel filter Charge/ Replace
Battery/ Charging System Clean/Replace
Fuel Injector plugged Clean/Replace
Contaminated fuel (water, Use correct fuel
additives, etc.) Test I Replace
Inadequate octane Charging system
Defective ETC (
Low battery voltage
Air intake restriction Dirty Air Cleaner Clean
Intake restriction Repair
Air Leak ETC gasket surfaces Repair/ Replace
Intake manifold Repair/ Replace
ETC Repair/ Replace
C
Engine lacks power Engine component See chapters 7-10
problems See chapter 16
Ignition problems See chapter 2
Overfilled with oil
Improper fuel delivery Plugged fuel injector Repair I Replace (
Dirty air cleaner Replace
Vacuum leaks Repair
Fuel pump Test I Replace
Fuel pressure regulator Test I Replace
Air temperature sensor Test I Replace
TMAP sensor Test I Replace
Plugged vent hose Clear (.
Low battery voltage ECM Test batt./Charging system

5.52
FUEL SYSTEM TROUBLESHOOTING PART 4

Engine overheats Internal Engine Parts Cooling System Refer to chapter 4
Lubrication & Cooling Engine Oil Refer to chapter 4
system Brake systems Refer to chapter 14
Low or incorrect oil Drive Belt Refer to chapter 12
Brakes dragging Ignition Coils Refer to chapter 16
Drive belt too tight FaultyECM Replace
Ignition timing Charging System Test I Repair
incorrect Faulty Battery Replace
Spark plug(s) Faulty Wiring Repair
Low battery voltage
Lean Air/Fuel mixture Fuel pressure regulator Repair/ Replace
Air leak Repair
Fuel injector plugged Clean/ Replace
CTS Test I Replace
Vent hose plugged I kinked Repair
Air leak at throttle body to Test I Repair
manifold seal
Won't Accept Non-Current Go to Dealer website and
New Calibration Calibration File Set download the most current
Low Battery Voltage Indian Motorcycle Calibration
Attempting Re-Flash File Set
Without Proper VIN,
Calibration I.D. Attach Battery Charger
number, or calibration During Re-Flash, and Re-
authorization code Charge Battery When Re-
Flash Is Completed
Enter Authorization Code Sent

With Accessory Kit

5.53
NOTES (

5.54
ENGINE REMOVAL
CHAPTERS
ENGINE REMOVAL
GENERAL INFORMATION ....................... . ............ .... .... . ........ ..... .......... .. ......... 6.2
SERVICE NOTES ...................................................................................... 6.2
SPECIAL TOOLS ..................... . .......... ......... ...... .... . .. ...................... .. ........ . 6.2
TORQUE SPECIFICATIONS ............ . ........... . .................. . ... ... .............. .. .......... 6.2
SERVICE SPECIFICATIONS .......... ... ..... .. . .. ........ . ....... . ................. . ................. 6.2
ASSEMBLY VIEWS ........................................................................................ 6.3
ENGINE BRACKETS I FASTENERS . ....... . .................... .. .......... . ........................... 6.3
ENGINE MOUNTING BRACKETS I FASTENERS ................................................... 6.3
ENGIN"E REMOVAL ............. . .... ... ....... ..... ...... ... .............. ... . . .. . . .... ................. 6.4
PREPARATION FOR ENGINE REMOVAL ........... . ........... . . . ..... ... ......... .. ............. . . . .. 6.4
REMOVING ENGINE FROM FRAME ........................................... . ..... ... .... . ..... .... . 6.5
ENGIN"E IN"STALLATION .................... . ..... ...... ..... . .............. ...... ..... .... .............. 6.7
ENGINE INSTALLATION . . ...... . .... .. ..... . ........... ... .............. . . . .... . ................... . .. 6.7
.)

6.1
(
ENGINE REMOVAL
GENERAL INFORMATION (
SERVICE NOTES TOOL DESCRIPTION PART NUMBER
A floor jack or commercially available motorcycle
engine lift or hoist is required for engine removal. Engine Hoist (Cherry Commercially Available
Arrange for assistance when removing and installing Picker)
the engine. Engine Stand Commercially Available
Once the engine is removed from frame, an engine
stand is recommended for engine disassembly and Bosch Automotive Service Solutions: I- 800- 345- (
assembly. 3322 or https://polaris.service-solutions.com/
Engine removal and installation methods may differ
slightly depending on available equipment, but TORQUE SPECIFICATIO NS
always be sure the engine and chassis are securely
supported at all times. PART DESCRIPTION TORQUE
SPECIFICATION (
REQUIRES ENGINE CAN BE SERVICED
REMOVAL FOR WITH ENGINE IN ABS Module Bracket - 8 ft-lbs (11 Nm)
SERVICE FRAME M6 x 1.0 x 12 (QTY.4)
Camshaft(s) I Bearings Airbox Removal Battery Box - M6 x 1.0 x 8 ft-lbs (11 Nm)
12 (QTY.3)
Crankshaft & Crankshaft Camshaft Chain I Guide
Component Service I Tensioner Assembly Brake Line Routing Tabs 84 in-lbs (9.5 Nm) C
- M6 x 1.0 x 12 (QTY.4)
Cylinder Heads Fuel Injectors I Throttle
Body I Fuel Rail Down Tube, Lower (Both 45 ft-lbs (60.0 Nm)
Sides) - MIO x 1.5 x 60
Cylinders Voltage Regulator, (QTY.4)
Stator, Rotor (Flywheel)
Down Tube, Lower LH - 45 ft-lbs (60.0 Nm)
Lifters Clutch MlO x 1.5 x 25 (QTY.l)
Oil Pump Gearshift Linkage
Down Tube, Upper LH - 45 ft-lbs (60.0 Nm)
(External)
MlO x 1.5 x 100 (QTY.2)
Balance Shaft Ignition System
Engine Mounts, Front - 18 ft-lbs (24.4 Nm)
Piston/Cylinder Oil Pump Drive M8 x 1.25 x 20 (QTY.2)
Pushrods Output Shaft Seal Engine Mounts, Rear - 75 ft-lbs (101.7 Nm)
Ml2 X 1.75 X 50 (QTY.4)
Transmission/All Torque Compensator
Internal Transmission Assembly Ground Wire - M6 x 1.0 84 in-lbs (9.5 Nm)
Parts x 12 (QTY.l)
Valve Covers Side Stand Bumper - 84 in-lbs (9.5 Nm)

M6 x 1.0 x 12 (QTY. I) (
Starter, Starter One-Way
Clutch, Starter Torque Side Stand Switch - M5 43 in-lbs (4.9 Nm)
Limit Clutch X 0.8 X 16 (QTY.2)
Crankshaft Position Starter Solenoid - M6 x 84 in-lbs (9.5 Nm)
Sensor Timing Wheel 1.0 x 12 (QTY.2)
SPECIAL TOOLS SERVICE SPECIFICATIONS

TOOL DESCRIPTION PART NUMBER ITEM SPECIFICATIONS
Engine Stand Adapter PF-51240 Approximately 200 lbs
Engine Dry Weight
(91 kg)
Motorcycle Table Lift I Commercially Available
Wheel Vise Approximately 4.5
Oil Capacity (Dry Fill)
12"xl2" Platform Jack Commercially Available Quarts (4.3 Liters)
9926140 ROZ - 2015 - 2016 Scout Service Manual

6.2
ENGINE REMOVAL
ASSEMBLY VIEWS
ENGINE BRACKETS/ FASTENERS
ENGINE MOUNTING BRACKETS/ FASTENERS

1 Bolt, Engine Mount - Ml2 x 1.75 x 250 8.8 (QTY.2) 51 ft-lbs ( 69 Nm)
2 Bolt, Engine Mount - Ml2 x 1.75 x 95 8.8 (QTY.2) 51 ft-lbs ( 69 Nm)
3 Nut, Hex - Ml2 x 1.75 (QTY.2) -
4 Spacer - 280D x 131D x 12.5(QTY.3) -
5 Screw, Hex, - MS x 1.25 x 30 (QTY. l) 19 ft-lbs (25 Nm)
6 Screw, Hex- MS x 1.25 x 35 8.8 (QTY.l) 19 ft-lbs (25 Nm)
7 Sidestand Assembly, Mount -
8 Nut , Hex- Ml2 x 1.75 (QTY.l) -

6.3
ENGINE REMOVAL
ENGINE REMOVAL (
PREPARATION FOR ENGINE REMOVAL 19. Remove the ignition switch cover bracket
fasteners CD and bracket Q).
Different methods can be used to remove the

engine depending on the equipment available to
the technician. All methods require the front
wheel to be held securely in an upright position.
1. Support motorcycle securely in an upright

position. Clamp front tire securely in a wheel vise.
2. Remove thermostat housing cover. See Thermostat
Housing Cover Removal I Installation, page 3.12.
3. Remove ignition side cover. See Ignition Side (
Cover Removal I Installation, page 3.11
page 3.9.
5. Remove the battery. See Battery Removal, page 20. Remove the thermostat cover bracket fasteners G)
15.11.
and bracket ©.
6. Remove the fuel tank. See Fuel Tank Removal,
page 5.20.
page 4.20.
8. Remove the radiator assembly. See Radiator
Removal I Installation, page 4.22
9. Remove the mufflers. See Muffler Removal, page
5.13.
10. Remove the exhaust head pipe assembly. SeeHead
Pipe Removal, page 5.14
11. Remove the sprocket cover. See Drive Sprocket
Cover Removal I Installation, page 12.7.
12. Loosen axle nut and remove belt from drive
sprocket. See Drive Belt Adjustment, page 2.32 21. Disconnect the radiator outlet hose a), oil cooler
13. Remove air box. See Air Box Removal, page 5.17. coolant feed hose ®, front head coolant outlet
hose (J), rear head coolant outlet hose ® and
14. Reinstall the frame tubes removed in previous step bypass hose ® from the engine.
and torque all fasteners to specifications. See Air
Box Installation, page 5.17.
15. Remove both driver foot controls. See Foot Peg
Driver Removal I Installation, page 3. 7
16. Remove brake line from right side of engine.
17. Disconnect clutch cable from clutch lever on
engine.
18. Remove horn assembly. See Horn Removal I

6.4
ENGINE REMOVAL
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 5.11 .
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 5. 11.
33. Disconnect the side stand switch connector @.
34. Disconnect the stator connector.
35. Proceed to engine removal. See Removing Engine
From Frame, page 6.5.
REMOVING ENGIN E FROM FRAM E

1. Perform the preliminary engine removal steps
24. Disconnect the CTS sensor connector ®· outlined in this chapter. See Preparation For
Engine Removal, page 6.4.
25. Disconnect both fuel injector connectors ® ·
2. Place a platform jack beneath the engine and raise
26. Disconnect both ignition coil connectors @ . enough to support engine. Note: Jack should
27. Disconnect the electronic throttle body connector firmly contact the engine crankcase.
@.

6.5
ENGINE REMOVAL
3. Remove the two front motor mount bolts CD and 8. Remove spacers (j) located between the right side
nuts CD from the engine case. engine case and mid frame.
9. Push engine slightly to the RH side to free up from

alignment dowels. With an assistant, lower the
engine from the frame and remove from vehicle.
C
6. Verify platform jack is placed securely under

engine cases.
7. Remove engine mount bolts © from right side of
frame and remove side stand assembly. (

6.6
ENGINE REMOVAL
ENGIN E INSTALLATION
ENGI NE INSTALLATIO N 6. Install the two engine mounting bolts 0 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 I Fasteners, page 6.3 in this . ·-r ' ,;
chapter for torque values and assembly views.
CAUTION
Arrange for assistance when installing engine. The
engine must be held securely to prevent damage to
engine, frame, wiring, or hoses. The engine is very
(fl
·.(
heavy and could cause severe personal injury if not

handled properly. Be sure engine is properly
supported before proceeding.
IMPORTANT! Be sure alignment dowels are in place

in the RH rear engine mounts prior to installation.
1. Clean mating surfaces of frame and engine

crankcase. Install alignment spacer dowels CD CAUTION
between right side engine case and mid frame. Be sure engine is aligned at the proper height and
angle with the dowel pins. DO NOT force engine
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.
7. Install the inner G) and outer © side stand

fasteners.
2. Secure motorcycle in an upright position with the

3. Position the engine on a platform jack to the left of
the motorcycle and slide into position so the
engine is orientated correctly front to back.
4. Slide the engine back until the rear mounting ears
are aligned with the mounting holes in the mid
frame. Adjust height of engine as needed to align
rear mounts and dowel pins.
5. Be sure all wiring and hoses are properly routed
before installing rear spacers and mounting bolts.

6.7
ENGINE REMOVAL
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. See Engine Brackets I
Fasteners, page 6.3.
!
,,--"'
7 \
\..__}
18. Connect both ignition coil connectors@.
/
19. Connect both fuel injector connectors®·
9. Torque the RH rear engine mounting bolts to 20. Connect the CTS sensor connector®·
specification.
C
21. Connect the TMAP sensor connector @.
22. Connect the overflow reservoir hose ® to the
thermostat housing fitting@.
10. Conne~t the stator connector®·
11. Connect the side stand switch connector ®·

12. Connect the gear position switch connector @).
See Sensors - Powertrain Management, page 5.11.
13. Connect the vehicle speed sensor connector®·
14. Connect the crankshaft position sensor connector
®·
15. Connect the oil pressure switch connector®· See
Sensors - Powertrain Management, page 5.11.
16. Connect the starter motor battery cable at the
terminal®·

6.8
ENGINE REMOVAL
25. Install the ignition switch cover bracket fasteners 1

~ and bracket ® · Torque fasteners to specification.
24. Install the thermostat cover bracket fasteners ® Ignition Switch Cover Bracket Fasteners: 8 ft-lbs (11
and bracket @. Torque fasteners to specification. Nm)
26. Install horn assembly. SeeHorn Removal I

27. Connect clutch cable to clutch lever on engine.
28. Install both driver foot controls. SeeFoot Peg
Driver Removal I Installation, page 3.7.
29. Install air box, frame tubes and torque all fasteners
to specifications. SeeAir Box Installation, page
5.17.
30. Install belt from drive sprocket and axle nut. Align
the drive belt. SeeDrive Belt Adjustment, page
2.32.
31 . Install the sprocket cover. SeeDrive Sprocket
32. Install the exhaust head pipe assembly. See Head
Thermostat Cover Bracket Fasteners: 8 ft-lbs (11 Nm) Pipe Installation, page 5.15.
33. Install the mufflers. See Muffler Installation, page
5.13.
34. Install the radiator assembly. SeeRadiator Removal
I Installation, page 4.22.
.)
35. Fill and bleed the cooling system. SeeCoolant
Drain I Fill, page 4.20.
36. Install the fuel tank. SeeFuel Tank Installation,
page 5.25.
37. Install the battery. SeeBattery Installation, page
15.11.
38. Install the seat. SeeSeat Removal I Installation,
page 3.9.
9926 140 R02 - 20 IS - 20 16 Scout Service Manual

6.9
(
ENGINE REMOVAL
39 . Install ignition side cover. Seeignition Side Cover (

Removal I Installation, page 3 .11.
40. Install thermostat housing cover. SeeThermostat
Housing Cover Removal I Installation, page 3 .12.

6.10
CYLINDER HEAD I VALVES
CHAPTER7
GENERAL INFORMATION ....... . ............. . .................................... ..... ...... . .... . .... 7.3
SERVICE NOTES .. ...... ... .. ..... .... .......... .... ......... . ........ . ...... . ... . .... .. .............. 7.3
SPECIAL TOOLS . ............. . ................ . . . .............. .. ... . . ..... . . . .. ............ . ...... . .. 7 .3
TORQUE SPECIFICATIONS ... . ...... . . . . . ......... . . ... .... . .. ... .. . .. ...... . .... . .. ............... . .. 7.4
SERVICE SPECIFICATIONS .. . . ....... . ..... ... . .. . ......... .... . . ................. .. . ... . .... .. . .. . .. 7.4
ASSEMBLY VIEWS .. . . .. . ... .. ..... .... ....... .. .... . .... . .. .. ... . . . ... ....... . .... .. . ...... . . . ... . . . ... .. 7.6
CAM CHAINS ......................... .. ........ .. .. . . .. . . .. . . . ........ . ...... . ....................... 7. 6
CYLINDER HEAD I CAMSHAITS .. . . ...... . ......... ... ......... . . . ... .. ... . . .. . .. . .. ............... . . 7. 7
CYLINDERHEAD ... ..... ........... . ... .. . . . .. ... . . ... . .. .... .. . .. ......... . ........ ... . ........ . ... . . 7.8
CAMSHAIT TIMING MARKS ........ . . .. .............. .... ........ .... .. .. .. ........... . .. . . ........... 7 .9
CAM CHAIN SERVICE . .. ...... ... ...... . .... . . . . .. . ... ... .. . ... .... ... .... . ........ ...... ....... . .. . .. . 7 .11
CAM CHAIN SERVICE NOTES . . ........... . ...... . ... .. ........ ..... .. .. ..... .... ........... . .. .. .... 7 .11
CAM CHAIN GUIDE (UPPER), REMOVAL .... ..... .. ... . ................... . ................ .. ........ 7 .11
CAM CHAIN TENSIONER REMOVAL . ...... . ... . . .. ... ... ....... . ............ . ......... . . .... ........ 7 .1 1
CAM CHAIN TENSIONER INSPECTION .. ... . .. ..... . ......... . .. ....... . . . .. .. .. . .. . .... . ............ 7 .1 1
CAMSHAIT SPROCKET REMOVAL ............... ... ........ .. .......... .. .... . .... .... . .. ...... . ... . 7.12
CAM DRIVE SPROCKET REMOVAL . ... . ...... .. .. . ...... ... . ... ....... ... .... .. ............ . ... . ..... 7.13
CAM DRIVE SHAIT REMOVAL .... .. ... .. . .. .. ... .. .... .. .. .......... .. ........... . .. . ... .. . ... .... .. 7 .14
CAM CHAIN GUIDE (LOWER), REMOVAL ......... . ..... . . . ... . .... .. .. . . .. .......... . .... . . ..... .. . . 7.14
CAM CHAIN REMOVAL ........ ..... ... ..... ... . ........ . ................... . ...... ... . . . . . ... . ... . . . 7 .1 5
CAM CHAIN INSTALLATION . . . .... .. ..... .. . . . . .. . ... . . . . ... . . ....... .. .. . . . ... . ................. . .. 7 .15
CAM DRIVE SHAIT INSTALLATION . ... . ......... .................................. . ... .. . .. ...... . . . 7 .15
CAM CHAIN GUIDE (LOWER), INSTALLATION ...... . .. .. . ... .. ... ...... . ... . .......... . ............. 7.16
CAM DRIVE SPROCKET INSTALLATION ... .... . ................... . . . .... . . . ....... ... . . .... . . . ... .. . 7 .17
CAMSHAIT SPROCKET INSTALLATION I TIMING PROCEDURE .. ... . . ... ......... ................... 7 . 19
CAM CHAIN TENSIONER INSTALLATION ... . .. .. ....................... . .... . ........... . . ...... . ... 7 .21
CAM CHAIN GUIDE (UPPER), INSTALLATION . . . ........ .. .. . . ...... .............. .... . . . . ...... . .. .. 7.22
CYLINDER HEAD SERVICE .. . . . ................... . .. . . . ... . ...... ........... . . .. . . .... . . . . . .... . ... . .. 7 .23
VALVE COVER REMOVAL .......... . ... . .. . . .... . ......... ......... ..... ....... ...... .. .. . .... .... . .. 7 .23
VALVE COVER INSTALLATION . .... . ......... . ............................. . .. .. ... . ..... . ... .. . ... .. 7 .23
VALVE CLEARANCE ASSEMBLY ........ .. ............... . . . .. . ........ .. ........ . .. ..... . .. .. . ... .... 7.24
CAMSHAITINSPECTION ....... . ................. . ......... . . ............ . ...... . ... ..... . . . .... .... 7.27
CYLINDER HEAD REMOVAL ..... . . . ..... ... ... .. ... ............... ....... . .... .. . ......... .. ...... . . 7.27
CYLINDER HEAD DISASSEMBLY ... ... ..... ........ ......... ... . . .. .. . .... . ... .............. . .. .. .... 7 .29
CYLINDER HEAD INSPECTION ...... ......... ......... .. ......... . ............ . .. .. ....... .. ... .. .. .. 7 .30
VALVE SPRING FREE LENGTH INSPECTION .......... .. .. . ........ . ... .. .... .. .... .. . ... ..... . ....... 7.30
VALVE INSPECTION . ........ . . .. ..... . ......... .... . . ...... . .. . . . . .. . ..... . .. ....................... . 7.31
VALVE INSPECTION - QUICK REFERENCE .. . . ... ... ................. , . .. ............ .... . ... . ...... . 7 .32
VALVE GUIDE REMOVAL I INSTALLATION .... .... ............ .. . . .... ........ .......... . ...... . ..... 7 .33
VALVE SEAT INSPECTION . . .. . .. . .. ....... . . . ...... ...... .......... . ........... .. .. ... ...... . .. .... .. 7.33
VALVE SEAT RECONDITIONING .... . ........ . .. ..... ......... ... .. . . . . . .. .. ......... . . . . .. . ......... 7 .33
CYLINDER HEAD ASSEMBLY ... .... . . . . . . ... .... .. . .... .. . . .. ..... . .... .. .. .. ... ... . ................. 7 .33

7.1
CYLINDER HEAD INSTALLATION .. .. ..... .. ............. .... .. ... ...... ...... ...... ..... ................. 7.34 (
INTAKE VALVE LASH - TAPPET SELECTION MATRIX ........... .. . . ..... . .. .. . .. ... .. ................... . . 7 .37
EXHAUST VALVE LASH -TAPPET SELECTION MATRIX .............. .. ..................... . . ... .... . ... .. 7 .38
TROUBLESHOOTING CYLINDER HEAD AND VALVE TRAIN .. . ... .. ................. . . . ...... . ............ 7.39

7.2
GENERAL INFORMATION
• Valve guide and seat reconditioning should be
SERVICE NOTES performed by a technician proficient in cylinder
head reconditioning techniques using high quality
• This chapter covers service of the cylinder heads, equipment with grinding stones. Do not attempt
camshafts, cam chains, tensioners and guides. cylinder head repair without the proper equipment
• Refer to Chapter 6 for engine removal and or experience in cylinder head reconditioning
installation. techniques.
• If cylinder heads are removed the cylinder base • The intake and exhaust valves cannot be re-faced.
gasket must be replaced also. • Cleanliness of parts is critical to engine life and
• Mark and store all mating parts for correct engine accurate parts inspection. Use clean solvent to clean
assembly. all disassembled parts. Dry parts with compressed
• Use Moly Assembly Paste - PIN: 2871460 or Indian air and lubricate before engine inspection and
Motorcycle Synthetic 15W60 Engine Oil to lubricate engine assembly.
parts where indicated.
• Handle and store all parts in such a way that they
will not be damaged or contaminated. SPECIAL TOOLS
• Some fasteners have a pre-applied locking agent,
and must be replaced if loosened or removed. TOOL DESCRIPTION PART NUMBER
Always replace fasteners that have a pre-applied
Valve Spring Compressor Commercially
locking agent or as directed in this service manual.
Available
• There are some precision machining steps to be
performed in this section. If you are not sure of your Crankshaft Locking Tool PF-51235-A
capabilities in these areas, have a competent
machinist perform these operations. Crankshaft Rotation Tool PF-51239
Seal and Bearing Driver Set PV-43558

2233 or https://polaris.service-solutions.com/
..)

7.3
TORQUE SPECIFICATIONS (
PART DESCRIPTION TORQUE SPECIFICATION
Cam Carrier Screw (QTY.9) 88.5 in-lbs (10.0 Nm)
Cam Chain Guide Screws (ALL) 88.5 in-lbs (10.0 Nm)
Cam Chain Tensioner (QTY.2) 26 ft-lbs (35.0 Nm) (
Cam Drive Carrier Bolts (QTY.4) 14 ft-lbs (19.0 Nm)
Cam Drive Sprocket Bolt (QTY. I) 52 ft-lbs (70.0 Nm)
Camshaft Sprocket Screws (ALL) 11 ft-lbs (15.0 Nm)
Cylinder Head Bolt, Primary (QTY.4) 1) 21 ft-lbs (28.0 Nm) (
2) 26 ft-lbs (35.0 Nm)
3) Plus 180 degrees
Cylinder Head Bolt, Secondary (QTY.2) 88.5 in-lbs (10.0 Nm)
Valve Cover Screws (QTY.3) 88.5 in-lbs (10.0 Nm)
(
SERVICE SPECIFICATIO NS
Camshaft Data
DESCRIPTION SPECIFICATION
Over Head Valve I 4 valves per cyl
Valve Train
2 Intake Valve I 2 Exhaust Valve
Intake Valve Opens At 1 mm Lift 9.0° BTDC
Intake Valve Closes At l mm Lift 41.0° ABDC
Exhaust Valve Opens At l mm Lift 49° BBDC
CAMSHAFT DATA (
Exhaust Valve Closes At l mm Lift 1° ATDC
Max Lobe Lift
INTAKE (10.10 mm)
EXHAUST (10.10 mm)
Max Valve Lift
INTAKE (10.10 mm)
EXHAUST (10.10 mm)
(.
9926140 R02 - 2015 - 2016 Scout Service Manual (_

7.4
Cylinder Head & Valve Train Data

Cam Chain
Tensioner Hydraulic I Self-Adjusting - -
(s)
.9844" (25.003
INTAKE mm)
Lobe Height .9763" (24.800 mm)
EXHAUST .9920" (25.197
mm)
.9028 - .9036 "

Cam Shaft Journal O.D. (Exhaust) (22 .933 - 22.954 .9016" (22 .900 mm)
mm)
.9028 - .9036"
Journal O.D. (Intake) (22 .933 - 22.954 .9016" (22 .900 mm)
mm)
Cylinder Warpage (Distortion) - .004" (.1 0 mm)
Head
0.006 " ± 0.00 l"
INTAKE (0. 152 mm± 0.05
mm)
Valve Clearance -
0.008" ± 0.00 l"
EXHAUST (0.023 mm± 0.05
mm)
Guide Height from Valve Spring Seat

(Installed) 11.4 -1 1.8 mm -
.2155 - .2 161"
INTAKE (5.474 - 5.489 mm)
Valve,
Valve Valve Stem O.D. -
Guide, .2147 - .2 153"
EXHAUST (5.453 - 5.468 mm)
Valve Seat
Valve Stem Deflection (INTAKE &
EXHAUST) - .005" (.13 mm)
.0354 - .0432"
INTAKE .0551" (1.399 mm)
(.899 - 1.097 mm)
Valve Seat
Width .0551 - .0629"
EXHAUST .0748" (1.899 mm)
(1.399 - 1.598 mm)
Valve Stem Runout - .0005" (.013 mm)
Valve Head Radial Runout - .002" (.05 mm)

Free Length (INTAKE & EXHAUST) 1.9330" (49 .1 mm) 1.9094" (48.5 mm)
Valve Intake Valve Maximum Lift .3976" (10.1 mm) -

Spring
Exhaust Valve Maximum Lift .3976" (10.1 mm) -
Spring Installed Height 1.3543" (34.4 mm) -

7.5
(
ASSEMBLY VIEWS
CAM CHAINS
( 4)
'--
NUMBER PART DESCRIPTION NUMBER PART DESCRIPTION

G) Carn Drive Shaft Assembly @ Chain, Carn Silent 6.35 pitch
CD Bearing Support Plate ® Sprocket, Carn Driven

G) Water Pump Driven Gear ® Bolt, Carn Chain Guide C
© Shaft Assembly @ Gear, Carn Idler Assembly
® Guide, Cam Chain Tensioner Front @ Screw, M5x0.8xl2
© Guide, Cam Chain Tensioner Rear ® Screw, M6xl.Ox30
CD Guide, Cam Chain Fixed Rear ® Bolt, M8xl.25x25
® Guide, Cam Chain Fixed Front ® Screw, M6xl.Oxl0
® Guide, Carn Chain Fixed Cover ® Bolt, Shoulder M6xl2xl5

@) Guide, Carn Chain Lower @ Screw, M 1Ox l.5x40
® Tensioner, Carn Chain Hydraulic @ Washer,34xl0x4

(

7.6
CYLI NDER HEAD/ CAMSHAFTS
/.--
\ 11
(/--"'
1 ·, ___
,,,------.,. '--'
( 2 ';--- - - - - - - - ' -
\.._j
TORQUE SPECIFICATIONS
NUMBER PART DESCRIPTION (IF APPLICABLE)
G) Valve , Intake (QTY.2 per head) -
CD Valve, Exhaust (QTY.2 per head) -
G) Cylinder Head Assembly (Front shown) -
© Spring Seat w / seal (QTY.4 per head) -
G) Valve Spring (QTY.4 per head) -
® Valve Retainer (QTY.4 per head) -
(J) Keeper, Valve (QTY. 8 per head) -
® Tappet, Valve (QTY.4) -
® Seal, Cam Carrier (QTY. I per head) -

@) Camshaft, Intake (QTY. I per head) -
® Camshaft, Exhaust (QTY. I per head) -
@ Carrier, Camshaft -
® Cam Carrier Bolt, Short (QTY. 7) 88.5 in-lbs (10.0 Nm)
® Cam Carrier Bolt, Long (QTY.2) 88.5 in-lbs (10.0 Nm)

7.7
(
CYLINDER HEAD
(
NUMBER PART DESCRIPTION (IF APPLICABLE)
CD Stud, Exhaust -
@ Cylinder Head ASM, Front -
CD Cylinder Head ASM, Rear -
© Cylinder Head, Front -
(J) Cylinder Head, Rear -
® Coolant Diverter -
@) Head Gasket, Front -
® Base Gasket, Front -
@ Base Gasket, Rear -
® Head Gasket, Rear -
I) 20.6 ft-lbs (28 Nm)
® Primary Head Bolt 2) 25.8 ft-lbs (35 Nm)
3) Plus 180 degrees
@ Secondary Head Bolt 88 in-lbs (10.0 Nm)

7.8
CAMSHAFT TIM ING MARKS

Camshaft Timing Reference
Drive Gear Timing Front Head TDC Rear Head TDC

Rear, TDC Sprocket Orientation Sprocket Orientation
Locking hole for

front piston TDC
(marked with F)
Camshaft Timing Front Cylinder
I
~!
I
I
-n \ \
JJ
1;_JI \\
c·
~ ,\ \
\' );1I I I
I
)
/ \ \
"~J\ \
7.9
Camshaft Timing Rear Cylinder
r n ! ).
-
- ·c/-
1 ' .' <,/ [
\
\
\
./
\: :!/
-- ~·· C
r1

7.10
CAM CHAIN SERVICE

CAM CHAIN SE RVI CE NO TES -_·: _· ,· ·. IMPORTANT :: . · · ..
Read the following tips to ease the removal,
installation and timing procedures when servicing the Protection has been built into the cam chain guide
cam chain and I or cylinder head assembly. system to prevent the chain from jumping time with
the tensioner(s) removed if the engine remains static.
• Drain the engine oil prior to servicing the cam This does not guarantee the chain will not jump time
chain. with tensioner(s) removed. Do NOT rotate the
• If the cam chain(s) or cylinder head(s) will be crankshaft with tensioner(s) removed or the chain
removed, loosen all camshaft sprocket bolts prior to may jump time. Two methods of tensioner removal
removing tensioners. Loosen exposed camshaft are provided below. Method 1 (recommended) is
sprocket bolts 1/2 turn, rotate crankshaft to expose the only way to guarantee the cam chain timing is
remaining bolts and loosen 1/ 2 turn. correct upon reassembly. Method 2 may result in
• MWAYS rotate the crankshaft CLOCKWISE by incorrect valve timing and engine damage if the
turning the primary drive gear stake nut. Use a 1 1/ chain jumps time.
4" wrench.
• Rotate the front piston to TDC on the compression Method 1 (Recommended)
stroke and lock the crankshaft prior to servicing the
cam chain(s) I cylinder head(s). See Locking the 1. Remove valve covers. See Valve Cover Removal,
Crankshaft for Service, page 10.5. page 7.23.
• DO NOT rotate the crankshaft if one or both of the
2. Lock the crankshaft for service with the front
cam chain tensioners has been removed.
piston at TDC on the compression stroke.
SeeLocking the Crankshaft for Service, page 10.5.
CAM CHAIN GUID E (UPP ER). REMOVAL 3. Remove the cam chain tensioners CD and sealing
1. Remove valve cover(s). See Valve Cover Removal, w ashers Q).
page 7.23.
2. Remove screws CD and lift guide off of cylinder
head.
Method 2
1. Remove cam chain tensioners and sealing washers.
CAM CHAIN TE NSIO NER IN SPECTIO N

CAM CHAIN TE NSIO NER REMOVAL 1. Visually inspect inner plunger CD for damage,
CAUTION scoring or burns.
Do not rotate engine with tensioner(s) removed. 2. Lubricate inner plunger with engine oil. Move
plunger in and out of outer plunger Q) to check for
smooth movement without binding.
3. Verify the oil passage opening is free from debris.
992 6 140 R02 · 20 15 • 20 16 Scout Service Manual

7 .11
4. Replace tensioner assembly if worn or damaged. 6. Rotate the crankshaft to expose sprocket bolts G)
and loosen 1/2 .turn.
Use a piece of nylon webbing or rope to create an

interference between the crank drive gear and clutch
gear, thus locking the crankshaft while loosening
sprocket bolts.
CAM SHAFT SPROCKET REMOVAL (

1. Place motorcycle in an upright position with front
wheel clamped in a wheel vise.
2. Drain engine oil and dispose of properly.
3. Remove valve cover(s) . See Valve Cover Removal,
page 7.23.
7. Repeat step 6 for remaining camshaft sprocket
4. Remove the primary cover. See Primary Drive bolts.
Cover Removal, page 9.7.
8 . Rotate crankshaft so the front piston is TDC on the
5. Remove upper cam chain guide(s) . See Cam Chain compression stroke and lock in position. See
Guide (upper), Removal, page 7 .11. Locking the Crankshaft for Service, page 10.5.
9. Remove the cam chain tensioner (s). See Cam
Chain Tensioner Removal, page 7 .11 . C
CAUTION
Do not rotate the crankshaft with tensioner(s)
removed. Engine damage may occur.
10.Remove the camshaft sprocket bolts completely. (
It will be necessary to use a thin 10mm spanner to

remove the sprocket bolts that are not exposed. The
bolts cannot be completely removed until the
sprocket is out of the cylinder head.

7.12
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 10.5.
2. Remove bolt and washer G) securing cam drive
gear to cam drive shaft .
..)

7.13
CYLINDER HE.AD I VALVES
4. Remove the cam drive carrier G) from the CAM DRIVE SHAFT REMOVAL
crankcase assembly.
1. Remove the camshaft sprockets. See Camshaft
Sprocket Removal, page 7 .12.
2. Remove the cam drive sprocket. See Cam Drive
Sprocket Removal, page 7.13.
3. Remove the screw CD securing the cam chain guide
CD from the crankcase assembly. (
4. Slack the cam chains enough to remove the cam

(
drive shaft G) and slide out of bearing bore to
remove.
CAM CHAIN GUIDE (LOWER). REMOVAL

1. Remove camshaft sprockets. See Camshaft
Sprocket Removal, page 7.12.

7.14
2. Start with the front cylinder and remove bolts G) CAM CHAIN INSTALLATION
from the guides.
CAUTION
The engine used in Indian Scout models is an
INTERFERENCE ENGINE. If the camshafts and
crankshaft must be turned independently of each
other to set valve timing, the camshafts must be set to
TDC prior to rotating the crankshaft. Failure to do this
may cause the pistons to contact the valves resulting
in engine damage.
1. Feed the cam chain (s) in through the top of the

cylinder head (s) keeping the front chain on the
outside (right side) of the rear chain.
2. Lay the chains over the camshaft hubs or hang
them in position using string to keep them from
falling into the crankcase.
3. Remove the guide (s) through the top of the

cylinder head.
CAM DRIVE SHAFT INSTALLATION

1. Apply a thin coat of assembly lube to the bearing
4. Repeat steps and 2 for the rear cam chain end of the cam drive shaft G) .
guides.
CAM CHAIN REMOVAL

1. Remove the cam drive shaft. See Cam Drive Shaft
Removal, page 7.14.
2. Remove lower cam chain guides. See Cam Chain
Guide (lower) Removal, page 7.14.
3. Lift cam chain(s) out of engine .
.)

7.15
2. Install the cam drive shaft Q): 4. Install the cam chain guide and spacer G) and
• Loop cam chains around respective sprockets torque screw© to specification.
• Engage water pump gear teeth with cam drive shaft
Slide cam drive shaft into bearing bore until fully
seated
3. Turn the cam drive shaft so the woodruff key is

pointing at 12 o'clock.
CAM CHAIN GUIDE [LOWER). INSTALLATION
1. Inspect the guides to verify the guide face isn't (
cracked or grooved from the chain. Replace
guides if damaged.
2. Lower the guides into position through the top of
the cylinder head(s).

7.16
3. Starting with the rear cylinder, hand-tighten the 3. Using a small screw driver CD or equivalent,
screws CD until seated and torque to specification. preload the gear teeth of the cam drive sprocket.
4. Align the timing marks on the primary gear and

cam drive sprocket as shown and slide the cam
Cam Chain Guide Screw s (lower): 88.5 in-lbs (10.0 sprocket onto the cam drive shaft.
Nm.)
~
CAM DRIVE SPROCKET INSTALLATION Q
1. Rotate the primary drive gear so the timing mark is
pointing at 12 o'clock.
f
:
2. Lock the crankshaft in position for service. See

Locking the Crankshaft for Service, page 10.5.

7.17
5. Slide the cam drive sprocket carrier G) into

position and hand tighten the four bolts © until
seated. Torque bolts to specification.
6. Install the cam drive sprocket bolt ® and washer.

Torque to specification.

7.18
CAMS HAFT SPROCKET INSTALLATION/ TI MING

PROCEDURE
Drive Gear Timing Front Head TDC Rear Head TDC

Rear, TDC Sprocket Orientation
2. Rotate camshafts so the lobes are positioned as

indicated in the image below.
Camshaft sprockets are interchangeable (identical
for all camshafts) and drilled offset so that they
cannot be installed incorrectly.
Letters I Timing Marks on sprockets will appear
right-side up if timed correctly and the respective
cylinder is at 'IDC.
CAUTION
DO NOT rotate crankshaft I primary drive gear
counterclockwise while timing the camshafts.
1. Lock the crankshaft so that the front piston is at

'IDC. SeeLocking the Crankshaft for Service, page
10.5.
3. Starting with the front cylinder, install the INTAKE

sprocket to the camshaft. Torque screws CD to
specification.
Threaded holes in camshaft hubs must be free from

oil and debris.

7.19
(
Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm) Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)
4. Take up the slack on the intake side of the cam

chain and lay it over the INTAKE sprocket. Verify
that the timing marks CD line up with the chain
installed and slack removed.
~
j.
. \
7. Install the front cam chain tensioner and torque to

specification. See Cam Chain Tensioner
8. Supporting the rear cam chain, remove the
5. Engage the cam chain with the EXHAUST sprocket crankshaft locking pin, rotate the crankshaft 300°
teeth and fit the sprocket to the camshaft hub. (CLOCKWISE) and re-lock the crankshaft with the
Verify the timing marks on both sprockets align rear piston in the TDC position. See Locking the
with the machined valve cover gasket surface when Crankshaft for Service, page 10.5.
slack is removed from the intake side of the chain. 9. The timing mark on the primary drive gear will be
at approximately 10 o'clock. Note: Disregard
location of double dots on the crankshaft gear.
C
6. Rotate the EXHAUST camshaft until the screw holes

line up and install one screw CD into the exposed
hole and torque to specification.

7.20
10. Working on the rear cylinder, install the INTAKE 13. Rotate the EXHAUST camshaft until the screw holes
sprocket to the camshaft. Torque screws © to line up and install one screw ® into the exposed
specification. hole and torque to specification.
oil and debris.
Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)
11. Take up the slack on the intake side of the cam

chain and lay it over the INTAKE sprocket. Verify
that the timing marks ® line up with the chain
installed and slack removed.
14. Install the rear cam chain tensioner and torque to

specification. SeeCam Chain Tensioner Installation,
page 7.21 .
15. Rotate the crankshaft and install the remaining
camshaft sprocket screws. Torque to specification.
Camshaft Sprocket Screws (All): 11 ft-lbs (15.0 Nm)
12. Engage the cam chain with the EXHAUST sprocket

teeth and fit the sprocket to the camshaft hub. 16. Rotate the crankshaft several times and stop on
Verify the timing marks on both sprockets align TDC of both cylinders to verify that the timing
with the machined valve cover gasket surface when marks still match up and that the engine turns
slack is removed from the intake side of the chain. freely.
CAM CHAIN TENSIONER INSTALLATION

1. Verify that the engine is at TDC and the timing
marks are properly aligned. SeeCamshaft Timing
Marks, page 7.9.
2. Install the tensioner (s) with new sealing washers
and torque to specification.
3. Install tensioner bolt and torque to specification.

7.21
CAM CHAIN GUIDE (UPPER). INSTALLATION

1. Install guide (s) and torque screws G) to
specification.
Carn Chain Guide Screws (upper): 88.5 in-lbs (10.0

Nm)
C
2. Install valve cover(s). See Valve Cover Installation,

page 7.23.

7.22
CYLINDER HEAD SERVICE

VALVE COVER REMOVAL VALVE COVER INSTALLATION
1. Secure the vehicle in an upright position. 1. Assemble new cover gasket © on the valve cover.
page 3.9.
page 5.20.
5. Use a T40 Torx to remove the three valve cover
screws CD.
2. Assemble spark plug tube seal G) on cylinder

head.
3. Install valve cover CD on cylinder head with new
isolators G) and hand tighten the valve cover
fasteners CD.
4. Reference the torque sequence and torque valve
cover screws to specification.
6. Remove the valve cover CD and gaskets.

7. Discard and replace the valve cover isolators G),
gasket seal©, and the spark plug tube seal G).
5. Install ignition coils. See Ignition Coil Removal I

6. Install air box. SeeAir Box Installation, page 5.17.
7. Install fuel tank. SeeFuel Tank Installation, page
5.25.
page 3.9.

7.23
VALVE CLEARANCE ASSEMBLY 5. Install the camshaft carrier bolts CD and tighten the
bolts evenly to specification.
Always inspect valve clearance prior to camshaft

installation or final engine assembly.
1. Reference the camshaft intake and exhaust

markings made during disassembly. If installing
new camshafts or if camshafts were not marked,
reference the part number stamped on the
camshaft ends.
Intake Camshaft - PN 3022484Exhaust Camshaft - PN
1204693
2. Lubricate the camshaft bearing journal surfaces

with Indian Motorcycle engine oil prior to
installation.
3. Carefully install the camshafts into the cylinder
head. The camshaft lobes G) should be positioned
as shown.
4. Carefully install the camshaft carrier Q) onto the

camshafts.
C

7.24
-1
If all valve clearance measurements are within
specification proceed to Camshaft Sprocket
Installation I Timing Procedure, page 7.19.
10. Remove the valve tappet from a valve that was out
of specification.
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.
11. Record the 3 digit number G) on the bottom of the

tappet.
6. Rotate the camshaft until the earn lobe above the

valve being inspected is facing up.
7. Measure the valve clearance using a thiclmess
(feeler) gauge ©. Record the measurement if
clearance is out of specification.
12. Reference the valve clearance measurement

recorded for that valve , along with the 3-digit
tappet number.
13. Refer to the appropriate tappet selection matrix
(Intake or Exhaust) on the following pages and
select the proper tappet.
14. Install the proper tappet.
8. Repeat steps 6 and 7 until all eight valves have
been inspected.
Lubricate the outer portion of the valve tappet upon
MEASUREMENT installation.
Intake Valve Clearance (cold): 0.006" ± 0.001"
(0.152 m.m ± 0.05 m.m) 15. Repeat steps 10-14 until all necessary valves have
Exhaust Valve Clearance (cold): 0. 008" ± 0. 00 l" been adjusted.
(0.203 m.m ± 0.05 m.m) 16. Reinstall the camshafts and camshaft carriers and
tighten the bolts evenly to specification.
9. If any of the valve clearance measurements are out
of specification, remove the camshaft carriers and
camshafts and proceed with this procedure.

7.25
17. Measure and confirm that valve clearance is now

within specification for each valve.
18. If valve clearance is not within specification, repeat
this procedure. ('
19.If all valve clearance measurements are now within

specification, remove the camshaft carriers and
proceed to Camshaft Sprocket Installation I Timing
Procedure, page 7. 19.

7.26
CAMSHAFT INSPECTION
For the following camshaft inspection procedure,
refer to the camshaft service specifications sec-
tion. See Service Specifications, page 7.4.
EXHAUST CAMSHAFI' INTAKE CAMSHAFI'
CamLobes \J
Cam Lobes <D

1 l
Thrust Face
1l
Thrust Face
LJ LJ
1.
~---Bearing Journals
Visually inspect camshaft journal surfaces for

scoring or signs of insufficient lubrication. Replace
71
camshaft if heavy scoring or damage is noted. Removing the cylinder head(s) releases pressure on
the cylinder base gasket(s). Cylinder base gasket(s)
2. Inspect height of each cam lobe for INTAKE and should always be replaced in conjunction with
EXHAUST camshafts. cylinder head removal I service.
3. Measure O.D. of each camshaft journal for INTAKE
and EXHAUST camshafts. I. Remove engine from frame and place on an engine
4. Inspect the camshaft hub face for damage or stand. See Removing Engine From Frame, page 6.5
surface roughness. 2. Remove the intake manifold assembly. See Intake
Manifold Removal I Installation, page 5.19
5. Inspect decompression device (EXHAUST
camshaft only).
6. Inspect camshaft thrust face (s) for uneven wear Repeat STEPS 3 - 11 for each cylinder head being
and scoring. serviced. Cylinder heads can be removed
7. Wash the camshaft in solvent. individually.
8. Oil the camshaft.

3. Remove the ignition coil from the cylinder(s) being
serviced. See Ignition Coil Removal I Installation,
CYLINDER HEAD REMOVAL page 16.3
CAUTION 4. Remove the camshaft sprockets. See Cam Drive
Sprocket Removal, page 7.13
Cylinder and Cylinder Head assemblies may have
extremely sharp machined surfaces. Gloves should 5 . Remove the lower cam chain guides. See Cam
be worn whenever handling these components to Chain Guide (lower) Removal, page 7 .14
prevent personal injury.

7.27
6. Carefully lower the cam chain into the cam chain 9. Using a long extension, remove the two screws Q)
gallery. from inside the cam chain gallery.
7. Remove the seven remaining screws CD and the
camshaft carrier.
;;:;~? ~/'-'?)
(
.·,,,. :
.~.
', ·' /
/
' / I ' ::-, "
/ -'',
\~- _)/···""" / ,, . .,, ~: / .• ' ~-~/":-·
' _>-;,~:, .::,_,<.,_.,'
·.,. ., .~ ... ·~ -..
.- -· \',\, ~>( "' '. :>>l~f<,

,
>;', .,-::--l~~></'.;-:_,:,,t J '. - , .
,., '·'
IO.Alternately loosen and remove cylinder head bolts (
CD.
8. Paying attention to location I orientation, remove
camshafts from cylinder head.
/";'\
(.
'~~~s~z{>::·,~·-, . ,. ,·_;.,

7.28
11. Remove the cylinder head assembly and cylinder 2.

head gasket by carefully lifting off of cylinder.
If tappets will be reused, wipe excess oil off using

solvent and a clean towel. Mark each tappet with a
marker so it can be matched to it's respective bore
upon reassembly.
Remove the tappets G) by lifting out of the bore.
CYLI ND ER HEAD DISASSEMBLY

CAUTION
Wear eye protection while removing valve springs.
3. Using valve spring compressor PV-1253 remove

Keep mated parts together for assembly. keepers Q), upper spring retainer CD and valve
spring © from valves.
1. Remove the cylinder head(s) to be serviced. See
Cylinder Head Removal , page 7.27.
._____/-;_-\
,------\_._;:; · ·-·/_
' --;'3 1
\...... __.,. /

7.29
4. Slide valve ® out through the bottom of the CYLINDER HEAD INSPECTION
cylinder head. 1. Visually inspect cylinder head for cracks or
damage. Pay close attention to the areas around
spark plug G) and valve seats CD.
5. Remove and discard the spring seat I valve stem

seal assembly ®·
2. Inspect cylinder head for distortion with a straight
edge and feeler gauge. Check in different
directions and locations on the cylinder head. For
cylinder head service limits, see Service
Specifications, page 7.4.
C
VALVE SPRING FREE LENGTH INSPECTION
1. Measure free length of valve springs. Replace
springs that do not meet specification. See Service
6. Clean carbon deposits from combustion chamber. 49.1 mm (1.933")

7. Clean gasket surfaces.

7.30
VALVE INSPECTION 6. Measure valve stem deflection G) for all valves to

determine if valve or valve guide requires
replacement.
Valve service specifications can be found at the
beginning of this chapter. See Service Specifications,
page 7.4.
1. Place valves on V-blocks as shown and measure

valve stem runout G) using a runout gauge or
similar tool.
', 1'·
A. Raise valve 10mm (0.400 ") off of seat.

B. Position dial indicator as shown. Measure
deflection in two directions perpendicular to each
other (X & Yaxis).
C. If valve deflection exceeds service limit
measure valve stem diameter.
7. Replace valve and repeat step 6 if valve stem 0.D.
2. Inspect the valve face for damage from burning, measures outside standard range. If valve stem
pitting or uneven contact. deflection exceeds service limits with a new valve
installed, valve guide must be replaced.
3. Place valves on V-block as shown and inspect
valve head radial runout Q). 8. Installation of new valve guides and/ or new valves
requires valve seat reconditioning. This work
j 2 \ should be performed by an experienced
',-< technician properly equipped to perform cylinder
\ head reconditioning.
4. Insert valves into their original locations in

cylinder head.
5. Inspect that each valve moves up and down
smoothly without binding in guide.

7.31
VALVE INSPECTION - QUICK REFERENCE

CONDITION ILLUSTRATION POSSIBLE CAUSE CORRECTIVE ACTION
Uneven seat width Bent valve stem, worn Replace valve and reface
valve guide seat
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
Contact area too narrow Use 45° stone

(.
Contact area free of pitting Correct None

and damage, centered in
seat, proper width.
·······--,

7.32
VALVE GUIDE REMOVAL/ INSTALLATION 6. Remove valve and measure contact area (valve
·•'. seat width). See Service Specifications, page 7.4.
CAUTION
Replacement of valve guides requires an oven,
special equipment and experience to do the job
correctly. If you are unsure of your ability to do the j Valve Seat Width I
repair professionally it is best to sublet the labor to a \\
competent machinist. Valve seat reconditioning is \
required when valve guides are replaced. \,\ ~-----+:-i,t----~
\
\
1. Support cylinder head and plas::e valve guide \\
remover into valve guide from the combustion
chamber side.
2. Drive or press old valve guides out of cylinder
head.
CAUTION
The cylinder head can be easily damaged if the 7. If valve seat is incorrect, recondition as needed.
procedure is done carelessly.
VALVE SEAT RECONDITIONING
3. Apply 90 weight oil to outside of new valve guides.
4. Drive or press new guides from rocker arm side of
head. Valve seat reconditioning should be performed by a
technician proficient in cylinder head reconditioning
5. Measure valve guide height from spring seat: techniques using grinding stones. The use of carbide
cutters is not recommended. Follow
recommendations of the manufacturer of the valve
Guide Height from Valve Spring Seat (Installed): 11. 4 seat reconditioning equipment being used. Do not
-11.8 nun grind seats more than necessary to provide proper
seat width and contact point on valve face.
6. Ream new valve guides to size to obtain specified
stem-to-guide clearance. Ream from combustion
chamber side of head.
CYLI NDER HEAD ASSEMBLY
7. Clean cylinder head thoroughly with clean
solvent. CAUTION
8. Inspect and recondition valve seats. Wear eye protection during assembly.
1. Lubricate valve stems with assembly lube.

VALVE SEAT INSPECTION
2. Install valve in head before installing seal. Hold
valve against seat wipe off the portion that extends
Valves cannot be ground. If valve face is burned or above the guide.
badly worn, replace the valve.
3. Apply Indian Motorcycle engine oil to valve guide
seal and install seal on valve, rotating the seal as
1. Remove carbon deposits from valves and seats. you install it.
2. Inspect valve face for burning, pitting or uneven 4. Press seal firmly in place on top of guide. Be
contact. careful not to dislodge spring from seal.
3. Apply a light coating of machinist's layout fluid or 5. Install valve spring and upper retainer.
paste to valve face.
4. Install valve into valve guide.
CAUTION
Do not compress valve springs more than necessary
5. Tap valve several times to make a clear impression to install keepers.
on the valve face. Do not rotate valve.
Support cylinder head so valves will not be
damaged.

7.33
(
6. Compress valve springs using a valve spring 4. Set cylinder head in place on cylinder and press
compressor and adapter. down over the locating dowels until fully seated.
7. Apply a small amount of grease to both sides of a
valve keeper.
8. Insert both valve keepers in place on valve.
9. Remove spring compressor.
(
10. Repeat previous steps for remaining valves.
11. Be sure all keepers are fully seated in groove.
CYLINDER HEAD INSTALLATION

CAUTION
Torque-to-Yield cylinder head bolts can only be
reused I re-torqued once following removal.
Attempts to reuse bolts beyond one re-torque may
result in lower sealing pressure and potential oil I
coolant leaks.
5. Apply a thin coat of Indian Motorcycle engine oil
to the cylinder head bolt threads and install bolts C
G) finger-tight.
The base gasket seal is broken when the cylinder
head is removed and must be replaced. See Cylinder
I. Verify that locating dowels CD are in position on the

cylinder deck. C
6. Torque cylinder head bolts in an "X" pattern

following the specified sequence:
I. 1st pass - 21 ft-lbs (28.0 Nm)
2. 2nd pass - 26 ft-lbs (35.0 Nm)
3. 3rd pass - Torque an additional 180°
2. Thoroughly clean cylinder and cylinder head
mating surfaces.
Gaskets and gasket sealing surfaces must be free of

oil and grease during assembly.
3. Install a new head gasket (D.
9926140 R02- 2015 - 2016 Scout Service Manual

7.34
7. Install screws © into cam chain gallery and torque 9. Lubricate camshaft lobes and bearing journals
to specification. with Indian Motorcycle engine oil and install into
cylinder head.
:~ " •.' .~
(. "': ( ···~.: ~ ..,..'
. #·-· ' 1
10. Insert the spark plug seal into the cam carrier and
Cam Chain Gallery Screws: 88.5 in-lbs (10.0 Nm) install carrier onto cylinder head.
11 . Temporarily install the upper cam chain guide and
8. Apply a thin coat of Indian Motorcycle engine oil torque the carrier screws per the specified
to each of the tappets CD and install them in the sequence.
same position from which they were removed.
Cam Carrier Torque Sequence
12. Check valve lash and adjust if necessary. See

Valve Clearance Assembly , page 7.24.
13. Remove upper cam chain guide.
14. Install cam chain. See Camshaft Sprocket
Installation I Timing Procedure, page 7.19.
15. Install upper cam chain guide and re-torque per
STEP 11.

7.35
l
16. Install valve cover(s). See Valve Cover Installation,

page 7.23.
17. Install intake manifold. See Intake Manifold
Removal I Installation, page 5.19.
18. Install engine in frame. See Engine Installation,
page 6.7.
C

7.36
INTAKE VALVE LASH - TAPPET SELECTIO N MATR IX

Tappet Thickness: Example 440 equals thickness of 4.40 mm. Part Number: 5138477-XXX (X's represent 3 digits
on tappet)
Intake Valve Clearance (cold):

.006 ± .002" (0.150 ± .05 mm)
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
Correct Valve Lash Tappet Marking (3 digits on tappet)

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
0.050-0.074 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 sos 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)
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 sos 508 510 512 515 518 520 522 525 528 530 532 535
sos 508 510 512 515 518 520 522 525 528 530 532 535 538
sg 0.251 -0.275 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502
0.276-0.300 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540
tn
0.301 -0.325 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542
-~"
"
'5' 0 .326-0 .350 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
«: 0 .351-0.375 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
~
.Q 0.376-0.400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
Q)
"',:u
Q)
0.401-0.425 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
I!! 0.426-0.450 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
"'
Q)
sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0 0.451-0.475 472 475 478 480 482 485 488 490 492 495 498 500 502
~ 0.476-0.500 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
~Q) 0.501 -0.525 478 480 482 485 488 490 492 495 498 500 502 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
"'Jg 0.526-0.550 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
.E
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 sos 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 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.651 -0.675 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0 .676-0.700 495 498 500 502 sos 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
0.726-0.750 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.75 1-0.775 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
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
0.926-0.950 520 522 525 528 530 532 535 538 540 542 545
0.951 -0.975 522 525 528 530 532 535 538 540 542 545
0.976-1.000 525 528 530 532 535 538 540 542 545

7.37
EXHAUST VALVE LASH - TAPPET SELECTION MATRIX

Example:
Tappet Thickness: Example 440 equals thickness of 4.40 mm. Part Number: 5138477-XXX (X's represent 3 digits
on tappet)
Exhaust Valve Clearance (cold):

.008 ± .002 " (0.200 ± .50 mm)
- 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 sos 508 510 512 515 518 520 522 525
Correct Valve Lash Tappet Marking (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
rstandaxd) I
C
'? 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
,§,
tJ> 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
:§ 0.301-0.325 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535
"'= 0.326- 0.350 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538
'o
~
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 SIS 518 520 522 525 528 530 532 535 538 540
j
,:Q
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 (
Q)
0.401 -0.425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
""~ 0.426-0.450 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 sos 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
Q)
(3 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
~ 0.476-0.500 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
~
.
ui 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
.c:= 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 sos 508 510 512 SIS 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 sos SOB 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 sos 508 510 512 SIS 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 5 15 518 520 522 525 528 530 532 535 538 540 542 545
0.851-0.875 505 508 510 5 12 515 518 520 522 525 528 530 532 535 538 540 542 545
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
0.95 1-0.975 5 15 518 520 522 525 528 530 532 535 538 540 542 545
0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545

7.38
TROUBLESHOOTING CYLINDER HEAD ANO VALVE TRAIN
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.
PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Worn Valve Guide(s) Replace Valve Guide(s)
Poor Seating ofValve(s) Repair or Replace
Broken Valve Spring(s) Replace
Spark Plug Not Seated Torque to Specification
Incorrect Valve Timing Repair I Retest
Valve Stuck Open Repair I Retest
Cylinder Head Gasket Repair I Retest
Hard Starting I Won't Start Low Compression
Leak
Slow Starter Motor Refer to Chapter 15
Worn Rings, Piston, or Refer to Chapter 8
Cylinder
Valve Clearance out of Adjust Valve(s)
Specification
Ignition Problem Refer to Chapter 16
Fuel Problem Refer to Chapter 5
Excessive carbon build- De-carbon Combustion
High Compression up in combustion Chamber
Electric Starter Straining chamber
to Turn Engine Over Excessive Starter Load Internal Engine I Drive Determine Cause of
Components Seized or Seizure or Binding
Binding
Valve Clearance out of Adjust Valve(s)
Low Compression Specification
Poor Seating of Valve(s) Repair or Replace
Poor idle Quality (Engine
Valve Guides Replace
Related)
Excessive Oil in Worn Rings, Piston, or Refer to Chapter 8
Combustion Chamber Cylinder
Engine Oil Overfilled Correct Engine Oil Level
Loose or Tight Valve(s) Adjust Valve(s)
Engine Noise Valve Train Area Broken or Weak Valve Replace
Spring(s)

7.39

RECOMMENDED
Worn Camshaft or Tappet Replace
Chain Tensioner and I or Replace
Guide Worn
Cam Bearings Worn or Replace
Damaged
Worn Pistons and I or Replace
Cylinders
Worn Wrist Pin, Wrist Pin Replace
Piston I Cylinder Area Bore and I or Connecting
Rod
Worn Piston Rings or Replace
Piston Ring Lands
General Exhaust Leak Reseal Exhaust
Chain I Sprocket Worn Replace
Timing Chain Area (
Guide Worn
Bottom End Area Main Bearings Refer to Chapter 10
Rod Bearings Refer to Chapter 10
Loose Side Clearance Refer to Chapter 10 C
Transmission Area Bearings Refer to Chapter 10
Air Intake Problem - Refer to Chapter 5
Fuel Injection Problem - Refer to Chapter 5
Ignition Problem - Refer to Chapter 16
Poor High-Speed Running Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft I Tappet Replace
Valves Opening and Incorrect Valve Timing Correct
Closing at Wrong Time
Low Compression Worn Piston, Rings, Repair I Replace
Cylinder, Poor Valve
Seating
Valve Timing Incorrect Cam Chain and Sprockets Correct
Lack of Power in all RPM Valve Float Weak Valve Springs Replace
Ranges
Insufficient Valve Lift Worn Camshaft I Tappets Replace
Ignition I Fuel Injection - Refer to Chapter 5 (EFI)
System or Chapter 16 (Ignition)
Oiling Problem Oil Overfilled Correct Engine Oil Level

7.40
CYLINDER I PISTON
CHAPTERS
CYLINDER I PISTON
GENERAL lliFORMATION ..................................... .. . ......... .. . .. ....... ............... ... 8.2
SERVICE NOTES .... . . ...... . ... .. . . ... . .. .............. . ..... . ...... . ......................... . . ... . . 8.2
SPECIAL TOOLS .. . . .. .. .. ....................... ......... .............. . ............ .. ... .. .... .. .. ... 8.2
TORQUE SPECIFICATIONS . .... ..... .......... .. .... .... ..... . ................ . ..... ..... ... . ...... .. . 8.2
SERVICE SPECIFICATIONS ........ . . .. ....... . . .. ...... . . . ...... . ........ . ..... ... . . .. .. . . ........... 8 .3
ASSEMBLY VIEWS . . ... .. ........ .. ....... .. ........... .. .. ... .... . . ... . .. . . . . .. . ...... . ....... . .. ........ 8.4
CYLINDER I PISTON . ............ .. . .. .... .. . .... .... . ...................... . ............ . ............ 8.4
CYLINDER I PISTON SERVICE ....... .. ... . ....... ... . . ............ . ...... .. ... ..... ... . ... . ............ 8.5
PISTON RING PROFILE AND ORIENTATION ..... . . . . ............. . .... ..... .... ... .. .... . . . .... ..... .. 8.5
CYLINDER REMOVAL ... . .... ........... .. .... .. ........... .... . . ....... ..... .. . .. .. ... .. ....... ._..... 8.5
CYLINDER INSP ECTION ..... . . ........... . . ... .... ...... ........ . ....... . ... . . . ................ ... ... 8.6
CYLINDER BORE MEASUREMENT ... . ..... .. .. . ......... ... .. . . .. . .... ... . . ... . ....... . . . . . . ...... ... . 8.6
PISTON TO CYLINDER CLEARANCE WORKSHEET .. ..... .. . ... .... ........... ..... .. .. ... ......... ... 8. 7
CYLINDER WARPAGE MEASUREMENT ......... .. .. .. .. ... .... ............ .... . ........ . .... . .. . ...... 8.9
PISTON & PISTON RING REMOVAL ...... ..... .... . . .... . . .. ........ .. ............ ... ............. .. ... 8. 9
PISTON & PISTON RING INSPECTION . ... ... ..... . . . . . ............ . ... .. . ....... . . .. . ...... . . . ... ..... 8.9
PISTON PIN I PIN BORE INSPECTION ............ .. .............. .. .. .. ...... .. .... . ..... . . . . ... .. ... 8.10
PISTON RING INSTALLATION .. . ... ... .. ..... . . . .... .... . ... .. ... . . . ... .. ... .. . . . . ...... . . .. . ....... . 8.11
PISTON INSTALLATION .. ...... .. . .. . ..... . ... .. .... ... . ....... . ... . . .......... . ... ... .. . .... . . .. . . .. 8.11
CYLINDER INSTALLATION ..................................... . ...... .... ... ...... . . .. ... ... .. .. . . . . 8.12
TROUBLESHOOTING CYLINDER I PISTON ......... .... . . .............. . . ... . . . ... .. . ............. . .. 8.14

8.1
CYLINDER I PISTON
GENERAL INFORMATION
SERVICE NOTES SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Clean the machine thoroughly before removing Piston Ring Compressor PV-43570-A
engine from frame.
Engine Lock Tool - PF-51612
Transmission
• This section covers service of the cylinder, piston C
and rings. The engine must be removed from the Engine Lock Tool - PF-51235-A
frame to perform the procedures in this section. Crankshaft
Refer to Chapter 6 for engine removal and Cylinder Bore Gauge PV-3017
installation.
• Mark and store all mated parts for assembly. Engine Case Splitting Tool PF-51234-A
Assemble engine by putting used parts that pass
inspection back in the same location. Straightedge, Feeler Commercially
• Machined mating surfaces are very delicate. Handle Gauge Available
and store all parts in such a way that the mating
surfaces will not be damaged. Bosch Automotive Service Solutions: 1-800-345-
• Many parts require assembly lubrication. Follow the 3322 or https://polaris.service-solutions.corn/
assembly lubrication procedures carefully.
• There are many precision measuring steps in this
section. If you are not sure of your capabilities in TORQUE SPECIFICATIONS (
these areas, have a competent machinist perform DESCRIPTION TORQUE
the precision part inspection operations. SPECIFICATION
• Cleanliness of parts is critical to engine life and
proper parts inspection. Use clean solvent and hot, Connecting Rod STEP 1: 22 ft-lbs (30.0 Nm)
soapy water to clean parts. Dry with compressed air Bearing Cap STEP 2:: Additional 90°
before inspection and engine assembly. Coat parts
with fresh lubricant to prevent oxidation after C
cleaning.

8.2
CYLINDER I PISTON
SERVICE SPECIFICATIONS
98.992 - 99.008 Check taper and
I.D. (3.8973 - 3.8979") out-of-round
Cylinder Out of Round Measure 50 mm down from 0.05 mm (.002")

head surface
Taper 0.05 mm (.002")
Gasket Surface Warpage - . Imm max. (.0039")
Piston Mark Direction Piston orientation is determined by arrow on piston
crown.
Position BOTH pistons so arrows point to front of engine.
Piston O.D. (Nominal) 98.933 - 98.947 mm Replace if piston-to-
(Measured 12 mm up (3.8949 - 3.8955") cylinder clearance is
from bottom of skirt, 90 excessive with good
degrees to pin) cylinder
Piston Piston Pin Hole I.D. 22.004 - 22.010 mm 22.047 mm
(.8663 - .8665") (.8679")
Piston Pin O.D. 21.995 - 22.000 mm 21.96 mm
(.8659 - .8661 ") (.864")
Piston to Cylinder .045 - .075 mm .15mm
(.0017 - .0029") (.006")
Piston to Piston Pin .004- .015 mm .030mm
Ring End Gap - Top .15 - .31 mm .80mm
(Installed) (.006 - .012") (.031 ")
Ring End Gap - 2nd .25- .50 mm 1.11 mm
(Installed)Ring End Gap - (.009 - .019") (.043")
Piston Ring Clearances 3rd (Oil Control Rails) .25 - 1.02 mm .80 mm
(Installed) (.009 - .040") (.031 ")
Piston Ring Marks - DOT mark must face UP on
all rings.
Top Ring .03 - .095 mm
.15 mm (.0059")
(1.2mm ring thickness) (.0001 - .0037")
Piston Ring to Ring 2nd Ring .02 - .066 mm

.IO mm (.0039")
Land (1.2mm ring thickness) (.0007 - .0025")
.03 - .13 mm
Oil Control Ring .25 mm (.0098")
(.00 I - .0051 ")

8.3
CYLINDER I PISTON
ASSEMBLY VIEWS
CYLINDER/ PISTON
,_/' ,1
(2:) j
/~ \
i 13 !
\,___,/
C
CD Circlip, Piston (QTY.4) -

CD Wrist Pin, Piston (QTY.2) -
- (
G) Piston (QTY.2)
© Oil Control Ring I Expander (QTY.2) -

G) Compression Ring #2 -
© Compression Ring # 1 -
(J) Gasket, Cylinder Base (QTY.2) -
® Cylinder, Rear -
® Bolt, Connecting Rod - M9 x 1.0 STEP 1: 22 ft-lbs (30.0 Nm)
(Single Use Fastener) STEP 2:: Additional 90°
@) Connecting Rod -
® Cylinder, Front -
@ Sealing Washer (Front Cyl. Only) -

® Cam Chain Tensioner (Front Cyl. Only) -

8.4
CYLINDER I PISTON
CYLI NDER/ PISTO N SERVICE

PISTON RING PROFILE AND ORIENTATIO N
·· - '.
··-. ·,
NUMBER DESCRIPTION
G) Arrow s on piston crown indicating installation direction. Both arrows point toward the front of the engine .
Q) Front piston is installed closest to the primary drive side of the engine.
G) 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.
CD Oil Control Ring

® Compression Ring No. 2
(J) Compression Ring No. 1
CYLI NDER REMOVAL

1. Remove cylinder head (s). See Cylinder Head
Removal, page 7.27.
2. Remove cylinder(s) CD. Support pistons to prevent
damage. Place shop towels around piston/ rings to
prevent damage.
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
m Top Compression Ring End Gap

3. Remove cylinder base gasket Q).
© Piston Marking Faces Front of Engine

8.5
CYLINDER I PISTON
4. Clean gasket surfaces of cylinders thoroughly.
CAUTION
Careless handling of cylinder, pistons or rings may
cause irreparable damage. Do not damage gasket
surfaces during cleaning.
(
CYLINDER INSPECTION
1. Visually inspect cylinder bores for sc:atches and
wear.
2. Inspect gasket surfaces for scratches or other
damage that may cause an oil leak.
CYLINDER BORE MEASUREMENT
1. Measure each cylinder bore in 6 places to
determine:
.-
Bottom measurement should be taken 2.6 in (66 mm)
up from base.
• Cylinder Bore Inside Diameter

• Cylinder Taper
• Out of Round
2. Use maximum measurement to determine wear.
3. Use the worksheet provided to record
measurements and calculate the clearance.
9926140 ROZ - 2015 - 2016 Scout Service Manual

8.6
CYLINDER I PISTON
PISTON TO CYLINDER CLEARANCE WORKSHEET

Front Cylinder Recorded Measurement Specification
Top "X"
Middle "X"
Bottom "X"
Top "Y"
Middle "Y"
Taper Service Limit: .05rnrn (.002")
Bottom "Y"
Difference between largest "Y" Taper for "Y" axis:
measurement and smallest "Y"
measurement
Difference between largest "X" Taper for "X" axis:
measurement and smallest "X"
measurement
Largest difference between any "X" Cylinder Out-of-Round: Out-of-Round Service Limit:
axis measurement and "Y" axis .05mm (.002")
measurement
Piston Skirt Measurement
Difference between largest "X" axis Piston-to-Cylinder Piston-to-Cylinder Clearance Service
measurement and piston measurement Clearance* Limit: .1 5 mm (.006")

8.7
CYLINDER I PISTON
Rear Cylinder Recorded Measurement Specification

Top "X"
Middle "X"
Bottom "X"
Top"Y"
Middle "Y"
Taper Service Limit: .05mm (.002")
Bottom "Y"
Difference between largest "Y" Taper for "Y" axis:
measurement and smallest "Y"
measurement
Difference between largest "X" Taper for "X" axis:
measurement and smallest "X"
measurement
Largest difference between any "X" Cylinder Out-of-Round: Out-of-Round Service Limit:
axis measurement and "Y" axis .05mm (.002")
measurement
Piston Skirt Measurement
Difference between largest "X" axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service
measurement and piston Limit: .15 mm (.006")
measurement
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.

8.8
CYLINDER I PISTON
CYLINDER WARPAGE MEASUREMENT 3. Push piston pin CD out to left side of engine and
1. Inspect cylinder for warpage at cylinder head remove the piston Q).
surface and base gasket surface.
4. Rotate rings in piston grooves. Rings should rotate

freely in grooves.
2. Place a straight edge diagonally across cylinder 5. Clean carbon deposits from piston.
mating surfaces in several positions. Attempt to
slide a .05rnrn (.002 ") feeler gauge under the 6. Spread rings only wide enough to remove them
straight edge in each position. from piston. Spreading rings too wide will damage
them.
3. Replace cylinder if warped beyond the service
limit. 7. Clean piston ring grooves. Break or cut a piston
ring in half. File or grind one edge square and
remove all burrs. Use this piston ring to carefully
PISTON & PI STON RIN G REMOVAL
I
clean piston ring grooves.
1. Cover crankcase with a clean shop towel to
prevent piston circlip from falling into the
crankcase.
A soft wire brush may be used to only clean the top
2. Remove the left piston pin circlip CD. of the piston. Do not use a wire brush to clean the 8
sides of piston or the piston ring grooves .
PI ST ON & PISTON RIN G INSPECTION

1. Visually inspect p iston for cracks, e x cessive wear,
scoring, etc.

8.9
CYLINDER I PISTON
2. Measure piston skirt 0. D. (90° to pin and 12 mm

from bottom of piston skirt). Replace piston if worn
7. Install rings onto a clean piston. Push rings in until
they are flush with piston. Using a feeler gauge, r
beyond the service limit. See Service measure side clearances for the 1st & 2nd rings.
··-- .. _ ..... !('... y)

!Insert Feeler Gauge ! I
(
12mm
T !_1 nsert Feeler _G au;f~!1:IJ!Mh-fA'l 0 aPrn.fi'J';~g~
(
_i_ i ff
r
,i./
3. Calculate Piston to Cylinder Clearance. Subtract 8. Replace parts that exceed service limit.
piston 0.D. from cylinder bore I.D. and compare to
specifications. See Service Specifications, page PISTON PIN/ PIN BORE INSPECTION
8.3. 1. Measure piston pin hole I.D. (as shown) as close to
the circlip groove as possible with a telescoping
4. Replace parts that do not meet specification.
gauge. Record the smallest measurement.
If piston-to-cylinder clearance exceeds service limit, C

measure a new piston and re-calculate clearance. If
piston-to-cylinder clearance exceeds service limits
with a new piston, cylinder must be replaced.
5. Use a piston to push each ring squarely into

cylinder bore from bottom (push rings 25-50 mm
into cylinder).
~
6.
,L
Measure installed ring end gap with a feeler
gauge and compare to specifications. See Service

8.10
CYLINDER I PISTON
2. Measure piston pin O.D. at three locations. Record 3. Install top and bottom rails with end gap located
largest measurement. as shown. See Piston Ring Profile And Orientation,
page 8.5
4. Install top ring and second ring with pip markings
facing UP.
5. Compress each ring by hand and rotate to be sure
they rotate freely in grooves.
6. Locate ring end gaps as shown below in relation to
arrow on piston crown. See Piston Ring Profile And
Orientation, page 8.5.
PISTON INSTALLATION
The pistons are marked with an arrow on the crown.
Install pistons on connecting rods with arrow facing
the FRONT of the engine.
···}~:;;;.~~:f·:~~---~::?"~,/ . . · "'<
3. Calculate piston pin-to-piston clearance. Subtract \ Arrows Point
pin O.D. from pin hole I.D. Forward
4. Measure connecting rod small end I. D. at two

locations.
·-.::-:-:"·:,-;-·
!~-;.
'~-
"- ·.·
\ ',
,<
-') =
" .~.
.!1 '
1. Place a clean shop towel over crankcase to prevent

foreign material from entering crankcase.
2. Install a new circlip on one side of the piston with
5. Calculate connecting rod-to-piston pin clearance end gap facing UP (12:00 position).
by subtracting pin O.D from rod hole I.D.
CAUTION
6. Compare measurements to specifications and Never reuse piston pin circlips.
replace any worn parts. See Service
3. Lubricate piston pin and I. D. of connecting rod
small end with engine oil or moly lube.
PISTON RING INSTALLATION
4. Install piston over connecting rod with arrow on
CAUTION piston crown facing FRONT of engine.
J The rings may be damaged if they are over 5. Push piston pin G) through rod and piston pin hole
expanded during installation. until it is stopped by circlip.
1. Lubricate all rings with engine oil.

2. Carefully install oil control ring expander with end
gap located as shown. See Piston Ring Profile And
Orientation, page 8.5.

8.11
(
CYLINDER I PISTON
6. Install remaining circlip CD with end gap facing up 5. Apply a small amount of crankcase sealant to the
(12:00 position.) crankcase parting lines on base gasket surface as
shown.
~>' .; ( \
,,-:,,,
7. Make sure both piston circlips are seated properly

in the groove. 6. Install new cylinder base gaskets onto crankcase. (
CYLINDER INSTALLATION
Inspect all sealing surfaces carefully for scratches or
imperfections. DO NOT allow oil or grease to contact
gaskets or sealing surfaces during the assembly
Be sure all top end parts are ready for assembly.
Sealant on crankcase parting line must not be process.
C
allowed to dry before top end is assembled and
torqued. 7. Apply a small amount of engine oil to inside
surfaces of a piston ring compressor band.
1. First wash cylinders with clean solvent, then with 8 . Install piston ring compressor over rings and
hot soapy water. compress rings into ring grooves.
2. Rinse the cylinders with clear water and CAUTION
immediately dry with compressed air. Cylinder
bore should be wiped with a clean white shop Be sure compressor band end gap does not align
towel and engine oil. with any ring end gap when compressing the rings.
3. Apply a light coat of engine oil to piston and rings.
4. Ensure cylinder alignment dowel pins are in place
and gasket surfaces are clean and oil-free. Install cylinders in their original locations. Cylinder
with cam chain tensioner is the front cylinder.
9. Remove protective covering from crankcase.

8.12
CYLINDER I PISTON
10. Carefully install cylinder (s) over piston/ ring

assembly. Do not force cylinder over piston.
Monitor rings carefully. If a piston ring becomes
dislodged from the ring compressor; remove
cylinder, inspect ring carefully for damage.
11. Remove piston ring compressor when rings are

fully captive in cylinder.
12. Slide cylinder down over piston until seated to
base gasket and crankcase surface.
13. Repeat for other cylinder.
14. Install cylinder head (s). See Cylinder Head
9926 140 R02 - 2015- 2016 Scout Service Manual

8.13
(
CYLINDER I PISTON
TROUBLESHOOTING CYLINDER/ PISTON

(
RECOMMENDED
Worn Valve Guide(s) Replace Valve Guide(s)
Poor Seating of Valve(s) Repair or Replace
Broken Valve Spring(s) Replace (
Spark Plug Not Seated Torque to Specification

Incorrect Valve Timing Repair I Retest
Valve Stuck Open Repair I Retest
Cylinder Head Gasket Repair I Retest (
Hard Starting I Won't Start Low Compression
Leak
Slow Starter Motor Refer to Chapter 15
Worn Rings, Piston, or Refer to Chapter 8
Cylinder
Valve Clearance out of Inspect I Adjust as C
adjustment necessary
Ignition Problem Refer to Chapter 16
Fuel Problem Refer to Chapter 5
High Compression Excessive carbon build- De-carbon Combustion (
up in combustion Chamber
Electric Starter Straining chamber
to Turn Engine Over Excessive Starter Load Internal Engine I Drive Determine Cause of
Components Seized or Seizure or Binding
Binding
Valve Clearance out of Inspect I Adjust as
Low Compression adjustment necessary
Poor Seating ofValve(s) Repair or Replace
Poor idle Quality (Engine Valve Guides or worn Replace
Related) valve stem seals
Excessive Oil in Worn Rings, Piston, or Refer to Chapter 8
Combustion Chamber Cylinder
Engine Oil Overfilled Correct Engine Oil Level
Valve Clearance out of Inspect I Adjust as
adjustment necessary
(
Broken or Weak Valve Replace
Spring(s)
Engine Noise Valve Train Area Worn Camshaft or Rocker Replace
Arm
Camshaft Bearing Inspect I Repair
Damage I Wear
Cam Sprockets Worn Replace

8.14
CYLINDER I PISTON

RECOMMENDED
Worn Pistons and I or Replace
Cylinders
Worn Wrist Pin, Wrist Pin Replace
Piston I Cylinder Area Bore and I or Connecting
Rod
Worn Piston Rings or Replace
Piston Ring Lands
General Exhaust Leak Reseal Exhaust
Chain I Sprocket Worn Replace
Timing Chain Area
Guide Worn
Bottom End Area Main Bearings Refer to Chapter 10
Rod Bearings Refer to Chapter 10
Loose Side Clearance Refer to Chapter 10
Transmission Area Bearings Refer to Chapter 10
Air Intake Problem - Refer to Chapter 5
Fuel Injection Problem - Refer to Chapter 5
Ignition Problem - Refer to Chapter 16
Poor High-Speed Running Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft I Tappets Replace
Valves Opening and Incorrect Valve Timing Correct
Closing at Wrong Time
Low Compression Worn Piston, Rings, Repair I Replace
Cylinder, Poor Valve
Seating
Cam Chain and Sprockets Correct
Valve Timing Incorrect
Damaged Cam Gears Replace
Lack of Power in all RPM
Ranges Valve Float Weak Valve Springs Replace
Insufficient Valve Lift Worn Camshaft I Tappets Replace
Ignition I Fuel Injection - Refer to Chapter 5 (EFI)
System or Chapter 16 (Ignition)
Oiling Problem Oil Overfilled Correct Engine Oil Level

8.15
(
CYLINDER I PISTON
NOTES (

8.16
CLUTCH I PRIMARY I SHIFT
CHAPTER9
GENERAL INFORMATION ..... . ...................................... .. . ..... .................... .. ..... 9 .2
SERVICE INFORMATION .............................................................................. 9.2
SPECIAL TOOLS ................... ... .................. ... ....................... ..... ........ .. ...... 9.2
TORQUE SPECIFICATIONS .. ...... . ...... . . ... ........................................................ 9.2
SERVICE SPECIFICATIONS ........................................................................... 9.2
ASSEMBLY VIEWS ........................................................................................ 9.3
PRIMARY COVER ............................... . .................................... ... .............. 9.3
CLUTCH PINION SHAFT ............................................................................... 9.5
CLUTCH ASSEMBLY ................................................................................... 9.6
SERVICE PROCEDURES ........................... . ..................................................... 9.7
PRIMARY DRIVE COVER REMOVAL ................................................................... 9.7
PRIMARY DRIVE COVER INSTALLATION .............................. ... ..................... . ....... 9. 7
CLUTCH PINION SHAFT REMOVAL . .... . ........... .... ........ .... .. .............. . . . .... .......... . 9.8
CLUTCH PINION SHAFT BEARING INSPECTION ....... ... . . ..... .. ..... . .... .... ........... .. .. . .. ... 9.8
CLUTCH PINION SHAFT SEAL REMOVAL I INSTALLATION ....... . ... .... . . . ... .... . ................. . 9.9
CLUTCH PINION SHAFT INSTALLATION ......... . ..................... . .............................. 9.9
SHIFT RATCHET REMOVAL I INSPECTION .... .... . . .... . ....................... .... ..... . ............ 9.9
SHIFT RATCHET INSTALLATION ..................................................................... 9.11
SHIFT ARM REMOVAL I INSTALLATION ........ .. ... .... ...... . ........... ... ........................ 9 .12
SHIFT SHAFT SEAL REPLACEMENT ...... ... ..................... ... ........ . ..................... .. . 9 .12
CLUTCH SERVICE ..................... ....... ......... . ............................ . ................. .. 9.13
CLUTCH RACK REMOVAL I INSTALLATION .. .. ................ .. ........... . ........................ 9.13
CLUTCH REMOVAL .................................................................................. 9.13
CLUTCH DISASSEMBLY ...................................................... .. ............ . ......... 9.14
CLUTCH INSPECTION ................................................................................ 9.15
CLUTCH ASSEMBLY .................................................................................. 9.16
CLUTCH INSTALLATION ............................................................................. 9.18
FLYWHEEL SERVICE ............................. .... . ... ... ... .................... ... . ... . . ............ 9.19
STATOR COVER REMOVAL ......... ......... ........................ . ... . .... .. . ..................... 9 .19
STATOR COVER INSTALLATION ............................................................... . ...... 9.19
FLYWHEEL REMOVAL ....................... ...... ...... . ........ .. ............ . ............ . ........ 9 .20
FLYWHEEL INSTALLATION .................... .. .. .... .............. . . . ............... ......... ...... 9.21
TROUBLESHOOTING CLUTCH I PRIMARY I SHIFT ............. . ...... . .............................. 9.22

9.1
(
GENERAL INFORMATION
SERVICE INFORMATION SPECIAL TOOLS
• Clutch and external transmission shift linkage TOOL DESCRIPTION PART NUMBER
service can be accomplished with the engine in the
frame. Case Splitting I Assembly Tool PF-51234-A
• Internal transmission or internal shifting mechanism
Engine Lock Tool - Transmission PF-51612
service requires engine removal and crankcase
separation. Engine Lock Tool - Crankshaft PF-51235-A (
• Oil additives of any kind are not recommended by
Indian Motorcycle. Using oil additives or oil of the Engine Stand Adapter PF-51609
wrong viscosity can have a detrimental affect on
clutch performance, operation, and service life. Moly Assembly Paste 2871460
• Burnt clutch plates are not an indication of defective
clutch plates. Burnt clutch plates indicate that a Bosch Automotive Service Solutions: 1- 800- 328-
problem exists within the clutch system, the clutch 6657 or https://polaris.service-solutions.com/ (
has been used improperly, or plates were
contaminated by improper oil or additives.
• Indian Motorcycle 15W/ 60 motorcycle oil is
recommended for all operating temperatures. If PART DESCRIPTION TORQUE
Indian Motorcycle 15W/60 oil is not available, a high SPECIFICATION
quality 15W/60 motorcycle oil suitable for use in wet
clutch transmissions can be used. Clutch Stake Nut 125 ft-lbs (170.0 Nm)
• Lubricate parts during assembly as described in the
Pressure Plate Screws 88 in-lbs (10.0 Nm)
procedures.
• Corroded or sticking shift linkage pivot points can Primary Cover Screws 88 in-lbs (10.0 Nm
cause abnormal shifting. Replace any linkage
components that are damaged or do not move Stator Bolts 88 in-lbs (10.0 Nm)
freely, and lubricate at regular intervals.
(_
ITEM SPECIFICATIONS
Clutch Type Wet, Multi-Disk
Clutch Operating Mechanism Manual I Cable Operated
Primary Reduction Ratio 1.674: 1
Transmission Shift Mechanism Manually Operated, Spring
Clutch I Gear Shift I Linkage Centered
Gearshift Pattern l-N-2-3-4-5-6
Clutch Spring (Coil Type, QTY.6) Spring Height - Free: 55.3 mm I
Installed 30.6 mm
Clutch Lever Free Play (Cable) .50-1.50 mm (.019 - .059")

9.2
ASSEMBLY VIEWS
PRIMARY COVER
,,-
( 7 )
\.._j
G) Screw, Primary Cover - M6 x 1.25 x 75 (QTY.7) 88 in-lbs (10.0 Nm
0 Screw, Primary Cover - M6 x 1.25 x 35 (QTY.6) 88 in-lbs (10.0 Nm
G) Cover, Primary -
© Gasket, Primary Cover -
G) Screw, Primary Gear Cover 7.3 ft-lbs (10 Nm)
© Bracket, Clutch Cable Retaining -

(}) Bracket, Cable Mount -
® Cover, Primary Drive -
® Gasket , Primary Drive Cover -
.)

9.3
(
Primary Cover Torque Sequence
(
Primary Drive Cover Torque Sequence

9.4
CLUTCH PINION SHAFT
__
r-·-=r--::-:.~ ~~\Oo
.
CJ f ' - - - -~ --
(/ 7 ' )
''-._j
NUMBER PART DESCRIPTION TORQUE (IF APPL11
CD Cover, Primary
0 E-Clip, External -
G) Washer -
© End Bearing, Pinion Shaft -
G) Bearing, Shaft (Clutch Pinion Shaft) -
® Seal, Shaft -~
(j) Pinion Shaft, Clutch -
..)

9.5
(
CLUTCH ASSEMBLY
- .. __ __J'
C
NUM- PART DESCRIPTION TORQUE (IF APPLICABLE)
BER
1 Screw, Pressure Plate (QTY.6) 88 in-lbs (10.0 Nm
2 Spring, Clutch (QTY.6) -
3 Pressure Plate, Clutch - C
4 Bearing, Clutch Lifter -
5 Lifter, Clutch Rack -

6 Nut, Clutch Retainer (Staking) 125 ft-lbs (170.0 Nm)
7 Washer, Flat -
8 Disc, Clutch Friction -
9 Disc, Clutch Steel -
10 Spring, Judder -
11 Seat, Judder Spring -
12 Clutch Hub, Inner -
13 Washer, Clutch -
14 Collar, Bearing -
15 Basket Assembly, Outer -
16 Spacer, Clutch -

9.6
SERVICE PROCEDURES
PRIMARY DRIVE COVER REMOVAL PRIMARY DRIVE COVER INSTALLATION
1. Place motorcycle in an upright position with the 1. Clean gasket surfaces of crankcase and cover.
2. Drain oil from engine. See Engine Oil I Filter
Change, page 2.9.
3. Remove the exhaust system. See Head Pipe
Removal, page 5.14.
4. Disconnect clutch cable from engine clutch lever.
See Clutch Cable Removal I Installation, page
l l. l 2Clutch Cable Removal.
5. Remove clutch cover fasteners G) and cover
assembly@.
3. Torque the primary cover bolts to specification

following the torque sequence.
6. Remove primary drive cover fasteners G), seal G)

and cover assembly ©.
4. Clean clutch cover and primary drive cover gasket

mating surfaces.
9926140 R02 - 20 l S - 2016 Scout Service Manual

9.7
(
5. Install new clutch cover gasket with flat side facing CLUTCH PINION SHAFT REMOVAL r
clutch cover ®· 1. Remove the Primary Cover CD. See Primary Drive
Cover Removal, page 9.7.
2. Remove the E-clip CD and washer from the end of
the clutch pinion shaft as shown.
6. Install clutch cover fasteners ® and torque in

sequence to specification.
3. Slide the pinion shaft G) out of the primary cover.
7. Connect the clutch cable. See Clutch Cable

8. Install exhaust system. See Head Pipe Installation, CLUTCH PINION SHAFT BEARING INSPECTION (,
page 5.15. 1. Apply engine oil to the bearings.
9. Check engine oil level. See Engine Oil Level 2. Temporarily install pinion shaft into primary cover.
Check, page 2.8. 3. Turn shaft by hand. Replace bearings that feel
rough, notched, or loose.

9.8
CLUTCH PINION SHAFT SEAL REMOVAL/ 2. Install washer (I) and E-clip G).
INSTALLATION
1. Remove clutch pinion shaft. See Clutch Pinion
Shaft Removal, page 9.8.
2. Protect cosmetic surfaces and carefully pry seal G)
out of primary cover.
SHIFT RAT CHET REMOVAL/ INSPECTION

1. Place motorcycle in an upright position with the
2. Shift transmission into neutral.
3. Lubricate outer edge of new seal with engine oil
and sealing lip with grease. 3. Remove shift pedal linkage from shift shaft.
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.
·.Y··· .' .; ' ., : .
CLUTCH PINION SHAFT INSTALLATION (:·-"?~·::~.~-
' /.;
1. Lubricate and install clutch pinion shaft G) until

fully seated in bearings.
5. Remove primary cover. See Primary Drive Cover

Removal, page 9.7.
6. Remove primary drive cover. See Primary Drive
Cover Removal.
7. Remove clutch assembly. See Clutch Removal,
page 9.13 .
.)

9.9
(
8. Using a 4 mm hex wrench, remove the screw G) 11. Inspect shift shaft return spring @) for cracks or
('
securing the shift star Q) 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.
9. Rotate the detent lever (J) so the spring ® is

relaxed. Using a 10 mm socket, remove the bolt ®
and washer ® securing the detent lever. to the (
engine case. 12. Inspect shift shaft ® for wear or damage.
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
·- ,/"····i-. ', •. • ' '-.l~) ; -··· the shift star.
.. ··/
14. Inspect fit of rivet ® on shift ratchet assembly. It (
·:.: ..,\.. .... ··· .. , should allow for free movement, but not be
excessively loose.
C
/-- ~,
----'"'----'. 11 ·:
\.,_,/
/~',
! 12 l
~ -_)
,,,.-.,
=-- - - - -( 13)
'--~/
15. Inspect shift star for wear.

16. Inspect detent roller arm for wear or damage.
17. Inspect de tent roller arm spring for cracks or
fatigue.
(_
9926 140 R02 - 2015 - 20 16 Scout Service Manual (

9.10
SHIFT RATCHET INSTALLATION 2. Install circlip and press new oil seal G) into
1. Lubricate the shift shaft G) with engine oil and position until flush with crankcase.
slide into bore until fully seated.
'
~
' \ ' '.
,,--~· ~
Verify that the return spring CD has properly engaged

the dowel G) as shown.
~' ' . ,.,,·'
3. Install the detent roller arm and spring assembly

©. Torque screw (j) to specification.
... ' .. '--"!''
/·.
(
. a/1,
'")-
'
~
4. Rotate the detent roller arm against the spring and

install a suitable locking pin ® to hold it in
position.
5. Verify that the shift star dowel ® is in place in the
shift drum and install the shift star@).
6. Install the shift star washer ® and screw @ and
torque to specification .
...)

9.11
(
7. Remove locking pin (8) to release the detent roller 2.

arm.
The Shift Shaft Seal requires removal as part of the

shift shaft removal procedure.
Apply assembly lube to inner & outer surfaces of C

new bearing.
Moly assembly paste PN: 2871460
3. Apply a small amount of grease to lip of seal and
apply engine oil to outside of seal.
4. Drive seal into place with a seal driver slightly
smaller than the 0.D. of seal. C
5. Install primary cover. See Primary Drive Cover
6. After installing primary cover, be sure shift shaft
returns freely to the centered position after
8. Install the shift arm. rotating up or down.
9. Install clutch assembly. See Clutch Installation,
page 9.18.
10. Install the primary cover. See Primary Drive Cover
Installation, page 9. 7.
SHIFT ARM REMOVAL/ INSTALLATION (

1. Remove shift pedal linkage from shift shaft.
SHIFT SHAFT SEAL REPLACEMENT (

1. Remove shift shaft assembly. See Shift Ratchet
Removal I Inspection, page 9.9.

9.12
CLUTCH SERVICE
CLUTCH RACK REMOVAL/ INSTALLATION CLUTCH REMOVAL
1. Remove the clutch cover. See Primary Drive Cover 1. Remove primary cover. See Primary Drive Cover
Removal, page 9.7. Removal, page 9.7.
2. Remove the six pressure plate screws CD and coil 2. Remove bolts CD, springs (I) and pressure plate G).
springs (I).
\,<1'_)\
_
~
~
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.
It is not necessary to remove the clutch plates to

service the rack assembly.
4. Remove the slip-fit clutch rack G) from the back

side of the clutch rack bearing.
5. Using a suitable bearing driver or press, remove
the clutch rack bearing © from the back side of
the pressure plate.
6. INSTALLATION: Reverse the removal procedure

to install.

9.13
5. Remove clutch nut © and flat washer (£). Discard 3. Lift the clutch assembly (I) out of the basket and set
the stake nut. aside.
6. Remove clutch assembly ® from clutch shaft.

4. Remove the inner hub G) and thrust washer©.
7. A new stake nut must be installed upon assembly.
(
CLUTCH DISASSEMBLY
CAUTION
Clutch is under spring pressure. WEAR EYE
PROTECTION.
1. Remove the clutch. See Clutch Removal, page

9.13.
2. Remove the sleeve G) from the back side of the
clutch assembly.
The clutch assembly consists of three different

types of friction plates and one type of separator
plate. See Clutch Assembly, page 9.6.
C
PART DESCRIPTION QUANTITY
Friction Plate A (£) 1
Friction Plate B ® 6
Separator Plate A (J) 7 C

Friction Plate C @) 1
Spring, Judder Clutch® 1
Seat, Judder Clutch ® 1

9.14
5. Remove Friction Plate 0). CLUTCH INSPECTION

1. Clean clutch plates, inrter hub, and outer basket.
Clutch Basket
2. Inspect clutch gear teeth CD for wear, cracks or
damage.
3. Inspect inside surfaces Q) of basket for cracks or
wear (grooves) from clutch plates.
6. Then alternately remove Friction Plates B © and

Separator Plates C (J).
4. Replace parts that fail inspection

5. Rotate basket bearing G). Check for smooth
rotation. Inner race should have no detectable
radial movement.
6. Lubricate bearing G) and collar© with engine oil.
/-,
,~~~~~~~--i(
, ...~~.....-Ir 7 ')
, .__/
.... ; :/?':;"~--''' t·:::.:."-"'.~~;,'<!°' . -!~
<
"¢/
~
7. Remove Friction Plate C @), Judder Spring ® and

Judder Spring Seat ®·
Clutch Hub

9.15
7. Inspect surface of steel plate guides @ on outer 14. Inspect lifter bearing visually for any signs or wear
edge of hub for wear, grooves, or damage. Check or discoloration. Rotate bearing inner race with
all posts ® for cracks or damage. your finger and check for smooth movement and
no play.
15. Replace clutch rack assembly if necessary.
CLUTCH ASSEMBLY C
Apply a thin coat of engine oil to all clutch

components prior to assembly.
1. Install the bearing collar CD into the clutch basket

(I) followed by the thrust washer G) and clutch hub (
©.
8. Visually inspect friction and steel plates for wear

or damage on both surfaces. Replace plates as a (
set if any plate is worn or damaged.
9. Replace steel plates if grooved, distorted or
discolored. Inspect plates for distortion by placing
[J
1
each plate on a precision flat surface. Insert a
feeler gauge between plate and flat surface in
several places. (
( 4) ( 3) ( 1)
Clutch Steel Plate Warp Service Limit: "-._j \.._./ '-.../
.008 in (.20 mm)
10. Measure thickness of friction plates in several

places. Thickness should be the same at each 2. Apply engine oil to judder spring seat @ and (
place. Replace plates that fail inspection. spring®·
Friction Plate Thickness (Minimum): .126 in (3.2

mm)
C,
Clutch Pressure Plate
11 . Inspect pressure plate for cracks, scoring, or wear
on friction surface.
Clutch Springs
12. Inspect clutch springs for cracks or distortion.
(
Clutch Release Rack and Bearing
13. Inspect clutch rack for broken or damaged teeth.

9.16
3. Install judder spring seat (flat ring), then judder 5. Place an oiled Separator Plate B ® into clutch
spring. basket followed by Friction Plate B ®·
Judder spring must be installed with concave side If friction plates are new, soak them in clean engine
facing UP (toward outside of clutch). The tallest edge oil for a few minutes before installing.
of spring will be outermost.
6. Continue stacking oiled clutch plates into clutch
basket alternating Friction Plate B ® and
Separator Plate B ® ·
4.
7. Install Separator Plate A ® followed by Friction

Refer to the Clutch Assembly View outlined in Plate B ® and Separator Plate A®·
this chapter for clutch plate orientation. See
Clutch Assembly, page 9.6. 8. Install the final Friction Plate A@).
Apply engine oil to Friction Plate C (J) and install.
9. Apply engine oil to hub bearing.
Friction Plate C has an inner diameter that is larger

than the other friction plates, allowing it to fit around
the judder spring.

9.17
10. Install the pressure plate ® and clutch springs @ 5. Install washer CD and a new stake nut ©.
and screws ®· Alternately tighten the clutch C
spring screws in a star pattern until fully
seated.
6. Lock the crankshaft as outlined in chapter 7. See

Locking the Crankshaft for Service, page 10.5.
(
7. Torque the stake nut to specification.
11: Torque clutch spring screws to specification.
8. Install clutch pressure plate assembly and torque

screws to specification.
(
CLUTCH INSTALLATION
1. Remove the pressure plate from the clutch
assembly and set aside.
2. Using a pin punch or similar tool CD, preload the
teeth of the primary drive split gear and hold in 9. Install primary cover. See Primary Drive Cover
place. Installation, page 9. 7. (
3. Slide the clutch assembly CD onto the transmission 10. Check engine oil and fill to proper level.
input shaft until fully seated. Note: Crankshaft
bearing damage will occur if the clutch assembly
is not fully seated.
4. IMPORTANT! Clutch assembly installation (
inspection. Verify the outer face of the clutch gear
is inset from the primary drive split gear .

9.18
FLYWH EEL SERVICE

STATOR COVER RE MOVAL
1. Drain cooling system. See Coolant Drain I Fill,
page 4.20.
2. Remove Crankshaft Position Sensor from the stator
cover. See Crankshaft Position Sensor, Test I
Replace, page 5.42.
3. Remove Ignition Cover fasteners CD and remove the
Ignition Cover Q).
STATOR COVER INSTALLATION

1. Assemble new gasket CD on stator cover Q) with the
gasket flat surface facing the engine.
4. Disconnect the radiator outlet hose CD at the left

engine cover.
2. Install fasteners CD and © in the locations

illustrated.
3. Install remaining stator cover fasteners and torque
all fasteners in sequence to specifications.
5. Disconnect the bypass hose © at the left engine

cover.
6. Disconnect the stator harness connector.
7. Remove the stator cover fasteners G) and stator
cover © .
992 61 40 R02 - 2015 - 2016 Scout Se rvice Manual

9.19
3. Remove flywheel bolt and washer G).

/ )
\\ \ \
' !
\\" '""'"'"-'--.' . Ji,?

4. Connect coolant hoses to stator cover.
5. Install the crankshaft position sensor and torque
fastener to specifications.
\\ --- '-,
Crankshaft Position Sensor Fastener: 88.5 in-lbs

(10.0 Nm)
6. Connect the stator connector. (

7. Fill the cooling system with 50/50 Premix Extended
Life Coolant. See Coolant Fill I Bleeding, page 4.22
4. Install flywheel remove tool PA-49316 © on the
FLYWHEEL REMOVAL flywheel ® and tighten puller to remove flywheel
assembly.
The flywheel contains powerful magnets. Use caution

when lifting stator cover off of flywheel to avoid
personal injury.
1. Remove stator cover. See Stator Cover Removal,

page 9.19. (
2. Remove the torque limiter gear pin CD and torque
limiter assembly CD.
5. Grasp flywheel assembly and lift off the

crankshaft.

9.20
FLYWH EEL INSTALLATION 5. Install flywheel bolt with washer G) and torque to
specification.
The flywheel contains powerful magnets. Use caution

when installing flywheel onto crankshaft to avoid
personal injury.
1. Clean flywheel and crankshaft taper thoroughly

with isopropyl alcohol or similar.
2. Inspect crankshaft taper surface and replace if
damaged.
3. Apply a bead of Loctite® 641 (Yellow) to the
internal flywheel taper and crankshaft external
taper surfaces. Refer to image below.
TORQUE
Flywheel Bolt:
STEP 1: Tighten both bolt to 133 ft-lbs (180 Nm)
STEP 2: Back out bolt 180° and re-torque to spec.
6. Install stator cover assembly. See Stator Cover

7. Check engine oil level. See Engine Oil Level
Check, page 2.8.
Do not allow Loctite® to contact the starter gear

bearing.
4. Install woodruff key G) and install flywheel

assembly Q) onto crankshaft.

9.21
TROUBLES HOOTIN G CLUTCH/ PRI MARY/ SHIFT

RECOMMENDED
Clutch lever pivot, Clutch lever pivot points Lubricate
bushings need
lubrication
Drive plates catching on Clutch primary driven Replace necessary parts
Clutch Lever Pulls primary driven gear gear I clutch plates
Excessively Hard basket
Clutch rack bearing Clutch rack Replace
damage
Clutch pinion shaft Pinion shaft bearings Replace (
bearing binding
Clutch springs weak Clutch springs Replace
Pressure plate worn or Pressure plate Replace
distorted
Clutch plates worn, Clutch Friction I Replace plates as
warped or distorted Separator Plates necessary
Clutch Slips Clutch rack mechanism Clutch rack mechanism Replace
sticking
Engine oil level low Oil level Correct oil level
(
Oil additives present in Oil quality Replace oil & filter (clutch
oil or used previously plates may need to be
replaced
Clutch lever, pivot, cable, Lever, pivots, bushings, Inspect
or lifter arm sticking bearings, cable
Oil additives present in Oil quality Replace oil & filter (clutch C
oil or used previously plates may need to be
replaced
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 I or Replace
warped or distorted drive plates
Weak clutch springs Clutch springs Replace
(.

9.22

RECOMMENDED
Transmission Will Not Shift Broken shift drum Shift drum Replace shift d rum
Bent shift forks Shift fork Replace shift forks
Worn shift drum Shift drum Replace shift drum
Broken gears Transmission gears Replace broken gear(s)
Damaged/broken bearings Transmission, shift cam Replace bearings that fail

bearings inspection
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
Bent shift shaft (internal) Shift shaft Repair or replace
External shift linkage binding or External shift linkage Repair or replace

damaged
Bent or distorted shift forks Shift fork Replace
Bent or distorted shift fork rails Shift fork rail Replace
Broken transmission components Transmission components Repair or replace
Transmission Hard to Shift Improper clutch operation Clutch Inspect, repair
Incorrect oil viscosity Oil quality Replace engine oil
Incorrect clutch cable adjustment - Adjust
Shift shaft damaged Shift shaft components Repair or replace
Sticking pivot point, bent external External shift linkage Repair or replace
shift linkage
Bent or distorted shift forks Shift forks Replace
Damaged shift drum grooves Shift drum Repair or replace
Shift detent plunger stuck Shift detent plunger Repair or replace
Bent/binding shift fork rails Shift fork rails Repair or replace
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
Damaged shift drum grooves Shift drum Replace
Bent or worn shift fo rks Shift forks Replace
Bent/binding shift fork rails Shift fork rails Replace
Worn engagement dogs on Transmission gears Replace

transmission gears
Transmission Noise Drive belt tension incorrect Drive belt Adjust or replace
Clutch plates bind or drag when Clutch plates I hubs Adjust I repair I replace
clutch is disengaged
Gear /bearing wearI damage Transmission components Inspect I replace

9.23
NOTES

9.24
TRANSMISSION I CRANKSHAFT
CHAPTER IO
GENERAL IN'FORMATION ........................... ... ....... .. ........ ....... .. .. .................... 10.3
SERVICE NOTES ..................................................................................... 10.3
SPECIAL TOOLS ...................................................................................... 10.3
SERVICE SPECIFICATIONS ........... . ...... . ... . ..... .. ........ . ................. ... ..... .. ...... .. 10.3
LOCKING THE CRANKSHAIT FOR SERVICE ......................................................... 10.5
ASSEMBLY VIEWS ......... .. ......... .... . . .. .. ........... . . . ................ ... .... .. ...... ........ .... 10.6
CRANKCASE .......... ... ............. . . . ................ . ...... ....... ..... .... .............. .. ..... 10.6
CRANKSHAIT ........ . ........ . ........... .. .. .... ...... . ...... . ................... ... ............... 10. 7
CRANKCASE BOLT LENGTH AND TORQUE PATTERN .......... . ............ . ... . .................... 10.8
TRANSMISSION 6 SPD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 .10
TRANSMISSION 5 SPD (SCOUT SIXTY) .................................... ... ...................... 10.12
SHIFr DRUM I SHIFr FORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 .14
BALANCE SHAIT ................. .. .. . ........... .. .... . ........... . ............................... 10.15
GEAR TRAIN .... ............................. ..... ...... ... .......... . ........ .... ...... .... ....... 10.16
BALANCE SHAFT SERVICE .......... ......... ...... ................ .... .. ....... ...... .... ...... .. ... 10.1 7
BALANCE SHAIT REMOVAL .............. . ........................................................ 10.1 7
BALANCE SHAIT INSTALLATION .................................................................. 10.17
STARTER DRIVE SERVICE .. .......... ......... ..... . ....... . ... .... ... . .. . ............ .... ......... . . 10.19
STARTER DRIVE REMOVAL ......................................................................... 10.19
STARTER DRIVE INSPECTION ........ . .................. . ...... . ..... . .... .... ..................... 10.19
STARTER DRIVE INSTALLATION ... ........ ...... ... .......... .... ........... ... .. .... ..... .. ....... 10.20
CRANKSHAFT SERVICE ............................ . ................................................. 10.21
CRANKCASE SEPARATION .. .. ................ .. .................................................. . 10.21
TRANSMISSION REMOVAL ...................... . ... . ................... .. .. ...... ............. . ... 10.23
TRANSMISSION INSPECTION ........... .... ........... . ........ . ............. . ............. ... .... 10.24
CRANKSHAFT REMOVAL ............................... .. ..... ... ........... . ............ . ......... 10.26
CONNECTING ROD SIDE CLEARANCE INSPECTION .......... .. .... .. ...... . ...... . ... ... .... .... 10.27
CONNECTING ROD REMOVAL I IDENTIFICATION .... . ........ . ................................... 10.27
CONNECTING ROD INSPECTION (BIG END) ......................... ..... .......... ...... ......... 10.28
CONNECTING ROD BEARING INSPECTION ........................................................ 10.29
CONNECTING ROD BEARING CLEARANCE INSPECTION .................. ..... .. . ............... 10.29
CONNECTING ROD BEARING SELECTION .............. ...... ............ .. .......... .. ........... 10.30
CRANKSHAIT INSPECTION .... . ... .............................................. . ................. 10.31
CONNECTING ROD INSTALLATION .............................................. ..... ............. 10.32
CRANKSHAITCLEANING ..... .. .................................... .... ..... .. ......... . .......... 10.32
MAIN BEARING INSPECTION ................. .... .................................. .... .... . ...... 10.32
MAIN BEARING OIL CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 32
LEFr CRANKCASE ASSEMBLY .... ....... ....... .................... . ......................... ...... 10.33
RIGHT CRANKCASE ASSEMBLY . ... ... . ... ....... . . .............. . ........ ..... .... ... ............. 10.33
CRANKSHAIT INSTALLATION .............. : ................... ..... . .. ....... .. ................... 10.34
TRANSMISSION INSTALLATION .................................................................... 10.34
CRANKCASE ASSEMBLY .... ... ......................... . ......................... . . . .............. 10.35

J 10.1
STAKE NUT INSTALLATION ...... .. ................................................... . ................. 10.37

TROUBLESHOOTIN"G ........................................................... ..... . . . .. .. ........ .. ..... 10.38
TROUBLESHOOTING . . ............. ... ....................................... . .......................... 10.38

10.2
GENERAL INFORMATION
SERVICE NOTES • When locking agents are required, use Loctite®
• Remove engine from frame to service internal Primer N to clean fastener before applying locking
transmission and/ or crankshaft components. agent Primer N reduces cure time of thread locking
SeePreparation For Engine Removal, page 6.4 . agent in addition to preparing the surfaces
• The crankcase must be separated to access internal
transmission components and crankshaft.
• Label and store parts neatly to speed the assembly SPECIAL TOOLS
process and ensure that matched parts like TOOL DESCRIPTION PART NUMBER
connecting rods, camshafts and bearings and
pushrods can be installed in their original location Case Splitting I Assembly PF-51234-A
• Crankshaft main bearing replacement requires line Tool
boring. This procedure requires full machine shop Clutch Holding Tool PF-51612
capabilities and specialized knowledge. It is
recommended that a qualified machine shop Crankshaft Locking Pin PF-52135-A
perform this procedure if it becomes necessary or
replace the crankcase assembly Drive Sprocket Seal Installer PF-51243
• Crankshafts and connecting rods are color coded
for manufacturing tolerances with a white or red Bosch Automotive Service Solutions: 1-800-345-
paint mark (or stamped "R" or W"). 2233 or https:// polaris.service-solutions.corn/
• All torque specifications are "dry" unless specified
for oil or locking agent. Refer to exploded views
SERVI CE SPECIFICATIONS
Connecting Rod I Crankshaft Specifications
PART PART SPECIFIC STANDARD SERVICE LIMIT
Connecting Rod Connecting Rod to .22 - .42 mm (.0087 - .65 mm (.025")
Crankshaft Side Clearance .0165")
Connecting Rod Bearing to .0254 - .0635 mm (.001 - .11 mm (.0043 ")
Crankshaft Oil Clearance .0025")
Connecting Rod Small End 22.01 - 22.02 mm (.8665 - 22.09 mm (.8694")
I.D. .8670")
Connecting Rod Width 21.01 - 21.11 mm (.8271 - 20.76 mm (.8173")
.8310")
Connecting Rod Big End I. 54.992 - 55.000 mm 55.030 mm (2 . 1665")
D. (White) (2.1650 - 2.1653")
Connecting Rod Big End I. 55.000 - 55.008 mm 55.038 mm (2.1668")
D. (Red) (2.1653- 2.1656")
Crankshaft Main Connecting Rod Journal 42.42 - 42.50 mm (1.670 - 43.46 mm (1.627")
Bearing I Rod Journals Width 1.673")
Crankshaft Rod Journal 0. 51.9920 - 51.9999 mm 51.9620 mm (2 .0457")
D. (White) (2.0469 - 2.0472")
J Crankshaft Rod Journal 0. 52.0000 - 52 .0080 mm 51.970 mm (2 .0460")

D. (Red) (1.8888 - 1.8891 ")
Main Bearing Oil Left .013 - .060 mm (.0005 - . IO mm (.004")
Clearance .0023")
Right .014 - .06lmm (.0005
- .0024")
Left Main Bearing Journal 59.9523 - 59.9703 mm 59.9323 mm (2.3595")
O.D. (2.3603 - 2.3610")
9926140 R02 -2015-2016 Scout Service Manual

10.3
PART PART SPECIFIC STANDARD SERVICE LIMIT (

Right Main Bearing Journal 64.9523 - 64.9703 mm 64.9273 mm (2.5561")
0.D. (2.5571 - 2.5578")
.05 - .30 mm (.0019 -
Crankshaft End Play
.0118") -
Balance Shaft Journal O.D., Left (Primary 24.980 - 24.992 mm I
Side) I Journal O.D., Right 24.969 - 24.979 mm -
(Cam Side)
Transmission
Shift Fork 12.00 - 12.026 mm (.4725 - 12.05 mm (.4744")
Shift Fork I.D. (Rail)
.4732")
(
6.036 - 6.136 mm (.2376 - 6.02 mm (.2370")
Shift Fork Pin O.D. .2416")
Shift Fork Rail 11.948 - 11.972 mm (.4704 11.92 mm (.4693")
Shift Fork Rail O.D. - .4713")
Shift Fork Rail Runout - .025 mm (.001")
l
Shift Drum Shift Drum Groove - Replace drum if any wear
is evident
Transmission Information
ITEM SPECIFICATIONS
Drive Train (General) Transmission 6 Speed I 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
C
Gear Ratio: 2nd Gear 1.882: 1
Gear Ratio: 3rd Gear 1.500: 1
Gear Ratio: 4th Gear 1.273: 1
Gear Ratio: 5th Gear 1.125: 1
Gear Ratio: 6th Gear (Overdrive) 1.036: 1

10.4
LOCKING THE CRANK SHAFT 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 ('IDC) 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 2.26.
2. Remove the clutch and primary drive covers. See
Primary Drive Cover Removal, page 9.7.
3. Using a 32mm wrench or socket, rotate the
crankshaft clockwise (primary side) until the front
piston is at 'IDC. See the Camshaft Timing Marks,
page 7 .9 illustration for details.
It may be necessary to rotate the crankshaft slight

forward or back to properly align holes.
4. Locate the two holes (CD and CD in the illustration),

marked "R" for rear piston and "F" for front
piston, beneath the primary drive gear.

10.5
ASSEMBLY VIEWS
CRANKCASE
/
/ -"
"-,( 25 i
i\,24
____/
j\.__ /
-
( 21 ·
\.,_j
# PART DESCRIPTION TORQUE # PART DESCRIPTION TORQUE

CD Dowel, Hollow - @ Dowel, Hollow -
CD Bearing, Needle Shift Shaft - ® Pin, Alignment -
Q) Seal, Shaft Water Pump Oil - ® Pin, Solid M8x20 -
(
© Seal, Water Pump - ® Pin, Solid M8x30 -
G) Nut, Special (18 Nm) ® Seal, Shift Shaft -
© Bearing, Water Pump Shaft - @) Bearing, Needle Shift Shaft -
Bearing, Needle Water Pump
(j) Plate, Bearing Retainer - @
Shaft
-
® Screw, Bearing Retainer (10 Nm) @ Bearing, Ball Shift Drum - C
Bearing, Ball Transmission Bearing, Ball Balance Shaft
® Output Shaft - ® Right -
@) Bearing, Needle Shift Drum - @ Screw, Bearing Retainer (10 Nm)
® Bearing, Cam Idler - @ Retainer, Bearing -
Bearing, Ball Transmission
@ Output Shaft
- @ Bearing, Ball Balance Shaft Left - c..
® Plate, Oil Deflector - ® Input Shaft -
® -
Input Shaft

10.6
CRANKSHAFT
/-----...
! 2 \ ,,-"
(3 )
\_) '- /
CD Bearing, Crankshaft Main (LH) - Non-Serviceable -

<I> Bearings, Connecting Rod (big end) -
CI> Crankshaft, Assembly -
© Circlip, Wrist Pin -
0) Wrist Pin, Piston -
® Piston, Assembly -
(J) Rod, Connecting Assembly -
22 ft-lbs (30.0 Nm) + 90° (tighten bolts
® Bolt, Connecting Rod Bearing Cap (QTY.4)
simultaneously)
® Bearing, Crankshaft Main (RH) - Non-Serviceable -

10.7
CRANKCASE BOLT LENGTH AND TORQUE

PATTERN
Left crankcase bolts 2, 3 and 5 in tightening

sequence are M8xl.25x40 all other bolts are
M8xl.25x75.
(.

10.8
Right crankcase bolt 13 in the tightening sequence is

a MS x l .25x60.
Torque case bolts to specification following the torque

sequence.

10.9
(
TRANSMISSION 6 SPD (
Input Shaft
~'
( 10 ) (
" /
NUMBER DESCRIPTION
G) Plug, Input Shaft
CD Input Shaft, Transmission
CD Gear, 5th Input
© Washer, Flat
® Ring, Retaining
© Gear, 3rd & 4th Input
(j) Washer
C
® Bushing, Plain
® Gear, 6th Input
@) Washer
® Ring, Retaining
@ Gear, 2nd Input

10.10
Output Shaft
NUMBER DESCRIPTION NUMBER DESCRIPTION

G) Washer, Flat ® Bushing, Splined
CD Gear, 1st Output @ Gear, 3rd Output
G) Washer, Flat ® Washer, Flat
© Gear, 5th Output ® Ring, Retaining
® Ring, Retaining @ Gear, 6th Output
© Washer, Flat @ Ring, Retaining
(J) Gear, 4th Output ® Washer, Lock 1T
® Bushing, Splined @ Gear, 2nd Input
® Washer, Lock 15T @ Bushing, Plain
@) Washer, Thrust 15T @) Output Shaft, Transmission

10.11
TRANSMISSIONS SPD (SCOUT SIXTY)

Input Shaft
J~
('-.__1_. /)
C
NUMBER DESCRIPTION
G) Plug, Input Shaft
CD Input Shaft and 1st Gear, Transmission

Spacer, Input Shaft (
CD
© Washer, Flat
® Ring, Retaining (External 28mm)
® Gear, 3rd & 4th Input
0 Washer
® Bushing, Plain
® Gear, 6th Input
@) Washer
® Ring, Retaining
@ Gear, 2nd Input

10.12
Output Shaft
/ '~ /~
( 13 ) (,,_
15 :
,, '
,,,--...,
,,
( 10/ i
NUMBER DESCRIPTION
CD 0-ring
CD Washer, Flat
CD Gear, 1st Output
© Washer, Flat
0) Ring, Dog 5spd
® Ring, Retaining
(J) Washer, Flat
® Gear, 4th Output
® Bushing, Splined
@) Gear, 3rd Output
® Gear, 6th Output
® Ring, Retaining
® Washer, Flat 1TH
® Gear, 2nd Output
@ Bushing, Plain
® Output Shaft, Transmission

10.13
SHIFT DRUM/ SHIFT FORK
. ·.'::..;:::..: ·.,:
~
! 3 )
\.:\
(r
/·-----
('-~_,lu
•. ;'
t ... ... .
C
NUMBER DESCRIPTION
CD Bearing, Shift Drum - Drive Sprocket Side
(i) Bearing, Shift Drum - Primary Side
CD Shift Rail
C
© Shift Rail
® Shift Fork, 1st and 4th
© Shift Fork, 5th & 6th
(J) Shift Fork, 2nd & 3rd
® Gear, 6th Output
® Gear, 3rd & 4th Input
@) Gear, 5th Output
® Shift Drum
(

10.14
BALANCE SHAFT
Balance shaft service requires engine removal and crankcase separation.
CD Bolt, Balance Shaft Gear - MlO x 1.5 x 40 (QTY. l) 59 ft-lbs (80.0 Nm)
CI) Washer -
G) Bearings, Balance Shaft -
Washer, Bearing Retainer Plate -
©
0) Screw, Bearing Retainer Plate - M5 x 0.8 x 12 (QTY.3) -
® Snap-Ring, Balance Shaft Split GearGear, Balance shaft -
(Inner) - Non-Serviceable
(J) Gear, Balance Shaft (Inner) - Non-Servicable -

® Springs, Pre-Load - Non-Serviceable -
Gear, Balance Shaft (Outer) - Non-Serviceable -
®
@) Balance Shaft -
® Key, Balance Shaft Retaining -

10.15
GEAR TRAIN 4th Gear (

1st Gear
C
5th Gear
2nd Gear
6th Gear
3rd Gear
i'\ \
Jl l_
'ts /
V

10.16
BALANCE SHAFT SERVICE

BALANCE SHAFT REMOVAL BALAN CE SHAFT INSTALLATIO N
1. Remove the engine from the chassis. See l. Lubricate balance shaft bearings with engine oil.
Preparation For Engine Removal, page 6.4.
2. Install the balance shaft assembly CD until fully
2 . Separate the engine cases. SeeCrankcase seated in bearing bore.
Separation, page 10.21.
3. Remove crankshaft assembly. SeeCrankshaft
4 . Remove transmission input and output shaft
assemblies. SeeTransrnission Removal, page
10.23.
5. Remove balance shaft retaining bolt CD and washer
Q).
3. Preload the teeth of the split-gear on the balance

shaft and lock in place with a pin punch or similar
tool Q).
6. Grasp balance shaft assembly G) and remove from

right engine case assembly.
7. Inspect sprocket teeth for wear or damage.
8. Check balance shaft for runout , or twisting.
9 . Rotate right and left balance shaft bearings by
hand while observing bearing rotation. Bearings
should run smooth and quiet and shaft should be a
snug fit in bearings.
10. Visually inspect bearings for damage.
9926 140 R02 - 20 IS - 20 16 Scou t Se rvice Manual

10.17
4. Fit the crankshaft assembly into the engine case 5. Install the balance shaft washer © and bolt ® ·
and align the timing marks CD on the crank and Torque to specification.
balance shaft gears as shown.
6. Install the transmission and output shaft

assemblies. See Transmission Installation, page
10.34.
7. Assemble the crankcase. See Crankcase
Assembly, page 10.35.
8. Rotate the engine to verify smooth operation and
install in motorcycle chassis.

10.18
STARTER DRIVE SERVICE

STARTER DRIVE REMOVAL STARTER DRIVE INSPECTION
1. Remove the stator cover. See Stator Cover 1. Inspect gear teeth for chips, cracks or excessive
Removal, page 9.19. wear.
2. Disconnect negative battery cable at battery to 2. Inspect shaft surfaces CD and bushing surface in
prevent starter motor CD from operating. torque limiting gear CD for excessive wear and
scoring.
3. Slide pin CD out of the torque limiting gear CD and
remove from the engine.
3. CD in starter drive crank gear.

Inspect bushing
4. Remove the flywheel assembly to access the 4. Inspectone-way clutch hub surfaces © for wear,
starter crank drive gear and one-way clutch ®· scoring or damage.
SeeFlywheel Removal, page 9.20
5. Inspect one-way clutch earns ® for wear, scoring
5. Lift and rotate the starter crank drive gear © to or damage.
remove from one-way clutch ® on flywheel ®·
6. Replace any worn or damaged components.

10.19
STARTER DRIVE INSTALLATION

1. Install one-way clutch assembly CD onto the
flywheel and torque fasteners CD to specification ..
(
Starter Clutch Screws:
88 in-lbs (IO Nm)
2. Insert the starter drive gear CD into the one-way

clutch CD.
C
3. For proper flywheel installation perform steps 1-5
in Flywheel Installation, page 9.21.
4. Install the starter torque limiter gear © and insert
shaft (J) into the crankcase bore.
::·. .; .;,,_,':, /' . . •. • • ........ . ·1_·_ • : ·; ___~.
l
5. Install the stator cover. See Stator Cover
6. Check engine oil and fill to proper level. See
Engine Oil Level Check, page 2.8.

10.20
CRANKSHAFT SERVICE
CRANKCASE SEPARATION 20. Remove three (Qty 3) M8xl.25x40 engine case
1. Drain engine oil. See Engine Oil I Filter Change, bolts G).
page 2.9.
2. Drain cooling system. See Coolant Drain I Fill,
page 4.20.
3. Remove engine from frame. SeePreparation For
Engine Removal, page 6.4.
4. Mount engine securely on an engine stand using
Engine Stand Adapter tool PF-51609.
5. Remove the cam chains/ chain guides. See Cam
Chain Removal, page 7.15.
6. Remove cylinder heads. See Cylinder Head
Removal, page 7.27.
7. Remove cylinders. See Cylinder Removal, page
8.5.
8. Remove primary cover. See Primary Drive Cover 21. Remove nine (Qty 9) M8xl.25x75 engine case
Removal, page 9.7. bolts Q).
9. Remove clutch assembly. See Clutch Removal, 22. Remove one (Qty 1) M8xl.25x60 engine case bolt
page 9.13. G) from primary drive side of engine case.
10. Remove flywheel. See Flywheel Removal, page 23. Place the Engine Case Splitting I Assembly tool
9.20. PF-51234-A on a flat surface and assemble the MS
11. Remove stator cover. See Stator Cover Removal, threaded spacers © and M 12 threaded spacers G)
page 9.19. into the main plate © as shown. Use only holes
marked with the letter B.
12. Remove the starter drive. See Starter Drive
13. Remove the balance shaft driven gear and drive
gear. See Balance Shaft Removal, page 10.17.
14. Remove the drive sprocket. See Drive Sprocket
Removal, page 12.7.
15. Remove the oil filter. See Engine Oil & Filter
Change, page 2.9Engine Oil & Filter Change,
page 2.9.
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.
18. Remove the speed sensor. See Speed Sensor

Removal.
19. Remove the gear position switch. See Sensors -
Collect the two switch contact pins and springs from

the end of the shift drum so they do not get lost.

10.21
l
25. Position the main plate assembly © onto the 28. Install MG 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. ( 8 )
'-..
11- C
: l ; ~.
26. Install the case splitting adapter (J) through the

Main Plate Mounting Bolts (All): 88.5 in-lbs (10.0 C
center hole in the main plate and thread into nut
Nm)
and washer until 1-2 threads are exposed on the
other side.
29. Holding nut @) stationary with an open ended
wrench, turn the case splitting adapter (J)
clockwise until the engine cases begin to part.
STOP.
C
27. Main plate adjustment: Turn threaded spacers

in or out to raise, lower and level the main
plate.
· . .. . · . IMPORT.ANT : 30. Using a soft-faced mallet, work around the seam of

the engine cases tapping lightly to release the
• Plate surface should be parallel to the surface of sealed bond.
the engine crankcase.
• Plate height is correct when the plate is resting on
the washer and the case splitting adapter contacts
the transmission output shaft.
• All threaded spacers must be in contact with
engine case prior to bolting on the plate assembly.

10.22
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 upper case
with a mallet until the cases are completely apart.
5. As an assembly, lift the input shaft G), output shaft

©, shift forks and shift fork rails G) out of the
engine case.
TRANSMISSION REMOVAL
CAUTION
Gloves should be worn at all times while working on
the transmission assembly to avoid personal injury.
1. Remove the shift ratchet assembly. See Shift

Ratchet Removal I Inspection, page 9.9.
2. Separate engine cases. See Crankcase Separation,
page 10.21.

10.23
TRANSMI SS ION IN SPECTIO N

Input Shaft (
( w') (a) (4)

C
;:-·. !_'.:::::::~:=~=:: ~~: C

~
~·
'
(/ 1 ) (
\..__,-
/.-· '"''\
i 11 )
\.__,/
( 9 )"'
'-....../
NUMBER MEASUREMENT LOCATION DIA.METER SPECIFICATION

G) Gear, 2nd - Input -
CD Retaining Ring, External -
CD Shim-25 x 34 x 0.5 -
G) Gear, 6th - Input 28.000 - 28.021 mm
G) Bushing I.D. - 25.02 - 25.04 mm I O.D. - 27.96 -27.98 mm
® Shim - 25 x 34 x 2 -
(J) Gear, 3rd & 4th - Input -
® Retaining Ring, External -
® Washer, Flat - 28 x 35 -
@) Gear, 5th - Input -
Bushing 28.015 - 28.035 mm (
®
@ Shaft, Input & 1st Gear -
992 6 140 R02 - 2015 - 20 16 Scout Service Manual

10.24
Output Shaft
(' ~8 J.
/
oJ~':iJ:1 r
( 1 ')
'-/
\ 7 ')
'--..../
NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION

CD Shaft, Output -
CD Bushing I.D. - 30.02 - 30.04 mm I 0 .D. - 33.96-33.98
mm
CD Gear, 2nd - Output 34.000 - 34.025 mm
© Washer, Toothed - 30 x 38 -
G) Retaining Ring, External -

© Gear, 6th, Output -
(J) Retaining Ring, External -
® Washer, Toothed - 28 x 35 -
® Gear, 3rd - Output 31.015 - 31.030 mm
@) Bushing, Splined O.D. - 30.975-31.005 mm
® Washer, Thrust - 15 Tooth -

@ Washer, Lock - 15 Tooth -
J
® Gear, 4th - Output 31.015 - 31.030 mm
® Gear, 5th - Output -

@ Washer, Flat - 24 x 35 -
@ Gear, 1st - Output 24.015 - 24.0.35 mm
® Washer, Flat -
9926140 R02 - 20 15- 2016 Scout Service Manual

10.25
10. Inspect shift drum grooves for wear. Pay close (

attention to corners of grooves where forks change
Refer to the Assembly View section in this chapter direction.
for component locations and exploded diagrams.
See Transmission 6 Speed, page 10.10. 11. Inspect surface of shift drum star for excessive
Refer to the Service Specifications section in this wear or damage.
chapter for complete transmission specifications. 12. Inspect right side shift drum bearing.
See Service Specifications, page 10.3.
13. Temporarily install shift drum in right hand case
bearing and inspect fit. Spin drum to check for
Shafts
smooth bearing operation.
1. Measure outside diameter of shafts and bearing
areas for wear and concentricity. Look closely at CRANKSHAFT REMOVAL
splines for wear. Inspect ends of shafts for signs of 1. Separate RH crankcase from LH case. See
wear: Crankcase Separation, page 10.21. C
• Dull finish
• Discoloration 2. Lift crankshaft assembly CD straight up until clear
• Rough or uneven surface of right side engine case.
• Measurement outside of specification
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 C
Check each gear for damage, cracks, wear
(rounding of dogs or surfaces), or discoloration.
Shift Forks, Shift Fork Rails
3. Inspect all contact surfaces of each shift fork.
Replace a shift fork if any part is discolored
(overheated), unusually scored, warped, or worn
beyond service limit. Connecting rod bearings and main bearings are
4. Inspect each shift fork pin for wear or damage and easily damaged. Be careful not to cause damage to
compare to specifications. these parts when servicing items within the
crankcase.
5. Inspect shift fork rails for wear, scoring, or runout.
6. Measure shift fork rail 0. D. for wear in 3 or 4
places along the length. The rail 0. D. should be
consistent over the entire length.
7. Slide rails into crankcase holes and check for a
good snug fit.
8. Visually inspect the shift drum bearing in the left (.
crankcase for wear or damage. The bearing must
be fully seated in the case and held in position by
the retaining plate. Replace the bearing if it is
loose in the bore, or if any side play is detected.
9. Temporarily install shift drum into bearing and
rotate, checking for smooth bearing operation.
Shift Drum

10.26
CONNECTING ROD SIDE CLEARANC E 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 CD between one connecting
rod and the crankshaft. Compare measurement to
specification outlined in this chapter. See Service
3. Remove connecting rod bolts and connecting rod

bearing caps.
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 10.31.
CAUTION
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.
1. Use a permanent marker to mark orientation of

connecting rods and rod bearing caps. These
parts MUST be installed in their original
locations. EXAMPLE: Right connecting rod must
be assembled on the right side with the bearing
cap that was removed from it. The bearing cap and
connecting rod must be assembled in the same
direction as it was removed using the same bolt.

10.27
CONNECTING ROD INSPECTION (BIG END) 3. Apply engine oil to threads of rod bolts. Torque
bolts to specification.
. · IMPORT.ANT
Connecting rod bolts can only be reused three
times. Failure to replace bolts after completing three
torque sequences may result in severe engine
damage. Each time a bolt has been torqued to
specification, it should be marked with a center C
punch.
EXAMPLE:
• 1st Torque: Manufacturer installation of connecting
rod bolts. \ \
• 2nd Torque: Torque for inspection per this ,S:if(\
(
procedure.
• 3rd Torque: Reinstallation following inspection.
-~~\
·~: :.
\\.
Discard bolts the next time they are removed. 1
I. Refer to Piston Pin I Pin Bore Inspection, page

8.1 Ofor connecting rod small end inspection.
CAUTION TORQUE (
Be sure to match connecting rod caps with their Connecting Rod Bolts:
respective rod and orient the cap properly before STEP 1: Tighten both bolts to 22 ft-lbs (30.0 Nm)
installing the cap. Secure the big end of rods in a vise STEP 2: Tighten both bolts an additional 90° ± 5°
equipped with soft, protective jaws before torquing
rod bolts.
4. Measure I. D. of connecting rod big end for size
and out of round and compare to specification. See C
Service Specifications, page 10.3.
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. C
9926140 R02 - 2015 - 2016 Scout Service Manual (

10.28
CO NNECTING ROD BEARING INSPECTION 2. Measure the connecting rod big end bearing I. D.
1. Inspect bearing inserts CD for unusual wear, with a dial bore gauge and record.
peeling, scoring, damage etc. Replace as a set if
damage is noted. Inspect bearing clearance and
refer to Bearing Selection Chart. See Connecting
Rod Bearing Selection, page 10.30.
3. Measure the connecting rod journal on crankshaft

and record.
4. Subtract the journal diameter from the connecting
rod bearing diameter to calculate oil clearance
and compare to specification. See Service
CO NNECTING ROD BEARING CLEARANC E Specifications, page 10.3.
INSPECTION 5. If service limits are exceeded, install new rod
1. Assemble the connecting rod cap with bearings
bearings and recheck oil clearance.
and torque to specification.
6. If service limits are still exceeded, determine if
TORQUE crankshaft or connecting rods need to be
replaced.
Connecting Rod Bolts:
STEP 1: Tighten both bolts to 22 ft-lbs (30.0 Nm)
STEP 2: Tighten both bolts an additional 90°

10.29
CONNECTING ROD BEARING SELECTION (

1. Two different dimension crankshafts were used. Identify the crankshaft by part number and use the
corresponding chart for bearing selection.
Date Code
Part Number
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 C
"W" for White. The letter will be etched onto the outer surface of the counterweight.
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.
Last Digit
"W"-White
"R" - Red
(.
5. Refer to the chart below to select the proper bearing insert.

FOR EXAMPLE: If the CONNECTING ROD grade is RED and the CRANKSHAFT stamp is W (white) (or not
(
stamped), use BLACK bearing inserts.
CONNECTING ROD BEARING SELECTION CHART FOR CRANKSHAFT PN 1204692

Connecting Rod Color Crankshaft Color Bearing Color (PIN Bearing Thickness
3514804-XXX)
WHITE Paint Mark ("W" RED ("R" Stamp) Blue ( - 027)
Stamp) l.409 - l.415 mm

10.30

WHITE Paint Mark ("W" WHITE ("W" Stamp Blue ( - 027)
Stamp) or not marked)
RED Paint Mark ("R" Stamp) RED ("R" Stamp) Blue ( - 027)
RED Paint Mark ("R" Stamp) WHITE ("W" Stamp Orange ( - 159) 1.413 - 1.419 mm
or not marked)

Connecting Rod Color Crankshaft Color Bearing Color (PIN Bearing Thickness
3514804-XXX)
WHITE Paint Mark ("W" RED ("R" Stamp) Blue ( - 027)
Stamp) 1.409 - 1.415 mm
WHITE Paint Mark ("W" WHITE ("W" Stamp Orange ( - 159)

Stamp) or not marked) 1.413 - 1.419 mm
RED Paint Mark ("R" Stamp) RED ("R" Stamp) Orange ( - 159)
RED Paint Mark ("R" Stamp) WHITE ("W" Stamp Black (Std)( - 067) 1.417 - 1.423 mm
or not marked)
CRANKSHAFT INSPECTION 4. Crankshaft and connecting rods are identified by

Record all measurements and compare to color. Be sure to compare measurements to
specifications. Replace crankshaft if any measurement specifications for the proper color (or non-
is worn beyond the service limit. See Service marked) connecting rod or crankshaft.
Specifications, page 10.3. Measure 0. D. of crankshaft rod journal in four
1. Measure the width of the rod bearing journal. places and compare to specifications.
5. Measure O.D. of main bearing journals.
l]J Right
2. Measure width of connecting rods at big end.
t
3. Visually inspect all bearing journals for scoring,
damage or excessive wear.

10.31
CO NN ECTING ROD INSTALLATION MAIN BEARING IN SPECTION

1. Make sure proper bearing clearance is achieved 1. Inspect crankcase main bearing surfaces for wear, C
by using the correct colored bearing insert for a peeling, scoring, or damage.
given color combination of connecting rod and
crankshaft. 2. Inspect alignment of bearing lubrication hole in
right crankcase half CD and left case half CD. Holes
2. Clean all oil off connecting rod, connecting rod must be aligned with their respective oil passage
cap and bearing inserts. in crankcase.
(
3. Install bearing inserts into connecting rods and
caps. First, install bearing tab into groove, then
press the rest of the bearing into place.
Procedure during disassembly called for marking of

connecting rods and caps. Ensure that each part is (
installed in original location including rod cap bolts.
4. Apply assembly lube to connecting rod bearings

and crank pin.
5. Install rods and caps onto the crankshaft,
observing the paint mark on the connecting rods. (
The paint mark must face away from the center
of the crankshaft. Be sure the identifier marks
made previously are aligned.
6. Tighten rod cap bolts: MAIN BEARING OIL CLEARAN CE IN SPECTION
1. Measure main bearing I. D. and concentricity with
TORQUE a dial bore gauge for right and left side. Compare
to specification. Subtract crankshaft main journal
C
Connecting Rod Bolts:
STEP 1: Tighten both bolts to 22 ft-lbs (30.0 Nm) diameter from main bearing diameter to calculate
STEP 2: Ti ghten both bolts an additional 90° oil clearance. See Service Specifications, page
10.3.
7. Check that the connecting rods rotate smoothly
and freely on crankshaft journal.
C
CRANK SHAFT CLEANING
1. Pass cleaning solvent through the oil passages to
ensure that passages are clear.
(
2. If crankshaft dimensions are within tolerances and
oil clearances are incorrect, the crankcase set
must be replaced.
(
2. After cleaning passages, verify crankshaft journals
and oil passage openings are free of debris.
10.32 99261 40 R02 - 20 15 - 20 16 Scout Service Manual (

LEFT CRANKCASE ASSEMBLY RIGHT CRANKCASE ASSEMBLY

Prepare LEFT crankcase for assembly: Prepare RIGHT crankcase for assembly:
Refer to crankcase assembly view for locations and Refer to crankcase assembly view for locations and
torque values. See Crankcase, page 10.6. torque specification. See Crankcase, page 10.6.
1. Clean crankcase and oil passages CD thoroughly. 1. Clean crankcase oil passages CD thoroughly. Rinse
Rinse and dry with compressed air. and dry with compressed air.
2. Install new ball bearings in crankcase as required. 2. Install new bearings in crankcase as required.
• Apply a film of lithium grease to outer race of • Apply a film of lithium grease to outer race of
bearings to prevent galling upon installation bearings to prevent galling upon installation.
• Press on outer race of bearings using an arbor press • Press on outer race of bearings using an arbor press
and a suitable arbor that is slightly smaller than and a suitable arbor that is slightly smaller than
bearing outside diameter bearing outside diameter.
• DO NOT press on inner race of ball bearings • DO NOT press on inner race of ball bearings.
3. Install bearing retainers as required and torque to 3. Install bearing retainers as required and torque to
specification. specification.
Torque Specification
4. Install the scavenge return tube CD with a new o- 7.3 ft-lbs (10 Nm)
ring.
5. Install rear scavenge oil inlet screen assembly G)
4. Install piston cooling jets CD with a new o-ring and
with a new o-ring. See Lubrication System, page
I
Torque Specification
4.8.
5.1 ft-lbs (7 Nm)
6. Install front scavenge oil inlet screen assembly
5. Install pressure lubrication pump oil pickup
with a new o-ring .
Torque Specification screen G) with a new o-ring and torque fastener to
specification. ·
7.3 ft-lbs (10 Nm)
Torque Specification 10
7.3 ft-lbs (10 Nm)

10.33
CRANKSHAFT IN STALLATION 5. Place crankshaft G) into right crankcase half.

(
1. Insert a punch or other suitable object into the

opening G) to align the balance shaft split gear
teeth.
6. Align crankshaft and balance shaft timing marks

©.
(
2. Rotate the balance shaft so the timing marks (I) are

facing the main bearing bore.
C
7. Remove the split alignment tool installed as part of
step 1.
TRANSMISSION INSTALLATION
1. Install balance shaft if previously removed. See
Balance Shaft Installation, page 10.17.
3. Apply assembly paste to main bearings. 2. If transmission shaft bearings were replaced, be
sure all bearing retainer plate screws are installed
4. Hold crankshaft over right crankcase and position and tightened to specification. See Crankcase,
rods so that left side rod is in cutout for rear page 10.6.
cylinder and right side rod is in cutout for the front
cylinder. (
9926140 R02 - 2015- 2016 Scout Service Manual (

10.34
3. Working on a flat surface, assemble the input shaft CRANKCASE ASSEMBLY

CD and output shaft CD so the gears are properly l. Clean crankcase mating surfaces to remove all
meshed. grease, oil, and old sealant.
2. Check to be sure all shafts are seated properly
(crankshaft, balance shaft, shift drum, shift forks,
input shaft, output shaft).
3. Check to be sure that alignment dowel pins and oil
pipes, etc. are in place.
4. Remove the drive sprocket spacer CD and o-ring CD
from the LH crankcase prior to installation.
4. Install shift rails G) into shift forks and assemble to

input and output shafts.
5. Lubricate parts with engine oil. Apply assembly
lube to ends of transmission shafts.
6. Install input shaft CD and output shaft CD, shift forks
and rails G) into the right crankcase. Verify both
shafts are fully seated and rotate freely.
5. Apply a light even bead of Loctite™ Ultra Black
598 to entire case sealing surface.
CRANKCASE SPUTLINB
SEALANT PATH
8. Rotate shift drum to align proper grooves with

forks.
.) 6. Spread sealant into a thin even layer on entire case
9. Move shift fork pins into drum grooves and seat mating surface. Be sure all areas are covered. DO
rails. NOT AIJ..,OW SEALANT TO DRY. CONTINUE
ASSEMBLY UNTIL CASES ARE SEALED AND AlJ..,
10. Install crankshaft. See Crankshaft Installation,
BOLTS ARE TIGHT.
page 10.34.
11. Assemble crankcase. See Crankcase Assembly,
page 10.35.

10.35
(
7. Lower the LH case onto the RH case and install 12. Install the o-ring and drive sprocket spacer (
rnainshaft I crankcase installer PV-45030 CD and removed in STEP 4 with tapered edge toward the
engine case assembly cup PF-51663 © onto the o-ring.
transmission output shaft.
13. Install the gear position switch. See Sensors -
14. Install the drive sprocket. See Drive Sprocket
Installation, page 12.8. (
15. Install the balance shaft driven gear and drive
gear. See Balance Shaft Installation, page 10.17.
16. Install the scavenge oil pump. SeeScavenge Oil
Pump Installation, page 4.14
17. Install the pressure lubrication oil pump.
SeePressure Lubrication Oil Pump Installation , C
page 4.15
18. Install the starter drive. See Starter Drive
19. Install the cam chains. See Carn Chain Installation,
8. Pull crankcase together by tightening nut ® and page 7.15. (
holding tool ® tapping on crankcase with a soft 20. Install the flywheel. See Flywheel Installation,
mallet. page 9.21.
21. Install the clutch assembly. See Clutch Installation,
page 9.18.
22 . Install cylinders. See Cylinder Installation, page
(
8.12.
23. Install cylinder heads. See Cylinder Head
24. Install the primary cover. See Primary Drive Cover
25. Install the stator cover. SeeStator Cover
26. Install engine in frame. See Engine Installation,
page 6.7.
(
The cases will mate before the output shaft is drawn
fully into bearing.
IMPORT.ANT
Continue to turn nut and tap case until sealant
(
squeezes out along the entire perimeter and
resistance is felt when turning nut.
9. Remove the tools from the output shaft.

10. Install crankcase bolts and torque to specification.
See Crankcase Bolt Length And Torque Pattern,
page 10.8.
11. Install a new output seal in LH crankcase using
seal installer PF-51243.

10.36
STAK E NUT INSTALLATION 4. Stake the stake nut as shown below using round
• A stake nut is located on the clutch side of the side of punch. Do not crack or tear staking lip. Do
transmission input shaft CD. not use a sharp chisel to stake the nut.
Be S U/'9 staking tlp dou not tNrlcnicil: In staking •rwL

Stake nut wtth round side of punch.
• Another stake nut is located on the crankshaft drive

gearend (D.
• It is important that they are torqued and staked

correctly for proper function
Do not reuse or reinstall any previously used stake

nut. A new stake nut needs to be installed every time
the nut is removed or loosened.
Use the following procedure to install the stake nuts

.) correctly:
1. Clean threads on shaft so there is no oil or
contaminants.
2. Thread NEW stake nut onto shaft finger tight.
3. Torque stake nut to specification.

10.37
TROUBLES HOOTING (
TRO UBLESHOOTING
RECOMMENDED
Transmission Will Not Broken Shift Cam Shift Cam Replace shift cam
Shift
Bent Shift Forks Shift Fork Replace shift fork(s) C
Worn Gearshift Pawl Shift Cam Replace shift cam
Broken Gears- Transmission Gears Replace necessary parts
Damaged/Broken Transmission, Shift Cam Replace necessary parts
Bearings Bearings
Worn Gear Shift Ratchet Shifter Ratchet Refer to chapter 9
Mechanism
Broken or out-of-place Shift Ratchet Spring Refer to chapter 9
spring on shift ratchet
Shift Detent Ratchet Stuck Shift Ratchet Repair as necessary
(
Seized Pivot Point, Bent External Shift Linkage Repair as necessary
External Shift Linkage
Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails
Fork Rails
Debris From Broken Parts Transmission Repair as necessary
Locking Transmission Components (
Excessive Noise Related Worn Main Bearings Crankshaft and/or Repair as necessary
to Bottom End of Engine Crankshaft Bearings
Worn Connecting Rod Connecting Rod Bearings Repair as necessary
Bearings and/ or Connecting Rod
and/or Rod Bearings C
Worn Connecting Rod Connecting Rod, Repair as necessary
Small End Bushing Connecting Rod Bushing,
Piston Pin, Piston
Worn, seized, chipped or Transmission Gears Repair as necessary
broken gear teeth
(.
Worn, seized, chipped or Transmission Bearings Repair as necessary
broken Transmission
Bearings
Originates from Primary Clutch, Oil Pump Drive Repair as necessary
Cover
Oil Pump Oil Pump, Oil Primp Drive Refer to chapter 4
C
Cam Drive Cam Chain, Cam Refer to chapter 7
Sprocket

RECOMMENDED (
Transmission Hard to Shift Improper Clutch Clutch Refer to chapter 9

Operation
9926140 R02 - 20 15 - 2016 Scout Service Manual (_

10.38

RECOMMENDED
Incorrect Oil Viscosity Engine oil and filter Refer to chapter 3
Incorrect Clutch Clutch Adjustment Refer to chapter 3
Adjustment
Bent, Rubbing, Sticky, Shifter Ratchet Assembly Refer to chapter 9
Broken Shift Shaft
Sticking Pivot Point, Bent External Shift Linkage Repair or replace
External Shift Linkage components as necessary
Bent or Distorted Shift Shift Forks Replace bent shift fork
Forks
Damaged Shift Drum Shift Drum Replace damaged shift
Grooves drum
Shift Ratchet Bent I Stuck Shift Ratchet Repair as necessary
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
of Gear
Worn Shift Drum Pawls or Shift Drum or Shift Replace damaged shift
Shifter Ratchet Linkage drum or shifter ratchet
Broken Shift Ratchet Shift Ratchet Spring Replace spring
Spring
Damaged Shift Drum Shift Drum Replace shift drum
Grooves
Bent, Worn, Distorted Shift Forks Replace shift forks
Shift Forks
Bent or Distorted Shift Shift Fork Rails Replace shift fork rails
Fork Rails
Worn Engagement Dogs Transmission Gears Replace necessary parts
on Transmission Gears

10.39
NOTES
(_
(_

10.40
FRONT WHEEL I SUSPENSION
CHAPTER 11
GENERAL INFORMATION ....... . . . ................ . ............... . .... . . . .......... . .. .. ............. 11.2
SERVICE NOTES . ............. . ........................................................... . .......... 11 .2
SPECIAL TOOLS .. ............ .. ........ . ................ . ........................................ ... . 11.2
TORQUE SPECIFICATIONS ........................ . ............................. .. ..... . .......... . .. 11.2
SERVICE SPECIFICATIONS ............. .. .............................. . ...... .... ................ . . 11.3
ASSEMBLY VIEWS ....................................................................................... 11.4
CONTROLS ............................................................ . ... . ......................... 11.4
HANDLEBAR ....................................... . ............ . .................................... 11.6
TRIPLE CLAMP .. . .......................................... .. .. . ..................................... 11. 7
FRONT FORK ASSEMBLY ...................................... . ... .. ................................. 11.8
FRONT WHEEL ... . . . .. . .... . . . ............. . .... . . . .............................. . ................. 11.10
SERVICE PROCEDURES ....... . ................. . ......... . ............. . . .. ... . ..................... 11.11
HANDLEBAR REMOVAL I INSTALLATION . .............................. . .............. . ........ . .. 11.11
CLUTCH CABLE REMOVAL I INSTALLATION ........... . .. . ........................................ 11.12
FRONT WHEEL REMOVAL I INSTALLATION .... . ................................................... 11.13
FRONT AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
FRONT WHEEL INSPECTION .............. . .. . ...................... . .............................. 11.14
BRAKE DISC REMOVAL I INSTALLATION .... . ................................................... . . . 11.14
FRONT WHEEL BEARING INSPECTION ......................... . .... . ............................. 11.15
FRONT WHEEL BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
FRONT FORK REMOVAL .............. . ...... . .............. . ... ... .... .. .......................... . 11.16
FRONT FORK DISASSEMBLY .................. . ........................ . ........................... . 11.18
FRONT FORK INSPECTION .................................................. . ...................... 11.21
FRONT FORK ASSEMBLY ....... . ................. . .......................... . ........ . ............. 11.22
FRONT FORK INSTALLATION ............. . ... . ..................................................... 11.25
TRIPLE CLAMP REMOVAL ................. . .............................. . ................. . . . ..... 11.26
TRIPLE CLAMP INSTALLATION I STEERING HEAD BEARING ADJUSTMENT ........................ 11.27
TROUBLESHOOTrnG ................................ . ..................................... . .......... 11.30
TROUBLESHOOTING . . . . ... . ...................... .. ... . .............. . ...... . .... . ................ 11.30

11.1
(
GENERAL INFORMATION
SERVICE NOTES SPECIAL TOOLS C
,·.:_·. ,...... ,.\w~G . , ... _ ·_ TOOL DESCRIPTION PART NUMBER
Indian Motorcycles are produced using the Fork Spring Compressor PV-49463
designated tires listed as original equipment. This
includes field testing to ensure stability and superior Fork Spring Compressor
Adapter I Cartridge Tool PF-51664-2
handling. The use of tires other than original (
equipment may cause instability which could lead to Fork Oil Seal Driver PF-51610
a crash, resulting in serious injury or death. Use only
the recommended tires inflated to the recommended Fork Seal Installation
PF-51611
tire pressures based on load conditions as listed on Tool
the tire information label. Tubeless tires are used on Wheel I Stem Bearing
certain Indian Motorcycle models. Operating the PF-51324
Removal I Installation Kit (
motorcycle with damaged rims creates a safety
hazard including air pressure loss, steering Spanner Socket
imbalance and/or reduced steering control. Do not (Steering Stem) PV-43508
attempt to repair or straighten damaged rims.
CAUTION TORQUE SPECIFICATIONS

Work performed to the front end of the motorcycle PART DESCRIPTION TORQUE C
usually involves supporting the machine with the SPECIFICATION
front end elevated. Take precautions so that the ABS Pulse Ring I Brake Disc 22 ft-lbs (29.8 Nm)
motorcycle is securely supported when the front tire Bolts
is off the ground. This reduces the possibility of
personal injury or damage to the motorcycle. Cartridge Screw, Fork 17 ft-lbs (23.0 Nm)
Clutch Lever Cap Screw 84 in-lbs (9.5 Nm)
Leaking front fork seals are a safety hazard and should
be replaced immediately if a leak is found. Fork oil Fork Cap to Jamb Nut 11 ft-lbs (14.9 Nm)
could contaminate front brake components which
could reduce stopping ability of the motorcycle. Fork Cap to Outer Tube 16 ft-lbs (21.6 Nm)
Contaminated brake discs or pads greatly reduce
available stopping force & increase stopping distance. Front Axle 52 ft-lbs (70.5 Nm)
Brake discs can be cleaned using commercially Front Axle Pinch Bolts 18 ft-lbs (24.4 Nm)
available brake cleaner. NEVER attempt to clean
contaminated brake pads. Replace pads as a set. Front Master Cylinder 84 in-lbs (9.5 Nm)
• Refer to Chapter 2 for MAINTENANCE of front end LH Switch Cube 31 in-lbs (3.5 Nm)
components.
• Refer to Chapter 13 for TIRE REMOVAL, REPAIR, RH Switch Cube 31 in-lbs (3.5 Nm)
& BALANCING
• Refer to Chapter 14 for BRAl{E SYSTEM service Riser Bolts 60 ft-lbs (81.3 Nm)
and repairs.
Riser Cap Bolts 22 ft-lbs (30 Nm)
Steering Lock Bolts 18 ft-lbs (24.4 Nm)
Steering Stem Adjuster Nut 29 ft-lbs (39 .3 Nm)
(.
Triple Clamp Nut, Top 72 ft-lbs (97.6 Nm)
Triple Clamp Pinch Bolts (All) 18 ft-lbs (24.4 Nm)
(_
11.2 9926140 R02 - 2015 - 2016 Scout Service Manual l

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.)
Fork Tube Diameter 41 mm (l.6lin.) Not Applicable
Fork Tube Runout - .20 mm (.008 in.)

Fork Oil Type Indian Motorcycle Fork Oil (PN: 2880015)
Fork Spring Pre-Load 42 mm (1.65 in. ) Not Applicable
5.0 N/ mm - 12.0 N/ mm
Fork Spring Rate Not Applicable
(0.042 - 0.106 lb/in)
Fork Spring Free Length 457.9 mm (18.02 in.) -
Oil level must be measured
Fork Oil Capacity (per leg,
and adjusted to 335cc Set Level
dry)
specification.

11.3
(
ASSEMBLY VIEWS
CONTROLS
(D Screw, LH Switch Cube 36 in-lbs ( 4 Nm) Tighten Top Two Screws First
@ Screw, Clutch Perch Clamp 145 in-lbs (16 .38 Nm)

Bolt (
(_
11.4
9926140 R02 - 2015 - 2016 Scout Service Manual l
PART TORQUE (IF APPLICABLE)

NUMBER NOTES
DESCRIPTION
Screw, RH Switch 36 in-lbs (4 Nm) Tighten Top Two
G)
Cube Screws First
-
Screw, Brake Lever
© Cap
12 ft-lbs (16 Nm) -
® Grip, Throttle - Ridge goes toward rider.

11.5
HANDLEBAR
(
G) Bearing, Ball -
CD Nut, Steering Head -
Bolt, Upper Fork Clamp - MS x 1.25 x 18 ft-lbs (24.4 Nm) See Tightening Procedure
CD 30 (QTY.2) Outlined in this Chapter
© Washer -
72 ft-lbs (97.6 Nm) See Tightening Procedure
0) Nut, Top Triple Clamp
Outlined in this Chapter
Bolt, Speedometer - MS x 1.25 x 40 22 ft-lbs (29.8 Nm) Tighten Front Bolts First,
® (QTY.4) then Rear
(.

11.6
TRIPLE CLAMP

72 ft-lbs (97.6 Nm) See Tightening
CD Nut, Top Triple Clamp
Procedure Outlined in this Chapter
CD Washer -
Bolt, Upper Fork Clamp - MS x 1.25 x 18 ft-lbs (24.4 Nm) See Tightening
G) 30 (QTY.2) Procedure Outlined in this Chapter
© Triple Clamp, Upper -

See Tightening Procedure Outlined in this
0) Nut, Steering Head
Chapter
© Bearing, Ball - 47 x 25 x 12 -
(J) ASM, Lower Bracket -
® Bearing, Sealed - 22 x 55 x 17 -
® Steering Lock -
Bolt, Steering Lock- M6 x 1.00 x 10
@) 77 in-lbs (8 . 7 Nm)
(QTY.2)
Bolt, Lower Fork Clamp - MS x 1.25 x 18 ft-lbs (24.4 Nm) See Tightening
® 30 (QTY.4) Procedure Outlined in this Chapter

11.7
FRONT FORK ASSEMBLY (
I
/
,r-- ---
-- I
I
/
I /''"'',
',.__j/
;9 i I
I
r, ---
1-1- / 11 \
I \ )
~ .
'- . / (
~10 )
a ;'/
~
§
,.-." u
tt,·
- ....' , ... _./ I
~ I
i~ (
I I II
/ It1
!
I
/I
I
I ff .,.-,,
I I
!
I -1,~,
I! ( 13 ; j
j !'l , . . . ./
.;I !I!.f
I (
I
I
II
I i I C
I
j
II
I
ff! I!
I
I
I
I ~
__~ -'.14)
l
-- ,I ,. _j

11.8
NUMBER PART DESCRlPTION TORQUE (IF APPLICA,BLE)
CD Assembly, Fork Leg -

CD Slide, Metal -
G) Washer -
© Oil Seal -
G) Snap Ring -
® Dust Seal -
(J) Assembly, Cap 16 ft-lbs (21. 6 Nm)
® Spacer -
® Washer -
@) Spring -
® Assembly, Cylinder -
@ Oil Lock -
® Fork Tube , Inner -
® Bushing -
@ Packing -
@ Bolt 17 ft-lbs (2 3.0 Nm)

11.9
FRONT WHEEL
I /----....,
(. __5,/\
\ (
I 2 I
\._...../
(
CD Bearing Spacer, Outer -

0 Wheel Bearing -
G) Bearing Spacer, Inner -
© Brake Disc -
® Ring, Tone, ABS -
© Screw, Pulse Wheel I Brake Disc - MS x 25 (QTY.5) 22 ft-lbs (29.8 Nm)

11.10
SERVICE PROCEDURES
HANDLEBAR REMOVAL/ INSTALLATION 6. Remove Throttle Grip ®·
Clutch cable must be routed, installed, and

adjusted correctly to function properly. Note how
cable is routed and secured before removing the
cable. Permanent cable damage may result if the
inner cable is bent or twisted during installation.
If the cable is incorrectly routed, installed, or
adjusted, serious injury or death may occur.
CAUTION
Cover painted or chrome parts to prevent damage.
Use care to protect fuel tank and front fender. Tank
removal is recommended. Secure, set aside, or
support parts as they are removed.
CAUTION
Keep brake reservoir in an upright position to
1. Place motorcycle in an upright position with the prevent air from entering the system. Bleeding is
front wheel clamped in a wheel vise
required if air enters the system.
2. Remove left hand Switch Cube screws CD.
3. Remove Clutch Lever perch screws CD. 7. Remove four speedometer screws®·
4. Remove Right hand Switch Cube screws CD. Re- 8. Press tab (j) down to remove the connector from
move Switch Cube. speedometer.
5. Remove Master Cylinder screws©. Place Brake as-
sembly in position that allows hose not to be
stressed.
,/

11.11
(
9. Lift handlebars out of upper triple clamp. CLUTCH CABLE REMOVAL/ INSTALLATION
Make an index mark on the handlebar along the
parting line of the riser cap to ensure proper Clutch Cable Removal
handlebar position upon reassembly. 2. Remove the cable routing clip CD and the clutch ca-
ble jam nut Q). (
10. Installation is performed by reversing the removal
procedure.
11. Line up the handlebar index mark made in STEP 9
and torque speedometer, starting with the front
bolts, to specification.
C
Speedometer Bolts: 22 ft-lbs (29.8 Nm) Tighten
Front Bolts First, then Rear
3. Protect the clutch release arm Q) with a shop towel.

Using an adjustable wrench, rotate the release arm
inward. Disconnect clutch cable from release arm.
C
, . ,/''
,/'
4. Withdraw the clutch cable from the mounting boss

located on the primary cover.
5. At the handlebar, pull the clutch cable casing
straight out until clear of lever perch and rotate ca-
ble outward to align inner cable wire with slot in
lever.
6. Pull lever slightly until slotted opening in lever is
clear of perch and slide cable barrel end down and
out oflever.
7. Note routing of clutch cable through frame.
8. Remove the clutch cable.
1. Clutch Cable Installation

11.12
CAUTION CAUTION
Do not kink, bend, or twist the inner cable or outer CALIFORNIA MODELS : Remove the charcoal canister
cable casing during installation prior to raising motorcycle wheels off the ground. As
the swingarm lowers it can contact the canister hose
fittings and damage them.
2. Route clutch cable in the same manner as removed.
3. Apply multi-purpose grease to the lever end of the 1. Secure the motorcycle in an upright position with
cable and install it in the clutch lever at the tie-down straps and a platform jack positioned
handlebar. beneath the engine cases.
4. Install the casing in the lever perch at the
handlebar.
5. Install cable in the mounting boss located on the
primary cover.
6. At the release arm end of the cable, pull the inner
cable until fully extended. Be sure the upper end of
the cable casing is seated in the lever perch at han-
dlebar end.
7. Apply multi-purpose grease to the lower barrel
end of the cable.
8. Rotate the release arm inw ard (as in STEP 3) until
cable can be installed in release arm.
9. Adjust clutch cable free play. See Clutch Lever Free
Play, page 2 .17.
FRONT WH EEL REMOVAL / IN STALLATION Do not operate the front brake lever with the calipers
or w heel re moved.
This procedure requires raising and supporting Removal

the motorcycle so that the front wheel is off the
ground. Precautions should be taken to ensure 2. Remove the front fender. See Front Fe nder
the motorcycle is properly stabilized at all times. Removal, page 3.9.
Failure to properly support motorcycle may result
3 . Loosen axle pinch bolts CD on lower right fork leg.
in personal injury or damage to the motorcycle.
CAUTION
- --
Do not twist the brake hose or brake line. Do not
\ \
allow calipers to hang from the brake hose. Secure
calipers in such a way to avoid hose damage.
99 26140 R02 - 20 IS - 20 16 Scout Se rvice Manual

11.13
4. Support wheel and remove axle (D. Spacers are FRONT WHEEL INSPECTION
loosely retained by the dust seals, but may fall out 1. Install front wheel in truing stand.
after wheel has been removed.
Bearings must be in good condition to accurately

measure runout.
2. Set up a dial indicator to measure radial runout (up (

and down) (A) and compare to specifications. See
Service Specifications, page 11.3.
3. Position dial indicator to measure axial runout
(side to side) (B) and compare to specifications.
See .Service Specifications, page 11.3.
Measurements should
be taken from inner
wheel surfaces.
/
Installation
5. Install front wheel and spacers into fork. (
6. Install the axle and torque to specification.
~:52ft-lbs~
1
·1-
i•>1J·1 t
7. Cycle the front suspension. Tighten axle pinch (

bolts to specification.
4. Visually inspect wheel for cracks.
5. Replace wheel if it fails visual or measured
Axle Pinch Bolts: 18 ft-lbs (24.4 Nm)Tighten each inspection. Do not attempt to straighten cast or
screw once after initial torque wheels.
C
8. Install front fender. See Front Fender Installation, BRAKE DISC REMOVAL/ INSTALLATION
page 3.10. 1. Remove front wheel. See Front Wheel Removal I
FRONT AXLE INSPECTION 2. Position wheel with brake disc and ABS tone ring
1. Place axle in V-blocks and inspect runout. (if equipped) facing up.
Compare to specifications in this chapter. See
Service Specifications, page 11.3. 3. Remove and discard brake disc I tone ring screws
CD.
2. Replace axle if it fails inspection. Do not attempt to

straighten a bent axle.

11.14
4. Remove tone ring CD and brake disc G) from 2. Check bearings by turning inner race by hand.
wheel. • Look for signs of discoloration, scoring, galling, or
contamination from moisture or dirt. Replace
,//,,···
bearings if any of the above are present.
• Turn the inner race of the bearings. The bearings
/
/ \ 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 .
. /-- \ _~ CAUTION
'- Do not reuse bearings after removing them from the
~ ~ wheel. Removal damages the bearings internally.
~
4. Inspect bearing fit into wheel hub. The outer race

5. Installation is performed by reversing the of the bearing must fit tightly into the bore. You
removal procedure. Use new brake disc bolts should not be able to move it (or remove it) by
for installation hand. Replace the wheel if outer race of a new
bearing does not fit tightly in the bore.
6. Torque new brake disc bolts to specification in a
star pattern.
FRON T WH EEL BEARIN G INSPECTIO N
Inspect bearings installed in the wheel. Do not

remove to inspect. Bearings cannot be repacked.
Replace both wheel bearings if one or both fail
inspection, or if either bearing was removed.
1. Visually inspect bearing seals CD on each side for

wear or damage .
/
. \
\

11.15
FRONT WHEEL BEARING REPLACEMENT FRONT FORK REMOVAL

CAUTION ---_- . : ,,.. ~-... · . -- A " .. - ·. - ._: <._?':-. -: :-:, . :_
; "···-· . '' -.. _, ... W~NING . ....~,,,_,,;,·-.· :_·-
Do not reuse bearings that have been removed. This procedure requires raising and supporting
,_ ·., . ·- ·-· NOTE .:. ground. Precautions should be taken to ensure
~+~":!"' •:. •--;. ~- : · ~. ·,. ·. ' • •-. • .: • the motorcycle is properly stabilized at all times.
This procedure requires the Wheel Bearing Removal Failure to properly support motorcycle may result (
I Installation Kit (PF-51324). Refer to special tool in personal injury or damage to the motorcycle.
manufacturer instructions for proper use of tool.
,. ...
1. Remove front wheel. See Front Wheel Removal I CAUTION
Installation, page 11.13. Do not twist the brake hose or brake line. Do not
allow calipers to hang from the brake hose. Secure
2. Remove brake discs. See Brake Disc Removal I
3. Carefully remove both seals using a suitable seal
removal tool and discard. Be careful not to scratch CAUTION
the seal bore. CALIFORNIA MODELS: Remove the charcoal canister
prior to raising motorcycle wheels off the ground. As
the swingarm lowers, it can contact the canister hose
1. Remove front fender. See Front Fender Removal,

page 3.9.
2. Secure the motorcycle in an upright position with
tie-down straps and a platform jack positioned (
beneath the engine cases.
(
4. Refer to special tool manufacturer instructions to
remove bearing from LH side of hub.
5. Remove bearing.
6. Remove spacer.
7. Extract or drive bearing from RH side of hub. (
8 . Installation: Use the Wheel Bearing Removal I
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, page 14.24.
12. Install the brake discs. See Brake Disc Removal I
13. Install the front wheel. See Front Wheel Removal I

11.16
FRONT WrlEEL I SUSPENSION
4. Remove front wheel. See Front Wheel Removal I 8. Slide fork leg down and remove.
5. Remove turn signal assembly by removing bolt CD
and nut CD.
f
·,' :
\.... ·-.., ___ ... /

/ "\.·\.:·· ··· ,,
6. Loosen top triple clamp pinch bolt CD .
....,.-·
7. Loosen lower triple clamp pinch bolts © .

11.17
(
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).
Refer to appropriate Front Fork Exploded View.

Clean fork tubes before disassembly.
Two types of fork caps have been used an "early" C

and "late" design. The "early" design cap is flat on
top with M37xl .5 threads and the "late" design cap
has a raised circle in the center with M35 x 1.5
threads. The caps and fork tubes are not
interchangeable between designs.
1. Secure Fork Spring Compressor (PV-49463) CD

vertically in a vise with drive bolt UP. Wear eye I face protection. Be sure spring is
engaged properly with pegs of tool as you compress
the spring in the following steps.
3. Mount special socket adapter(PF-51664-1) Q) and (

30mm socket in spring compressor (PV-49463).
Center socket adapter (PF-51664-1) in holding
fixture with all thumb screws G).
/~ \
l'-._1
_,/I

11.18
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.
5. Place special tool (PV-49463) in soft jawed vise 9. Remove Spring (J) from fork tube.
with the drive bolt © facing up. Adjust length of
spring compressor by turning drive bolt (4) as
required until fork cap is captive in socket.
(7-)----·
10. Pour fork oil out of tube assembly.

11. Remove fork cartridge by inserting Fork Cartridge
Tool (PF-51664-2) with a 3/ 8" extension into fork
6. Rotate fork tube until cap is unscrewed completely tube.
from fork tube.
/]
u
7. Back off spring compressor and remove special

socket along with Cap assembly.

11.19
(
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.
®·
18. Remove Washer.

14. Carefully lift dust seal out of outer fork tube with a
small flat screwdriver.
(

11.20
19. Remove Slide ® · 3. Inspect slider CD for dents or other indentations

due to rocks or other road debris or damage. If
damage is found on exterior of slider, insert fork
tube into slider and move the tube through the
complete travel range. Check for resistance or
binding in the damaged area. If binding or
resistance is evident, replace the slider.
r1i~
,___ , ----
/
(,-----..
\,_2./;
20. Remove the lower bushing from the inner tube.
4. Inspect oil lock valve G) for scoring, excessive or

abnormal wear.
FRONT FORK IN SPECTION

1. Measure fork spring free length and compare to
specifications on Service Specifications, page
11.3.
5. Visually inspect the damper rod p iston ring ©.

Replace component if scoring, deep scr atches
2. Inspect fork stanchion tube CD for scoring, heavy and/or excessive wear is noted.
scratches, dents due to rock s or other road debris,
or e xcessive wear. Replace tube (s) if deep
scratches, pitting, or dents are found.
99261 40 R02 - 201 5 - 20 16 Scout Se rvice Manual

11.21
(
6. Place fork tube in V-blocks and measure runout. 2. Lubricate and install a new lower.bushing on inner
Replace the tube if runout exceeds service limit fork tube.
listed at Service Specifications, page 11.3.
, ._ , -~ ~ -. !
=-.:;;ic;
.
'
.. •
.. .. =~
'
..
. .
:"I
'\ , ~ - =·=3 ::::

- . .......
(
Do not attempt to straighten bent fork tubes. Doing

so will weaken the tube and make the motorcycle
unsafe to operate. 3 . Apply a light film of fork oil to outside edge and
inside seal lips of new oil seal.
FRO NT FORK ASSEMBLY

Install oil seal with markings facing UP (toward top of
tube and retaining ring).
Clean all parts prior to assembly.
1. Lubricate and install new bushing @ into fork

slider. C
(\'.,,,_../
2\--:- ---
4. Install Fork Seal Installation Tool (PF-51611) on

fork tube.
9926 140 R02 - 20 IS - 2016 Scout Service Manual

11.22
5. Lubricate the surface of the inner fork tube and 9. Wipe away any excess grease or oil. Install dust
slide backing washer and new oil seal onto fork seal (use opposite end of Fork Seal Tool (PF-
tube. 51610) until fully seated in outer tube.
6. Insert fork tube in fork leg. Cylinder Installation

7. Use the Fork Seal Tool (PF-51610) © to install oil 10. Be sure screw threads in bottom of Cylinder
seal until seated. Be sure top edge of seal is past Assembly are clean and not damaged.
(below) retaining ring groove.
11. Place Cylinder Assembly @) along with Oil Lock ®
into fork slider. Carefully align bottom of Oil Lock
with recess in bottom of fork.
8.. Install a new retaining ring (J) fork tube.

11.23
12. Prevent fork cartridge cylinder from turning by 18. Seal top of tube with your hand and push
inserting Fork Cartridge Tool(PF-51664-2) with a downward against air pressure. Hold for 10- 15
3/ 8" extension into fork tube. seconds. This will help force trapped air from
cartridge and tube.
() (
13. Install a new cylinder screw ® and a new crush

19. Mount fork assembly upright in a soft jawed vise
washer ® . by brake caliper mounts on slider.
20. Install Spring (J) into fork tube.
14. Torque cylinder screw to specification.
21. Place Washer © and Spacer ® on top of spring.

Place Fork Cap on Spacer. (
Oil Filling I Cartridge Air Bleeding

15. Set fork leg upright.
16. Lift tube to top of travel range.
17. Tip fork leg at an angle to reduce air bubbles.
Slowly add 335cc of Indian Motorcycle fork oil.

11.24
22. Install fork spring socket adapter (PF-51664-2) in FRON T FORK IN STALLATION
compressor as outlined for disassembly.
23. Slowly compress fork tube assembly with drive nut
Clean the fork tubes and the clamping surfaces of the
© until fork cap enters the outer tube, and threads triple clamps to remove any oil or grease prior to
start to make contact. installation.
1. Install one fork tube assembly into lower triple

clamp.
/~----....
( 4 '.' --- - -
' , ...,,/
24. Rotate outer tube to start cap. Use care to avoid

thread damage.
2. Continue to slide tube through lower triple clamp

and into upper triple clamp. Stop when the top of
the fork cap is flush with the top of the upper triple
clamp.
' '
\
25. After cap thread is started, continue to turn tube \
and adjust spring compressor pressure as
required until cap is fully seated against top of
outer tube.
26. Tighten fork
specification.
cap to outer tube. Torque to
3.
\
Torque the bottom bolt on the lower triple clamp
CD.

11.25
(
4. Torque the top bolt on the lower triple clamp CD. TRIPLE CLAMP REMOVAL
·_.· ·..-;_ -: . :' - .. A. WARNING . . . . . . '. . ...
This procedure requires raising and supporting
ground. Precautions should be taken to ensure
the motorcycle is properly stabilized at all times.
Failure to properly support motorcycle may result (
in personal injury or damage to the motorcycle.
CAUTION
Do not twist the brake hose or brake line. Do not
allow calipers to hang from the brake hose. Secure C
5. REPEAT steps 3 - 4.
CAUTION
6. Torque the upper triple clamp bolt CD. CALIFORNIA MODELS: Remove the charcoal canister
prior to raising motorcycle wheels off the ground. As
the swingarm lowers it can contact the canister hose
1. Secure the motorcycle in an upright position with

tie-down straps and a platform jack positioned
beneath the engine cases.
..,'
Lower Triple Clamp Bolts: 18 ft-lbs (24.4 Nm)

Upper Triple Clamp Bolt: 18 ft-lbs (24.4 Nm)
7. Repeat steps 1 through 6 for the other fork tube. (

8. Install brake line guides (if removed).
9. Install front wheel. See Front Wheel Removal I
Installation, page 11.13. Do not operate the front brake lever with the calipers
10. Install brake caliper. See Front Caliper Service, or wheel removed.
page 14.24.
2. Remove the front fender. See Front Fender
11. Install front fender. See Front Fender Installation, Removal, page 3.9.
page 3.10.
3. Remove front wheel. See Front Wheel Removal I
12. Inspect all bolts for proper torque. Inspect hoses Installation, page 11.13.
and wiring for proper routing.
4. Remove Speedometer assembly.
13. Lower front end of motorcycle to the ground and
test front suspension I fork operation. 5. Remove Headlight assembly.
6. Remove the handlebar I riser assembly. See
Handlebar Removal I Installation, page 11.11 .
9926 140 R02 - 20 15- 20 16 Scout Service Manual

11.26
7. Remove fork tubes. See Front Fork Removal, page 11. Remove stem adjuster nut CD with a suitable
11.16. spanner socket.
8. Remove brake line guides from upper and lower
triple clamp.
9. Remove center nut CD and washer on upper triple
clamp.
Support lower triple clamp while removing the

adjuster nut.
10. Slide upper triple clamp off steering stem. 12. Remove lower triple clamp, with steering stem,
and lower bearing (outer race will remain in head
tube).
13. Inspect bearings and bearing races.
TRIPLE CLAMP INSTALLATION/ STEERING

HEAD BEARING ADJUSTMENT
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 I
stem to frame.
'' ~
1 '/

11.27
3. Grease and install upper bearing Q) onto stem and 10. Set upper triple clamp in place on stem. Install
push it down until seated in upper bearing race. washer © and nut ® and tighten top nut until it is
finger tight.
4. Screw adjuster nut CD (shoulder side down) onto

the steering stem until it is finger tight.
~
Nut will be torqued after fork tubes are installed.
~ ~· 3 :
" 11. Slide fork tubes through lower triple clamp and
___,,,/ '
into upper triple clamp. Align top edge of fork cap
with top edge of upper triple clamp and hold in
position.
12. Tighten top triple clamp pinch bolt enough to hold
tubes in place. Leave lower triple clamp pinch
bolts loose.
13. Torque the top steering stem nut to specification.
5. Turn triple clamp assembly fully to the right.

6. Torque adjuster nut to specification using suitable
spanner wrench.
CHECK STEERING STEM BEARINGS at this time. Pull
firmly on fork tubes with a front-to-rear motion. If
movement can be felt in steering bearings,
Steering Stem Bearing Adjuster Nut: 29 ft-lbs (39.3 disassemble and go back to STEP 10. Tighten
Nm) steering stem adjuster nut an additional 5 degrees,
and reassemble following STEPS 10-15. Repeat this
7. Place a mark on the frame in alignment with one of procedure until no play can be felt.
the slots on the adjuster nut.
8. Turn lower triple clamp from lock to lock five 14. Verify fork tube height in upper triple clamp. The
times and return to full right position. top of the fork cap should be flush with the top of
the upper triple clamp.
9. Loosen adjuster nut 90 degrees (1 / 4 turn) so the
reference mark on frame is aligned with the next 15. Torque the upper triple clamp pinch bolts (both
one of the four slots on the stem nut. sides) to specification.
Upper Triple Clamp Pinch Bolts: 18 ft-lbs (24.4 Nm)
16. Torque bottom bolts on lower triple clamp to

specification.

11.28
FRONT' WHEEL I SUSPENSION
17. Torque top bolts on lower triple clamp to

specification.
Lower Triple Clamp Pinch Bolts (ALL): 18 ft-lbs (24.4

Nm)
18. Repeat STEPS 15-17.

19. Install handlebar assembly. See Handlebar
20. Install front wheel. See Front Wheel Removal I
21. Verify all fasteners are installed and properly
torqued.

11.29
TR OU BLESHOOTIN G
TRO UBLESH OOTING
PROBLEM POSSIBLE CAUSE REP.AIR RECOMMENDED
Heavy Steering Steering Stern Nut Over Tightened Torque to specification
Damaged Steering Stern Bearings Replace
or Races
Bent Steering Stern Replace
Front Tire Damaged or Worn Replace
Low Tire Pressure Inflate to specification
Pulls to One Side or Wanders Damaged Steering Stern Bearings Replace
or Races
Steering Stern Nut Over Tightened Torque to specification
or Under Tightened
Rear Wheel Not Aligned Correctly Align
Bent Front Axle Replace
Damaged or Excessively Worn Replace
Front Tire I Incorrect Tire
Damaged Wheel Bearings Replace
Damaged Swing Arm Bearings Replace
Loose Swing Arm Pivot Nut Torque to specification
Bent Frame or Swingarrn Replace
Handlebars Oscillate (Wobble) Bent Front Axle Replace
Wheel Has Excessive Runout True (Spoked) I Replace (Cast)
Tire Mounted Incorrectly Check Mounting and Balance
Damaged Tire I Worn Tire Replace
Loose Steering Stern Nut Torque to specification
(
Incorrect Tire Replace
Incorrect Tire Pressure Correct
Noise Corning From Front Worn Fork Bushings Rebuild Forks
Suspension
Low Fork Fluid Determine Cause I Replace Fork
Oil
Loose Fasteners Torque to specification
Loose Steering Stern Bearings Determine Cause I Correct
Front Wheel Oscillates (Wobbles) Bent Front Rim Replace
Damaged Front Wheel Bearings Replace
Damaged or Incorrect Tire Replace

11.30
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED

Front Wheel Oscillates (Wobbles) Loose Axle Torque to specification
Fork Tube Height Unequal Install Correctly
Fork Oil Level Unequal Set Correctly
Fork Spring Free Length Different Replace
Between Right & Left
Wheel Assembly Out-of-Balance Balance
Front Suspension Too Soft Weak Fork Springs Replace
Low Fork Oil Level Determine Cause/Replace Fork Oil
Wrong Weight Fork Oil Replace
Contaminated and/or Deteriorated Replace
Fork Oil
Low Tire Pressure Set Correctly
Front Suspension Too Hard Tire Pressure Too High Set Correctly
Bent Fork Tubes Replace
Wrong Weight Fork Oil Replace
Too Much Fork Oil Set Correctly
Plugged Oil Passages Rebuild Front Forks
Damaged Sliders Replace
Forks Binding Correct
Wheel Turns Hard Damaged Wheel Bearings Replace
Front Axle Bent Replace
Brake Dragging Repair as Necessary
(Hydraulic or Mechanical Problem)
Brake Dragging (Bent Disc) Replace
Improper Assembly After Repairs Correct as Necessary

11.31
(
NOTES r

11.32
REAR WHEEL I SUSPENSION
CHAPTER 12
GENERAL INFORMATION ..... . . . ............... . . .. . . ............................... .. ...... . ....... .. 12.2
SERVICE NOTES .................................... . ... . ............ . ...... . .. . ................. . ... 12.2
SPECIAL TOOLS ................................. . ..... .. ...................... . ............ .. .... . ... 12.2
TORQUE SPECIFICATIONS ...................... .. ................... . .. . ..... . .................. . ... 12.2
SERVICE SPECIFICATIONS ........ . .............................. . ................... . .. . .. . ........ 12.3
ASSEMBLY VIEWS ............ .. ........ . ... . .. . ............... . ............. . ......... . . .. .......... . ... 12.4
REAR SUSPENSION ....................... . ........... . .......... . .. . ................. . ............... 12 .4
REAR WHEEL .... .. . .. ........... . ................... .. ........... . . . . . ...... . . . ..................... 12.5
DRIVE BELT SERVICE .. . . . .. . ... . ......... . ... . .......... . ......... . .... . . . ............. . ........... . . . . 12.6
DRIVE BELT INSPECTION .... . ........ . .............................. . . . ............. . ............... 12.6
DRIVE BELT REMOVAL .......... . ...... . . . .............. . . . ..... . .............. . .................. . .. 12.6
DRIVE BELT INSTALLATION ......... . . . . . ..... . .. . . . ............. . .............. . ... . ............. . .. 12.6
DRIVE SPROCKET SERVICE ........... . ... .. ..... . .. . .................................................. 12.7
DRIVE SPROCKET COVER REMOVAL I INSTALLATION ........ . ... . .. . ......... . .................... 12.7
DRIVE SPROCKET REMOVAL ................ . ......... . ...... . . . ...... . ..... . ................... . .... 12.7
DRIVE SPROCKET INSPECTION . . ........ . ............. . ........ . ........................ . ........... 12.8
DRIVE SPROCKET INSTALLATION . .. ................... ... ........... .. . .. ......... . ............... . . 12.8
DRIVENSPROCKETSERVICE ........ . .......... . ... . .. . .. . .. ... ....... . ....... . .......... . ... .. ..... 12.10
DRIVEN SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 .10
DRIVEN SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 .10
DRIVEN SPROCKET INSTALLATION . . ........... ... . . ........................ . ..... . . . ............. 12.11
REAR WHEEL SERVICE . . . . ...... ... ...... .. ... . ... .. .... . ....... . ........................ . ....... . .. . 12.12
REAR WHEEL REMOVAL I INSTALLATION .......... . .... . .... . .................. . . . ... . ........... 12.12
REAR AXLE INSPECTION ... . ... . ......................... . ............. . . . ....... . .. . ......... . . . .. 12.13
REAR WHEEL INSPECTION ...... . . . ......... .. .. . ....................... . .. . ... . .................. 12.13
REAR WHEEL BEARING INSPECTION ....... .. ..... .... . .. ....................................... .. 12.14
WHEEL BEARING REPLACEMENT ... . ...... . . . . . .. . .. ... . . .......................... .. ... . . . ..... . . 12.14
BRAKE DISC REMOVAL I INSTALLATION .......... . ... . .. .. .... . ....... . . . ........ . .. . .. . .......... 12.15
SHOCK ABSORBER REMOVAL ...... . ..... . ........ . ........ . ..................................... . . 12.15
SHOCK ABSORBER INSPECTION ..... . ..... . .... . ........... . ............................... . ... ... 12 .15
SHOCK ABSORBER INSTALLATION .......... . . . . ... ... . . . .. . ... . ...... . ............. . ...... . ..... .. 12 .16
SWING ARM SERVICE . .. .. . ........ . ............. ..... ...... . .............. . . . ... . ............. . ...... 12 .17
SWINGARM REMOVAL ............ . ... . ............ .. ............. ... . .. ........................... 12.17
SWINGARM BUSHING I BEARING REPLACEMENT .. . ................................ . ... . ......... 12.18
SWINGARM INSTALLATION .......... .. ............ .. .... . ....... . ..... .. ............ . ............. 12.19
TROUBLESHOOTIN'G ... . . . . . ......... . . .. ... . ..... . ............... . ............ . . . .... . ... . ... . ...... 12.21
TROUBLESHOOTING REAR WHEEL I SUSPENSION ............ . .................. .. ............... 12.21
TROUBLESHOOTING FINAL DRIVE .................. . .............................................. 12.22

12.1
(
GENERAL INFORMATION
SERVICE NOTES TORQU E SPECIFICATION S
-;,.,,;,_.- ' , - ¥ ' - - • ' ' ' " t- ;•,. ,,;.; :. • r , • ~ ·.• •
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PART I FASTENER TORQUE
SPECIFICATION
This motorcycle was produced with the designated
tires as original equipment. The testing to ensure Belt Guard, Lower 96 in-lbs (11.0 Nm)
stability and superior handling was done using the
OEM tires. Using non-OEM tires could result in poor Brake Disc 22 ft-lbs (29.8 Nm)
motorcycle stability and handling, which can lead to Drive Sprocket Cover 84 in-lbs (9.5 Nm)
a crash resulting in serious injury or death. Use only
the recommended tires inflated to the recommended Drive Sprocket Lock Plate 88.5 in-lbs (10.0 Nm)
tire pressures.
Drive Sprocket Nut 180 ft-lbs (244.0 Nm)
Tubeless tires are used on certain Indian Motorcycle Gusset Plate 55 ft-lbs (75.0 Nm)
models. Operating the motorcycle with damaged rims
creates a safety hazard including air pressure loss, P-Clamp Screws (Brake Line 84 in-lbs (9.5 Nm)
steering imbalance and/ or reduced steering control. I W.S.S.)
Do not attempt to repair or straighten damaged cast or Rear Axle Nut 65 ft-lbs (88.0 Nm)
spoked rims. Always use genuine Indian Motorcycle
parts or equivalent so that quality is not compromised. Rear Caliper Mounting Bolts 31 ft-lbs ( 42.0 Nm)
The use of tire valves and valve cores other than
original equipment replacement Indian Motorcycle Shock Absorber Bolts 55 ft-lbs (75.0 Nm)
parts could cause tire deflation which may lead to loss (Upper & Lower)
of control, resulting in injury or death. Do not allow any
motorcycle to leave your service area without tire Swingarm Nut (LH) 65 ft-lbs (88.0 Nm)
valve caps securely installed. Swingarm Shaft, Initial 8 ft-lbs (11.0 Nm)
• The rear shock absorber is serviceable. Torque (Before Outer Nut
• Refer to Chapter 2 for maintenance of rear wheel & Installation) C
suspension components, and suspension ride height
adjustment. Swingarm Shaft, Jamb Nut 75 ft-lbs (102 .0 Nm)
Wheel Speed Sensor 96 in-lbs (11.0 Nm)
SPECIAL TOOLS
SPECIAL TOOL PART NUMBER (
Swing-arm Bushing Tool PF-51237
Shock Spanner Wrench PV-46993
Bearing Removal I PU-51324
Installation Kit
Platform Jack Commercially Available

12.2
Axle Runout - .20 mm (.008")
Rear Wheel Runout Axial I Radial .80 mm (.030 inch) 2.0 mm (.080")
Rear Wheel Size I Type All Models 16" x 3.5" Cast -
Rear Wheel 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 Chapter 2 for Ride Height
Suspension Ride Height All Models Measurement procedure -
Spring Rate All Models 400 lbs I 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 I RH Needle Bearing -
Journal: 24.95-25.00 mm
Swing Arm Needle Bearing Bore O.D. (RH) 31.946-31.972 mm -
Swing Arm Ball Bearing Bore 0 .D. (LH) 41.967-41.992 mm -
Wheel bearing O.D. (approx) 51.987-52.00 mm -
Wheel bearing I.D. (approx) 19.998-20 .00 mm -

12.3
(
ASSEMBLY VIEWS
REAR SUSPENSION
·c
TORQUE TORQUE
# PART DESCRIPTION # PART DESCRIPTION
SPECIFICATION SPECIFICATION
G) Nut 85 ft-lbs (115 .2 Nm) @ Washer -
CD Washer - ® ASM, Shock -
CD Needle Roller Bearing - ® Screw 65 ft-lbs (88 Nm)
© Seal - @ Screw 65 ft-lbs (88 Nm)
® Swing Arm Bushing - @ Axle, Rear -

® Swing Arm Pivot - ® Plate, Indicator -
Swing Arm Bushing
(J) (Ball bearing) - @ Nut -
® Ball Bearing - ® Adjuster, Axle -
® Retaining Ring - @) ASM, Swing Arm -
@) Washer - @ Nut 65 ft-lbs (88 Nm)
® Screw - @ Ring, E-Clip -

12.4
REAR WH EEL
''\
'\..._j1 !
CD Screw 22 ft-lbs (29.8 Nm)
CD Ring, ABS (If Equipped) -

G) Spacer, Axle -
© Seal, Bearing -
0) Bearing, Wheel -
® Rotor, Brake -
(j) Wheel, Rear -
® Spacer, Bearing -
® Damper -
@) Spacer, Bearing Outer -
® Bearing -
® Sprocket -
® Spacer, Bearing, Sprocket -
® Ring. Retaining -

12.5
(
DRIVE BELT SERVICE r

DRIVE BELT INSPECTION DRIVE BELT INSTALLATION
1. Inspect belt tension and adjust if necessary. See 1. Inspect sprockets and verify sprocket fasteners
Drive Belt Inspection, page 2.31. are tight.
2. If one or more component is damaged, replace 2. Install drive belt with the Indian Motorcycle script
belt and both sprockets as a set if the drive system situated so that it reads correctly when viewed
has been in service for 5000 miles or more (8000 from the LH side of the motorcycle.
(
Km).
3. Install the drive sprocket cover. See Drive
Sprocket Cover Removal I Installation, page 12.7.
DRIVE BELT REMOVAL
4. Install shock absorber. SeeShock Absorber
If belt is to be reinstalled, mark direction of rotation 5. Install the rear wheel. See Rear Wheel Removal I
on the outer surface of belt. Reinstall belt in same Installation, page 12 .12. C
direction as it was removed.
6. Set drive belt alignment and tension. See Drive
Belt Adjustment, page 2.32.
A mis-aligned rear axle can cause drive line noise

and damage the drive belt, which could cause belt
failure and loss of control of the motorcycle.

or death may occur if the motorcycle tips or falls.
1. Loosen rear axle and axle adjusters. See Rear

Wheel Removal I Installation, page 12.12.
2. Remove left rear shock. Shock Absorber Removal,
page 12.15
(
3. Remove drive sprocket cover. See Drive Sprocket
4. Remove belt from drive sprocket.

12.6
DRIVE SPROCKET SERVICE

DRIVE SPROCKET COVER REMOVAL/ 4. Loosen both axle adjuster nuts Q) evenly to move
INSTALLATION wheel forward until belt is loose.
1. Remove bolts CD and drive sprocket cover Q). ·. '· \...._ .·...--..... -·· ___ /
5. Pull belt off drive sprocket.

2. To install the drive sprocket cover, reverse the 6. Remove two locking plate screws © and locking
removal procedure.
plate G).
3. Torque drive sprocket cover bolts to specification.
Drive Sprocket Cover Bolts: 85 in-lbs (9.6 Nm)
DRIVE SPROCKET REMOVAL

2. Remove the drive sprocket cover. SeeDrive Sprock-
et Cover Removal I Installation, page 12.7.
3. Loosen rear axle nut CD so that wheel assembly can
be moved forward to slacken drive belt.
7. Remove drive sprocket G) and drive sprocket re-

taining nut ®· See Locking the Crankshaft for Serv-
ice, page 10.5.

12.7
C
8. Remove 0-ring (J) and spacer ® and from output 4. Inspect the machined sealing surface of the spacer
shaft. sleeve ©. Replace the spacer sleeve if it is
v1 grooved or otherwise damaged.
-I
~7 }
' /
(
DRIVE SPROCKET INSPECTION 5. Sprockets and belt normally exhibit a polished

1. Visually inspect sprocket teeth G) for excessive appearance due to normal operation. Belt
wear and damage. replacement is not required unless
uncharacteristic damage is noted, or if the mileage
service interval is reached. Belt or sprocket
damage is usually due to debris trapped between
belt and sprocket, or from improper maintenance
and adjustment.
(
DRIVE SPROCKET INSTALLATION
If replacing the output shaft seal, it will be necessary

to use the Output Shaft Seal Tool (PF-51243) for
proper installation.
1. Place new output shaft seal over the output shaft

and drive into position using the Output Shaft Seal
Tool (PF-51243).
2. Inspect splines CD for a tight fit on output shaft
splines. 2. Apply grease to a new 0-ring G) and install on
output shaft.
3. Install seal sleeve CD with the chamfer on inside
diameter of sleeve facing in, toward 0-ring .
.~ '""
! / .~\
,.
'l
.
;
-
,
3. Inspect the back surface of sprocket hub G) where

it contacts the seal sleeve. Replace if worn or if
surface is rough.

12.8
4. Clean shaft threads and sprocket nut to remove all 13. Adjust belt tension and wheel alignment. See
previous thread locking agent. Drive Belt Adjustment, page 2.32.
5. Apply a light film of anti-seize compound to
splines of shaft. Place belt onto front sprocket,
place sprocket over splines of output shaft.
6. Apply Loctite TM 262 to threads of shaft and nut.
7. Install drive sprocket nut and torque to
specification.
Install Clutch Shaft Holding Tool (PF-51232) on clutch

shaft prior to tightening sprocket nut.
8. Install lock plate G) and tighten screws © until

lightly seated on plate.
The lock plate can be installed in many positions and

either side of the plate can be used. If the plate still
does not align, tighten sprocket nut slightly and try to
fit the lock plate again.
9. Rotate the plate CLOCKWISE until it stops and

hold it firmly against the nut.
10. Torque lock plate screws to specification.
11. Remove the clutch shaft holding tool and install the
clutch assembly. See Clutch Installation, page
9.18.
12. Install the drive sprocket cover. See Drive
Sprocket Cover Removal I Installation, page 12. 7.

12.9
(
DRIVEN SPROCKET SERVICE

DRIVEN SPROCKET REMOVAL DRIVEN SPROCKET INSPECTION
1. Visually inspect sprocket teeth G) for excessive
CAUTION wear and damage from foreign material or road
Protect brake disc surface while working on wheel. debris.
1. Remove rear wheel. See Rear Wheel Removal I

2. Remove the LH wheel spacer G) from the driven
sprocket roller bearing.
2. Inspect the back side of the sprocket where it

engages the damper (I) for wear, galling or
roughness. Surface must be smooth, with no burrs
or surface irregularities.
3. Lift the driven sprocket assembly (I) off of the drive

damper G). C
'\.,
\
\
C

12.10
3. Visually inspect the cushion drive damper G) for DRIVEN SPROCKET INSTALLATION
cracks or deformation. Replace damper if damage 1. Install cushion damper G) into wheel hub.
is found.
2. Install sprocket assembly CD onto wheel hub
making sure the cushion damper is properly
engaged.
r"
i 3 !
\ ___/
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 G) into the sprocket
with the belt if any one item is damaged or worn roller bearing.
beyond a normal polished appearance.

12.11
(
REAR WHEEL SERVICE

REAR WHEEL REMO VAL/ IN STALLATIO N
Rear wheel removal involves supporting the machine /

with the rear end elevated. Take precautions so that
the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death
can occur if the motorcycle tips or falls.
Make sure the exhaust system has cooled to room

temperature before elevating the motorcycle. The
drive belt may be damaged if it comes into contact
with HOT exhaust components.
CAUTION
If working on a motorcycle equipped with a charcoal Do not hang rear brake caliper from the brake line.
canister (EVAP) , remove the canister prior to Do not twist the brake line or damage may result.
elevating the rear of the motorcycle to prevent
damage to the canister hose fittings.
1. Place the motorcycle in an upright position on a lift Do not apply rear brake pedal after the brake caliper
table with the front wheel clamped in a wheel vise. has been removed.
2. Remove saddlebags, if equipped.
5. . Remove rear ABS wheel speed sensor mounting
3. Position a platform jack beneath the engine cases
bolt CD and sensor G), if applicable.
and raise until the rear tire is barely in contact with
the ground.

12.12
6. Loosen right and left axle adjusters@. 12. Torque fasteners to specification.
-
- TORQUE
Axle Nut: 65 ft-lbs (88.0 Nm)
Wheel Speed Sensor Bolt: 96 in-lbs (10.8 Nm)
Rear Caliper Mounting Bolts: 31 ft-lbs (42.0 Nm)
Set drive belt tension and alignment. See Drive

Belt Tension, page 2.31 and Drive Belt Adjustment,
page 2.32.
REAR AXLE INSPECTION

l. Install rear axle in V-blocks and measure runout
and compare to service limit. See Service
7. Remove clip ®, rear axle nut © and washer (J) 2. Axle diameter should be measured on bearing
from side of swingarm. surfaces.
19.965 - 19.990mm 19.965 - 19.990mm
REAR WHEEL INSPECTION
Wheel bearings must be in good condition.
1. Set up a dial indicator to measure axial and radial

runout of the wheel and compare to service limit.
See Visual Inspection I Runout, page 13.8.
2. Visually inspect wheel for cracks or other damage.
3. Replace wheel if it fails visual or measured
inspection.
9. Push wheel forward and slide drive belt to the

LEFT side off of the rear sprocket.
10. Remove rear wheel assembly by sliding it to the
rear of the motorcycle.
11. Installation is performed by reversing the
removal procedure.

12.13
(
REAR WHEEL BEARING INSPECTION 4. Carefully pry seal G) out of RH side of hub.
If possible, also inspect wheel bearings before

removing the wheel from the vehicle. Do not remove
I
bearings from wheel to inspect. Bearings cannot be
repacked. Replace both bearings if one or both fail
inspection, or if either bearing was removed. (
1. Visually inspect integral bearing seal for damage.

2. Inspect bearing fit in wheel hub. The outer race of
the bearing must fit tightly into the bore. You
should not be able to move outer race by hand.
3. Slide axle into wheel and check for smooth C
rotation and tight fit.
5. Refer to special tool manufacturer instructions to
remove bearing from brake disc side of hub.
Due to extremely close tolerances, the bearings must
be inspected visually, and by feel. Look for signs of 6. Remove bearing.
discoloration, scoring, galling, or contamination from 7. Remove spacer.
moisture or dirt. Replace bearings if any of the above
are present. Turn the inner race of the bearings. The 8. Extract or drive bearing from sprocket side.
bearings should turn smoothly and quietly. The inner 9. Installation: Use the Wheel Bearing Removal I
race should be firm with minimal side to side Installation Kit PF-51324) to install new wheel
movement and no detectable up and down bearings. Refer to special tool manufacturer
movement. instructions for proper use of tool.
10. Install new seal into the RH side of hub.
WHEEL BEARING REPLACEMENT 11. Install the brake disc. See Brake Disc Removal I
CAUTION
12. Install driven sprocket. See Driven Sprocket
Do not reuse bearings that have been removed.
13. Install the rear wheel. See Rear Wheel Removal I
This procedure requires the Wheel Bearing Removal
I Installation Kit (PF-51324). Refer to special tool
manufacturer instructions for proper use of tool.
1. Remove rear wheel. See Rear Wheel Removal I

2. Remove driven sprocket. See Driven Sprocket
3. Remove brake disc. See Brake Disc Removal I
(

12.14
BRAKE DISC REMOVAL/ INSTALLATION SHOCK ABSORB ER REMOVAL

1. Remove the rear wheel. See Rear Wheel Removal I
2. Remove the driven sprocket and cushion damper. Shock absorber removal involves supporting the
See Driven Sprocket Removal, page 12.10. machine with the rear end elevated. Take
precautions so that the motorcycle is securely
3. Position wheel with brake disc facing up. supported when the rear tire is off the ground. Severe
4. Remove and discard ABS tone ring (if applicable) I personal injury or death can occur if the motorcycle
brake disc screws G). tips or falls.
5. Remove the ABS tone ring (if applicable) CD and l. With the rear wheel properly supported, remove
brake disc G). the lower shock fastener G) and upper shock
fastener CD and remove shock absorber.
"'-:-·-' · .

removal procedure.
7. Torque brake disc bolts to specification in a star SHOCK ABSORBER INSPECTION
pattern. Ensure rotation arrows on rotor are noted l. Measure spring installed height and record so ride
and followed. height adjustment can be returned to rider's
preference.
@3)--,,i. \.
~

12.15
C
2. Loosen spring collars G) and CD completely to 6. With shock upright, move damper rod through
relieve spring tension. entire travel range. Damper rod should move
smoothly with consistent damping through the
entire travel range, and return to the fully
ex tended position when released.
7. Inspect shock spring for cracks or distortion.
Measure free length and compare to specification.
("
See Service Specifications, page 12 .3.
SHOCK ABSORBER INSTALLATION

1. Lift shock into position and install top shock
washer G) bolt CD finger tight.
,./ ;' . . .,,
-~., ·. :=
:,·// ,' ,.· . C
3. Slide spring G) off of shock.

/
/
/
/
/
C
"f" . : ' ,';; ,.

~- .."'
(
2. Install the lower shock bolt G) finger tight.
4. Thoroughly clean the shock spring.

5. Inspect eyelets and (i) for cracks, damage or loose
fitting eyelet. Replace shock if either eyelet is
cracked.
/ ,
(
/
,
__.,.,.,,,,,,.
3. Torque upper and lower shock bolts to

specification.

12.16
SWIN GARM SERVICE

SWIN GARM RE MOVAL 3. Position a platform jack beneath the engine cases
and raise until it contacts the engine.
Swingarm removal involves supporting the machine

with the rear end elevated. Take precautions so that
the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death
can occur if the motorcycle tips or falls.
Make sure the e xhaust system has cooled to room

temperature before elevating the motorcycle. The
drive belt may be damaged if it comes into contact
with HOT e xhaust components.
4. Re move rear w heel assembly. See Rear Wheel

Removal I Installation, page 12 .12.
If working on a motorcycle equipped with a charcoal
canister (EVAP), remove the canister prior to 5 . Remove rear shocks. Shock Absorber Removal,
elevating the rear of the motorcycle to prevent page 12.15
damage to the canister hose fittings.
6. Remove the rear brake hose rear p-clamp bolt CD
located on the left inner surface of the swingarm.
1. Place the motorcycle in an upright position on a lift
table with the front wheel clamped in a w heel vise.
1
I_!':.-/'.;.:;./1f·,.~.,-;~.::··~_-.:_·.1_~,·/·/r
._,""~~f~
.. .((.;'\
.· r:(1 . f" . ,'.; j ' y __
,, '-:,,,,,V' , ,,
' ' /::.::l! ~;.'.\ ~' /
7. Re move upper belt guard bolt (f) from front and
2. Remove e xhaust assembly. See Muffler Removal, two bolts from the back side of guard.
page 5.13.

12 . 17
(
8. Remove lower belt guide bolts G). SWINGARM BUSHING / BEARIN G REPLACE MENT
REMOVAL
1. Remove swingarm assembly from motorcycle. See
Swing arm Removal, page 12 .17.
2. Remove shock absorber assembly from swingarm.
See Shock Absorber Removal, page 12.15.
3. Remove the internal snap-ring CD followed by the
bearings Q) from the LH side of the swingarm.
9. Remove swingarm nut © and washer ® from the

right side of the swingarm pivot shaft.
4. Working from the RH side of the swingarm, gently

pry the seals G) out of the bearing bore.
C
5. Remove needle roller bearing © .

6. Inspect bearing bores for any galling or damage.
INSTALLATION
1. Working on the LH side of the swingarm, press or
drive new bearings Q) into the bearing bore using
a suitable bearing driver.
2. Install internal snap-ring CD.
11. Support and remove the swingarm assembly
3. Using the bearing driver drive a new needle bear-
towards the rear of the motorcycle.
ing © into the RH side of the swingarm until fully
seated.
4. Press new outer seals G) into the bearing bore until
seated.

12.18
5. Install shock absorber assembly. See Shock Ab- 6. Install upper belt guard and torque screw CD two
sorber Installation, page 12.16. screws on the back side of guard to specification.
6. Install swingarm assembly. See Swingarm Installa-
tion, page 12.19.
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 (7) on swingarm shaft. Slide the
swingarm shaft ® into the left side of the frame.
7. Install lower belt guard and torque screws CD to

specification .
.· ~
' · :.-...;
5. Install the swingarm shaft washer ® and nut © onto

the end of the swingarm shaft. Torque nut to
specification.
8. Install rear shocks. Shock Absorber Installation,

page 12.16

12.19
C
9. Install the rear brake hose rear p-clamp bolt CD lo-

cated on the left inner surface of the swingarm.
10. Install the rear wheel. See Rear Wheel Removal I

11. Make sure that the following applies:
The rear wheel turns freely, without any
interference between the belt guard, the tire,
and the swingarm.
Brake line is properly routed and secured.
The left and right axle adjusters are aligned
properly (wheel is in alignment).
The rear brake functions properly. C
All fasteners have been tightened correctly.
There is adequate clearance between swingarm
and exhaust mufflers and mounting.
The swingarm is not loose, it doesn't wobble
from side to side, and it doesn't move up and
down more than 1/32 of an inch when pushed
and pulled firmly.
page 3.9.
13. If equipped, install the charcoal canister. See Evap-
orative Emission Control System (CA Models),
page 2.24.
14.Adjust ride height as required. SeeRear Shock Pre-
load Inspection, page 2.38.
15. Test ride motorcycle to be sure rear suspension op-
erates smoothly without binding or abnormal
noises.

12.20
TROUBLESHOOTING
TROUBLESHOOTING REAR WHEEL / SUSPENSION
Rear Wheel Feels "Loose" or Loose fasteners Torque to specification
Wobbles
Distorted (bent) rear wheel Replace wheel
Worn or damaged wheel bearings Replace wheel bearings
Worn or damaged swing arm bushings. Replace swing arm bushings
Damaged or incorrect rear tire Replace rear tire
Unbalanced rear wheel assembly Balance tire/wheel
Low tire pressure Inflate to specification
Loose swing arm, axle or suspension fasteners Torque to specificatio n
Shock bushing failure Replace shock bushings
Rear Suspension Too Hard Incorrect preload adjustment Adjust to rider & load
Damaged shock absorber Replace I Rebuild shock
Damaged or corroded suspension mount Correct as necessary

bushing
Damaged or corroded swingarm bushings Replace
High tire pressure Deflate to specification
Drive belt adjustment too tight Adjust drive belt tension
Rear Suspension Too Soft Incorrect preload adjustment Adjust to rider & load
Damaged shock absorber Rebuild or replace shock
Weak shock spring Replace shock spring
Excessive load placed on motorcycle Reduce load weight
Rear Suspension Noisy Loose fasteners Torque to specification
Worn wheel bearings Replace
Worn swing arm bushings Replac.e
Damaged shock absorber Replace as necessary
Worn shock bushings Replace shock bushings
Wheel Drags (Turns Hard) Incorrect drive belt adjustment Adjust drive belt tension
Brake problem Diagnose and Service
Loose fasteners Torque to specification
Bent rear axle Replace
Damaged wheel bearings Replace
Tire contact with object or chassis Determine point of contact and correct

12.21
(
TROUBLESHOOTING FINAL DRIVE (

PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED
Belt Shows Excessive Wear Out-of-Alignment Align rear wheel
On One Side
Belt Squeal Out-of-Alignment Align rear wheel
Belt Whine I Noise Out-of-Alignment .Align rear wheel C
Belt Damage Inspect Belt
Incorrect Belt Tension Adjust Tension
Broken Sprocket Teeth Foreign material damage I Loose drive Replace parts or repair as necessary
belt or sprocket
Broken or Torn Cogs on Belt Foreign material damage I Loose drive Replace parts as necessary (
belt or sprocket
Belt Jumps Sprocket Teeth Worn, damaged or out of adjustment Replace parts as necessary
belt or sprockets
Belt Loose Adjust Belt
Excessive Wear, Binding Belt Tight Adjust Belt
Suspension
Broken Belt Belt weakened by foreign material Replace Belt, Replace Sprockets
damage . Belt run excessively tight or
loose.
(.

12.22
TIRES
CHAPTER13
TIRES
GENERAL INFORMATION ...................................................... .. ............. . ........ 13.2
SERVICE NOTES .............. . ................ ..... .. .. ........ .. ........ . .......................... 13.2
SERVICE SPECIF1CATIONS ..................... . ........ . ................. . ......................... 13.2
TIRE INSPECTION .... ............................... . . . ................................................. 13.3
TIRE WEAR PATTERNS . . ............ . .......... . ...... ......... . . . . .. . .......... .... ................. 13 .3
OZONE CRACIGNG .... . ..... ... ............... .. ......................... . .......................... 13.3
FRONT TIRE CUPPING ...................... . .............................................. .. .. ... . .. 13.3
TIRE SERV1CE ... . ................................................... . ... . . . ..... . ....... .... .......... .. 13.4
TIRE CHANGING .............................................. ... . . ......................... .. ..... .. 13.4
TIRE REMOVAL .. ...... .. . .. ........ . ...... .. .............. .. ..... . . .. ....... .. .................... . . 13.4
TIRE INSTALLATION ................. . .................................................... ..... ...... 13.5
TIRE BALANCING . . .............. ..... ..... .... .................. .. ............. . .................... 13.7
WHEEL INSPECTION .. . ........ .... ............................ . ... .... .............................. . . 13.8
VISUAL INSPECTION I RUNOUT .. .. ...... . ........... . .. .. ............... .. ...................... .... 13.8
TIRE REPAIR PRECAUTIONS ................... . . .. .. .. .. .. .... .... ....... . ........................... 13.8
VMVE STEM ......................... . ............ . .............................. . ..... ... ....... . ...... 13.9
VALVE STEM INSPECTION .. . ................... . .................. . ................................. 13.9
VALVE STEM INSTALLATION - RUBBER ... .... ....... .. . .. ......... . .......... . . . .... . ................ 13.9
VALVE STEM INSTALLATION - METAL ... . . ......... .... ...... ... .. . .. ... . .. ... . ....... . .............. 13.9
TROUBLESHOOTING ................................................................................. 13.10
TROUBLESHOOTING .. . ..... . . .. ........... .. ...... . .............. .. .. . ............... . ............ 13.10

13.1
(
TIRES
GENERAL INFORMATIO N (
SERVICE NOTES
Do not attempt to repair tires that have:

If a consumer wishes to replace the Original • Punctures with a diameter of greater than 6mm
Equipment Manufacturer (OEM) tires with another (0.240").
brand of tire, Indian Motorcycle recommends • Cuts with a length of greater than 6mm (0.240").
contacting the tech-line of the tire manufacturer • Any punctures or cuts on the sidewall of the tire.
being considered to ensure compatibility. Indian • Tread depth ofless than 1.6mm (.063 ") for the front
Motorcycle makes no other recommendation other tire.
than the OEM tires. Tires other than OEM may or may • Tread depth ofless than 1.6mm (.063") for the rear
not adversely affect the handling characteristics of tire.
the motorcycle or may not have adequate tire • Ply separation.
clearance. • Tread separation.
• Severe tread cupping.
C
• Cuts, gouges or scratches on the sealing surface of
the bead.
The use of tires other than original equipment may • flat spots on the tread.
cause instability which can lead to a crash resulting • Bubbles, separation or any unusual damage to the
in serious injury or death. Use only the recommended inner liner of the tire.
tires inflated to the recommended tire pressures. • Chemical sealants or balance additives added to
Operating the motorcycle with damaged rims creates the tire.
a safety hazard including air pressure loss, steering
imbalance and/or reduced steering control. Do not
attempt to repair or straighten damaged rims.
All repairs must be made from inside the tire.
No form of temporary repair should ever be
attempted. Secondary damage caused by a C
penetrating object may not be detected and tire or
tube deflation may occur at a later date.
When a tire reaches the minimum tread depth
listed below, replace the tire immediately.
(
CAUTION
Overloading and under-inflation lead to premature
tire wear. Do not deviate from the specifications for
loading or inflation.
(.
SERVI CE SPECIFICATION S
Refer to Chapter 11 (Front Wheel and Suspension) for front wheel specifications.
Refer to Chapter 12 (Rear Wheel and Suspension) for rear wheel specifications.
Tire Specifications
POSITION TIRE TYPE I 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)
(_
9926140 R02 - 2015- 20 16 Scout Service Manual l

13.2
TIRES
TIRE INSPECTION
TiRE WEAR PATTERNS FRONT TIRE CUPPING
SYMPTOM
Wear on Left Side

Tire Wear Patterns
CAUSE
Riding on Crowned
Roads
Front of tread block worn more than rear of tread
block:
• The cupping of front tires is somewhat normal.
• Rear tires are subjected to forces in both directions.
The forces of braking and acceleration result in even
13
I
tire wear.
Under-inflation or • Front tires are subjected only to the forces of
Edges Worn braking. When the brakes are applied, tire
Excessive Loads
deflection is increased and wear occurs in only one
Excess Wear in the Over-inflation or Tire direction.
Middle of Tire Abuse • Incorrect tire pressure is the number one cause of
excessive tire cupping. Too little tire pressure
Under-inflation, causes the tire to over-deflect which increases the
Cracks in Tread Grooves Excessive Loads, amount of scrubbing and causes more tire cupping.
Suspension Bottoming • Binding or improperly assembled front forks can
also contribute to excessive tire cupping. If the front
Tread Block Cupping
forks do not react as they should the tire acts as the
(Usually Front Tire -See Normal Braking Wear
sole suspension component and tread deflection
Below)
increases.
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.

13.3
(
TIRES
TIRE SERVICE (
TI RE CHAN GI NG TIRE RE MOVAL
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 This procedure is written assuming that a
variations. pneumatic, electric, or manually operated rim-
The three general methods are: clamp type tire machine is being used.
(
• Pneumatic or electrically operated tire machine
1. Remove wheel I tire assembly from motorcycle.
• Manually operated tire machine
See Chapter 11 for front wheel removal and
• Manual manipulation of tire irons
Chapter 12 for rear wheel removal.
Indian Motorcycle permits and recommends all three 2. Remove valve core G) from valve stem and let all
of the general methods, but realizes that careless or air escape.
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. C
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 I
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 3. Mount the wheel assembly onto a tire bead
taken when performed. Care must be taken when breaker and break the bead starting at the valve
using tire irons to not damage or stress the tire bead, stem and continue around the circumference of the
Also, the opposite bead needs to be in drop center of rim as necessary.
wheel during mounting and dismounting of the tire.
4. Flip the wheel assembly over and repeat STEP 3 on
Be very careful not to damage the rim, tire, inner tube,
the other side. C
brake disk, or sprocket regardless of which method is
used. CAUTION
IMPORTANT: 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.
Refer to manufacturer's instructions for proper

tire changer operation. (
Mount the tire and wheel assembly on the tire

machine per the manufacturers instructions.

13.4
TIRES
6. Carefully work around the circumference of the TIRE INSTALLATION

upper bead CD with the tire lever until it is
completely off of the rim.
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 of
liquid 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 G) have directional arrows that must be
7. Lift the lower tire bead up until the tire lever can observed when installing tires to rims CD.
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.
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.
1. Lubricate both tire beads with rubber lubricant.
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.
Refer to manufacturer's instructions for proper

tire changer operation.
Mount the tire and wheel assembly on the tire

machine per the manufacturers instructions.

13.5
(
TIRES
3. Orient tire correctly as to the directional arrows. 13. Inflate tire observing the precautions listed below. (
4. Push tire on to rim until one bead is installed. It Tire Inflation & Precautions
shouldn't be necessary to use tire irons to put one • Wear approved eye protection
side of the tire onto the rim. Remember to keep • Lubricate the tire beads with a tire mounting
bead(s) in the drop center of the wheel whenever lubricant before inflation.
possible. • Lock assembly on mounting machine or place in
safety cage before inflating to seat beads
(
• 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
C
the tire, lubricate the tire beads and repeat
inflation procedure.
Confirm tire is positioned correctly by observing
directional arrows. 16. Install wheel assembly onto balance stand and
spin. Observe the wheel assembly while it is
5. Lubricate the tire bead. spinning to make sure the tire is seated properly.
(
6. With your hands, push as much of the remaining 17. Adjust tire pressures to specifications.
tire bead as possible into the rim, pinching both 18. Balance tire I wheel assembly.
· upper and lower beads into the drop center.
7. When no more of tire can be installed by hand,
press down on portion of tire in front of you with FOR REPAIRED TIRES: Speed should not exceed
your knee to keep the top bead in the drop center. 50 MPH for the first 24 hours after repair and
8. Install the tire lever and work around the repaired tire should never be used over 80 MPH.
remaining circumference of the wheel until the Inspect inflation pressure after tire cools for at least
bead is fully installed onto the rim. 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
Be sure both beads are forced as far as possible into (
same as the original tires when new. When new tires
the drop center of the rim.
are installed, they should not be subjected to
maximum power or hard cornering until a reasonable
9. Install valve core if it was removed. "scrub" period of approximately 100 miles has been
10. Line up balance dot. covered. This will permit the rider to become
accustomed to "feel" of new tires or tire
11. Confirm that the directional arrows are pointing in combination, and achieve optimum road grip.
the correct direction. (.
Inspect and adjust tire inflation pressure after tire
12. Bounce tire on the floor several times while cools down for at least three hours following "run-
rotating tire. This will expand tire bead outward in".
slightly which will make tire inflation easier.
(_

13.6
TIRES
TIRE BALANC ING
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.
The use of liquid balancer/sealer 1s not

recommended.
This procedure will outline balancing wheel assembly
in a gravity balance stand. If a pendulum or spin type
balancer is being used, reference the manufacturer's
instructions that came with the equipment.
1. Mount wheel assembly in a commercially
available balance stand.
2. Remove all balance weights. Clean tire and rim
thoroughly.
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.
CAUTION
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, dismount the tire
and rotate it 90° without regard to the yellow
balance dot, and re-balance the wheel I tire.
Adhesive Weight P/N 1521682
8. Install wheel I tire assembly onto motorcycle. See
Chapter 11 for front wheel installation and
Chapter 12 for rear wheel installation.

13.7
TIRES
WHEEL INSPECTION
VISUAL INSPECTION/ RUNOUT
1. Clean the rim
corrosion.
of all rubber particles and ::;;_--; ';, .. .
:-:t ·: - ·. .
..-
TIRE REPAIR PRECAUTIONS
,._._ .._.
WARNING .. ,
-. ·, _ __::,_.,.';.
.-.:, -~',- :~ _
C
2. Inspect wheel for cracks and/or distortion. Only permanent plug-patch repairs of small tread
area punctures from inside the dismounted tire are
3. Inspect bead seating area for scratches, distortion, recommended. Never perform an exterior repair and
or damage that could prevent proper sealing. never use an inner tube as a substitute for a proper C
4. Measure wheel for radial runout CD. repair. Speed should not exceed 50 MPH for the first
24 hours after repair and the repaired tire should
5. Measure wheel for axial runout CD. never be used over 80 MPH. Inspect inflation
pressure after tire cools for at least three hours
following initial operation.
(
i! 11
11 11
{
II
11
11 Axia1+f I
/
Il 2 I!
(
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
13.2. Replace wheel if any measurement e xceeds
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.

13.8
TIRES
VALV E STEM
VALV E STEM IN SPE CTION 2. Remove valve stem G), o-ring CD, nut G) and valve
1. Remove the valve stem cap and spray the valve stem © .
stem down with a mild soap and water solution.
2. Observe the area around the base of the valve
stem and valve core area. If any bubbles form over
a 1-2 minute period, the valve stem or inner tube
should be replaced.
3 . Inspect valve stem for cracks or visible damage
and replace if necessary.
Valve stem replacement is recommended w hen tire

is being replaced.
VALVE STEM INSTALLATION - RUBBER

1. Remove tire from wheel and cut valve stem with a 3. Clean gasket or o-ring sealing surface of rim.
diagonal cutter to remove. 4. Place new valve stem (with seal washer or 0-ring
2. Clean tire valve hole and sealing area thoroughly. installed) through hole in rim and position it so the
stem is perpendicular from wheel center and,
3. Lubricate tire valve and hole with P-80 rubber valve opening facing away from surface
lubricant or equivalent. containing direction indicator.
4. Place tire valve into hole and screw a tire valve
installation tool (commercially available) onto
valve.
Directio n
5. Place a small wood block against the rim to Indicator
improve leverage point and keep the pulling angle
as straight as possible.
6. Pull the valve until fully seated and remove tool.
Valve Stem
VALVE STE M IN STALLATION - METAL Orientation
The Scout model uses directional tires and w heels.

Pay close attention to markings to ensure proper tire
and valve stem orientation.
5. Hold stem and tighten nut to specification.
1. Remove tire from w heel. SeeTire Removal, page
13.4.
6. Install tire. See Tire Installation, page 13.5.

j
.)

13.9
(
TIRES
TROUBLESHOOTING C
TROUBLESHOOTING
Rear Wheel (Wobbles) Bent rim Replace
Worn or damaged wheel bearings Replace as a set
Worn or damaged swing arm Replace as a set C
bushings.
Damaged or incorrect tire Replace rear tire
Wheel assembly out-of-balance Balance wheel
Loose swing arm, axle or Torque to specification
suspension fasteners.
Handlebars Oscillate (Wobble) Bent front axle Replace
(
Tire mounted incorrectly Inspect and re-mount tire
Damaged tire Replace
Loose steering stem nut Adjust to specification
Incorrect tire Replace
C
Incorrect tire pressure Inflate to specification
Front Wheel Oscillates (Wobbles) Bent rim Replace
Damaged or incorrect tire Replace
C
Loose axle or axle pinch bolts Torque to specification
Right and left fork not installed at Repair
same height
Fork oil level incorrect Fill to specification
Fork spring free length different Replace spring that does not meet
between right & left specification
Wheel assembly out-of-balance Balance wheel
9926140 R02 - 2015 - 2016 Scout Service Manual (__

13.10
BRAKES
CHAPTER14
BRAKES
GENERAL INFORMATION ...... ...... . . .................. .... ............. .... .. .... .......... ... ...... 14.2
SERVICE NOTES ....................... . ..... .... . . ................................ .. .............. . . 14.2
SPECIAL TOOLS .......................... . .... ..... .................... . ........ . .................. .. 14.3
TORQUE SPECIFICATIONS .... ... . .. . .... .. ......................................... . .... . . .... ...... 14.3
SERVICE SPECIFICATIONS ........ ......... ....................... . .............. . . .. ............. .. 14.3
ASSEMBLY VIEWS ........................... . ......... .. .. ... . . ............... . ........................ . 14.4
FRONT BRAKE SYSTEM ................................................ . ... . . .. ...................... 14.4
REAR BRAKE SYSTEM ... .. .... . .... ... ........ . .... . .......... . .......................... . ........... 14.5
BRAKE LINE ROUTING ...... .. ..... . . . ....................................... . .................... . .. 14.6
REAR MASTER CYLINDER ......... . . .. ... .. ....... . ......... . ............ . ..... . .... .. ... .. ..... ... .. 14.8
FRONT BRAKE CALIPER .................... . ......................... . ........ . ...................... 14.9
REAR BRAKE CALIPER ............................................................................. 14.10
ABS MODULE ........................... . .......................................................... 14.11
ANTILOCK BRAKE SYSTEM (ABS) INFORMATION ...... . .... ..... .................. .... ... ...... . . 14.12
ABS SYSTEM SAFETY PRECAUTIONS ..... . . . . .. ... ...... . . ..... ........ .. .... ... . .... .. ... . . . ...... 14. 12
ABS GENERAL INFORMATION ..................................................................... 14. 12
ABS SYSTEM COMPONENTS ...... . .. . ............. . . . ........................... .. ... . .... . ....... 14. 13
ABS OVERVIEW OF OPERATION ............. . .. . ..... . ......................................... . .. 14.13
ABS SYSTEM SERVICE .. . ...... . ...... . ............. .. .. . ..... . ........................ . .............. 14. 14
WHEEL SPEED SENSOR REPLACEMENT ..... . . . ................................................... 14.14
WHEEL SPEED SENSOR AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 .15
ABS MODULE REPLACEMENT . .... . ... .... .................... . ................. . ........ . ......... 14.16
ABS BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 .17
BRAKE FLUID REPLACEMENT I BLEEDING PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 .17
ABS BRAKE VACUUM BLEEDER ... . ............. . ........................... . ........ . .... .. ...... . 14.18
ABS FLUID CHANGE ................ • ........ . ..................................................... 14.18
ABS REAR BRAKE BLEEDING .............. .. ................................... .. ..... . ............ 14.18
ABS FRONT BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 .19
BRAKE LEVER RESERVE INSPECTION . . ...... .. .. . ............... .. ... . ........ .. ... .. ...... . .... .. 14.20
BRAKE SYSTEM SERVICE . .. ................ . . . . .... ........................... . . .... . .. .. .. ......... 14.21
FRONT BRAKE PAD REPLACEMENT .......... ... ............................. .. .................... 14.21
REAR BRAKE PAD REPLACEMENT ................................................................ . 14.21
BRAKE DISC INSPECTION .................... . ........ ... ............... ....... .................... 14.22
) FRONT MASTER CYLINDER SERVICE ...... . ...... . ......................................... ... .... 14.22
FRONT CALIPER SERVICE ..... . ........... . ....................................................... 14.24
FRONT CALIPER INSTALLATION ......... . .......... ... . . ........... .... ... . ..... . ................. 14.26
REAR MASTER CYLINDER SERVICE . . .. ..... ...... .. .. .... ........ ... ... . ........ ... ... . ........... 14.26
REAR CALIPER SERVICE ...... .. . . ....... .. ........................................ . ............ . .. 14.27
REAR CALIPER INSTALLATION ......... .. ............... .. . . .. ...... ......... . .................... . 14.28
TROUBLESHOOTING ........ . ............. . ........... . ........... . ............. . .......... . . .. ..... . 14.29
TROUBLESHOOTING ....... ...... . . . . . . ............ .. ................ . ............... ... .. . . . .... . . 14.29

14.1
(
BRAKES
GENERAL INFOR MATION (

SERVICE NOTES
Use only genuine Indian Motorcycle replacement
parts when servicing the brake system. Clean all
system components prior to disassembly, including
the fluid reservoir cover (s) to reduce the chance of
debris entering the system during repair or
maintenance work. Start with a clean work area away
from dust, water or other contamination. Cleanliness is
very important for proper brake system maintenance
and repair. Follow procedure outlined in this manual
carefully, including fastener torques and the
application of special lubricant in required areas.
Special lubricants are included with service kits.
Contaminated brake discs or pads greatly reduce the

amount of stopping force available & increase
stopping distance. Brake discs can be cleaned using
a commercially available brake disc cleaner. Follow
the manufacturer instructions printed on the C
container. NEVER attempt to clean contaminated
brake pads. Always replace pads as a set.
The brake system uses ethylene-glycol based fluid

(DOT 4). Do not use or mix with different types of
fluid such as silicone-based (DOT 5) or any
petroleum-based fluid .Do not let water or moisture
enter the master cylinder when refilling. Water
significantly lowers the boiling point of the fluid and
can result in poor braking.Do not use brake fluid
taken from old, used or unsealed containers. Never
reuse brake fluid.Keep brake fluid containers
C
completely sealed and out of reach of children.Brake
hoses should be replaced whenever the exterior
shows signs of deterioration or damage. Brake hoses
should be replaced every four (4) years regardless of
their exterior condition.Bleed the brake system any
time it is disassembled or when the brake action is (.
spongy.Always inspect the operation of the brakes
before riding the motorcycle.Replace sealing
washers whenever brake lines are removed.Always
remove the master cylinder fluid reservoir cover and
inspect the fluid level when brake pads are replaced.
NOTICE: Brake fluid and some types of brake C

cleaners will damage paint, plastics and some rubber
compounds. Cover or remove plastic and painted
parts before working on the brake system. If brake
fluid is spilled on cosmetic surfaces, immediately
rinse the area with a mild solution of soap and water
until all traces of brake fluid are removed. Make sure
(_
the master cylinder reservoir being worked on is level
and clean before removing the cap.
9926 140 R02 - 2015 - 2016 Scout Service Manual (_

14.2
BRAKES
SPECIAL TOOLS SERVICE SPECIFICATIONS

TOOL DESCRIP,TION PART NUMBER STAN-
ITEM SERVICE LIMIT
DARD
ABS Tool (Lever Reserve) PV-50104
Replace every 24
Vacuum Brake Bleeder Commercially Available Specified Brake months or 10,000 miles
DOT4
Fluid (16,000 km)
Brake Disc
TORQUE SPECIFICATIONS 5mm 4.5 mm (.177") (Min)
Thickness, Front
TORQUE
PART I FASTENER Brake Disc 4.5 mm (.177") (Min)
SPECIFICATION 5mm
Thickness, Rear
Banjo Bolt, Front (Caliper, Ml 16 ft-lbs (22 Nm)
C)
Brake Disc - .30 mm (.012") (Max)
Runout
Banjo Bolt, Rear (Caliper, Ml 16 ft-lbs (22 Nm) Brake Pad Wear When wear limit
C) Limit (Front & - groove is no longer
Bleeder Screw (All) 60 in-lbs (5.4 Nm) Rear) visible
Brake Disc, Front 22 ft-lbs (30 Nm) Brake Pedal Free No

Play (Pedal Ad- -
Brake Lever Clamp 8 ft-lbs (11 Nm) Clearance) just-
ment
Caliper Body, Front 35 ft-lbs (27.0 Nm)
No
Brake Caliper Mounting 31 ± 4 ft-lbs (42 ± 6 Brake Lever Ad- -
Fasteners Nm) Freeplay (Front) just-
ment
Caliper Slide Bolt, Rear 20 ft-lbs (27.0 Nm)
Caliper Stud, Front 20 ft-lbs (27.0 Nm)
Master Cylinder Cover, Front 13 in-lbs (1.5 Nm)
Master Cylinder Cover, Rear 13 in-lbs (1.5 Nm)
Pad Retaining Pin 10 ft-lbs (13.5 Nm)
Wheel Speed Sensor (Both) 7 ft-lbs (9.5 Nm)

14.3
(
BRAKES
ASSEMBLY VIEWS C
FRONT BRAKE SYSTEM
. . ·7~- /'
.
'+.'
}
....,,.... -·· · . '• ····-~:0;>- (;' , !
,~
' 10 J C
\..__.../
C
/
.i
G) Bolt, Front Disc - M8 x 25 22 ft-lbs (30 Nm)
CD Screw, ABS Sensor - M6 x 15 7 ft-lbs (9.5 Nm) C

Q) Screw, Caliper - Ml x 25 31 ft-lbs ( 42 Nm)
© Bolt, Banjo - 10 x 1.25 16 ft-lbs (22 Nm)
a) Snap Ring, External -

® Bolt, Banjo - 10 x 1.25 16 ft-lbs (22 Nm)
(j) Rubber Seal -
® Pivot Pin, Brake Lever 8 ft-lbs (11 Nm)
® Rubber Diaphragm -
@) Cover, Front Master Cylinder -
® Screw, Front Master Cylinder Cover 13 in-lbs (1.5 Nm)
@ Screw, Brake Lever Clamp 8 ft-lbs (11 Nm)

14.4
BRAKES
REAR BRAKE SYSTEM
{~
'{9)
.. ., .
·~·
.... •
CD Valve, Bleeder 60 in-lbs (6.8 Nm)
CD Bolt, Caliper - 10 x 25 31 ft-lbs (42 Nm)
CD Bolt, Banjo - 10 x 1.25 16 ft-lbs (22 Nm)
© Rubber Seal -
G) Bolt, Banjo - 10 x 1.25 16 ft-lbs (22 Nm)
© Rubber Seal -
(]) Rubber Diaphragm -
® Cover, Rear Master Cylinder -
® Screw, Rear Master Cylinder 13 in-lbs (1.5 Nm)

14.5
BRAKES
BRAKE LINE ROUTING
/"
( 1)
{~ .,,· C
1' 5 • ~ - .·-
/
'-....../
/f: / --,4 _./ -'' .. _/_ .v

( 4
\ _ ./
~~ ~-------1<3") '-.._j
C
G) Brake Line, Rear (Rear Caliper to Master Cylinder) -

CD Brake Line, Front (Front Caliper to Handlebar)
C
G) Screw, P-Clamp - M6 x 1.0 x 12 84 in-lbs (9.5 Nm)
© Screw, Bracket - M6 x 1.0 x 35 60 in-lbs (6.8 Nm)
® Screw, P-Clamp - MB x 1.25 x 40 18 ft-lbs (24 Nm)
(_
9926140 R02 -2015- 2016 Scout Service Manual

14.6
BRAKES
ABS Models
-
( 4 )
''--_../
,. . .-- "
2 ) /------
/ {3 ,
\___,J
CD Brake Line , Rear (Rear Caliper to ABS Module) -

CD Brake Line, Rear (Rear Master Cylinder to ABS Module) -
G) Brake Line, Front (Front Caliper to ABS Module) -
© Brake Line, Front (Handlebar to ABS Module) -
G) Screw, P-Clamp - MS x 1.0 x 12 84 in-lbs (9 .5 Nm)
® Screw, Bracket - MS x 1.0 x 35 60 in-lbs (6 .8 Nm)
(j) Screw, P-Clamp - MS x 1.25 x 40 18 ft-lbs (24 Nm)

14.7
(
BRAKES
REAR MAS TER CYLI NDER (
I/
\
2~:I
___
1·-
\
3"'}
C
,~-
I,
7 )\
(~
\, ~/
C
G) Screw, Rear Master Cylinder Cover 13 in-lbs (l.5 Nm)
0 Cover, Rear Master Cylinder -

G) Rubber Diaphragm - C
© Reservoir, Rear Master Cylinder -
® 0-Ring, Sight Glass -
® Sight Glass -
(j) Spring - (
® PCup -
® SCup -
@) Pushrod -
® Piston -
® Piston Washer -
® Piston Snap Ring -
® Dust Boot -
@ PushrodNut -
@ Clevis Nut 8 ft-lbs (11 Nm)
® Clevis -

14.8
BRAKES
FRONT BRAKE CALIPER
/··-......
( 6 \
\,_,)
G) Brake Pads -
CD Lower Slide Pin 18 ft-lbs (24.4 Nm)
G) Bracket -
© Lower Dust Boot -
CI) Upper Dust Boot -
® Piston -
(j) Piston Seal -
® Pad Spring -
® Caliper Body -
@) Pad Retaining Pin 120 in-lbs (13.5 Nm)
® Screw, Bleeder 48 in-lbs (5.4 Nm)
® Upper Slide Pin 10 ft-lbs (13.5 Nm)

14.9
BRAKES
REAR BRAKE CALIPER
, ';\
( 5 ;
"· (
/-"\
\ 10 )
"-._./
CD Brake Pads -
CD Mount Bracket - (
CD Guide Pin -
© Piston -
® Dust Seal -
© Screw, Bleeder 48 in-lbs (5.4 Nm) (
(J) Pad Retaining Pin 10 ft-lbs (13.5 Nm)
® Caliper Body -
® Pad Wear Clip -
@) Dust Seal -
® Guide Pin -
@ Pad Spring -

14.10
BRAKES
ABS MODULE
ABS Module I Assembly View
-------··. -
iii
[ _ -
~
-
~
[
r;i
~
I
IT -
I
i I
-
Terminal Layout Hydraulic Circuit Diagram

(Module Side)
Master Cylinder Master Cylinder
(Front) (Rear)
BAT CAN H: CAN HIGH

i:==~===l RVWB : REAR VELOCITY WHEEL BATI'ERY
IG: IGNTI10N
FVWB: FRONTVELOCITYWHEEL BATI'ERY
GND:GROUND
CAN L: CAN LOW
NC: NOT CONNECTED
RVWS: REAR WHEEL SPEED SENSOR
FVWS: FRONT WHEEL SPEED SENSOR
BAT: BATTERY
Front Caliper Rear Caliper

14.11
BRAKES
ANTILOCK BRAKE SYSTEM (ABS] INFORMATION

ABS SYSTEM SAFETY PRECAUTIONS ABS GENERAL INFORMATION
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 l?ck-up and 1mpr~ve
general brake system, brake fluid, . and ABS specific control . of th~ motorcycle durmg extreme brakmg
precautions and system information. Do not attempt events, mcludmg:
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 (10 kph).
tire pressure may reduce the effectiveness of the • If the lamp is not illuminated when the key is ON,
anti-lock brake system. connect Digital Wrench and perform an ABS System
• Alw ays install the recommended size and type of inspection to determine the cause. C
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.
• improper operation • The ABS light is controlled via CAN BUS.
• Wheel speed sensors provide feedback for anti-lock
brake operation.
• If fuse is open or removed, the ABS light will remain (
ON after 6 mph (10 kph). ABS will not be active.
Normal (conventional) braking will be available
provided the system components (master cylinder,
lines, calipers, e tc.) are in working order.

14.12
BRAKES
ABS SYSTEM CO MPO NENTS AB S OVERVI EW OF OPE RATIO N

The following parts function in the same manner as the The ABS system is active and available when vehicle
same component in a non-ABS system, although parts speed exceeds 6 mph (10 kph).
are not necessarily interchangeable. Always refer to The system uses two independent Hall-Effect Wheel
the appropriate ABS parts information when replacing Speed Sensors. One sensor is mounted to the front
a component or component parts. caliper and one is mounted to the rear brake caliper
I
• Front Brake Calipers bracket. Two Pulse Rings are also used, one mounted
• Rear Brake Caliper to the left front brake disc hub and one to the rear
• Front Master Cylinder brake disc hub, which rotate with the wheels. When
• Rear Master Cylinder the vehicle is in motion, the multiple reluctor
• Brake Light Switch segments on each pulse ring pass by the center pole 14
• Brake Lines of the respective wheel speed sensor, generating an
electrical pulse signal in the sensor which is sent to
In addition to the brake system components listed the ABS Module which is located in front of the rear
above, the following are exclusive to ABS equipped wheel.
vehicles: The ABS Module interprets wheel speed signal pulses
• Wheel Speed Sensors (Front located on front to determine speed, rate-of-change, and front I rear
caliper; Rear mounted on rear caliper bracket) wheel speed differential to determine if wheel lock-up
• Wheel Speed Sensor Pulse Rings (Front and Rear is about to occur. When w heel lock-up is imminent
mounted to wheel with 5 disc bolts) during a braking event , the ABS Module controls the
• ABS Module Assembly operation of solenoids and a pressure pump (located
• ABS Related Wiring inside the ABS Module) to regulate the amount of line
• ABS Indicator Lamp pressure and cycles (length of time) applied to the
caliper pistons and brake pads. This pressure I time
modulation can often be felt at the brake lever or the
brake pedal during an ABS braking event and is a
normal condition. Note that the brake fluid is not
diverted inside the module and does not "flow " in the
system any more than occurs in a conventional (non-
ABS) brake system.
If the surface coefficie nt changes (such as moving from
wet pavement to dry pavement) the ABS system will
recalculate (in a matter of milliseconds) and adjust
pressure output to caliper(s) as required.
In the event of a system fault , the ECM turns on the
ABS indicator lamp (via the CAN BUS) and leaves it on
even after vehicle speed exceeds 6 mph (10 kph)
activation speed.
If a system fault occur s , the light will remain on (and
ABS will not be active) until the ignition key is turned
to OFF position and back to ON.
The ABS Module Assembly is serviceable only as an
assembly. The module itself is not rebuildable .
Disconnect negative (-) battery cable from battery
before servicing ABS brake lines or system
components.
9926140 R02 - 201 5 - 20 16 Scout Se rvice Manual

14.13
BRAKES
ABS SYSTEM SERVICE

WHEEL SPEED SENSOR REPLACE MENT
Removal - Front Removal - Rear
1. Remove bolt G) securing the Wheel Speed Sensor 7. Remove bolt CD securing the Wheel Speed Sensor
to bracket. to the bracket.
2. Withdraw speed sensor and remove any existing 8. Withdraw speed sensor and remove any e xisting
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. (
Installa tion - Rear
5. 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 specification.
Wheel Speed Sensor Air Gap Adjustment, page Perform adjustment procedure if necessary. See
14. 15. Wheel Speed Sensor Air Gap Adjustment, page
14.15.

14.14
BRAKES
WHEEL SPEED SENSOR AIR GAP ADJUSTMENT 6. Reinstall Wheel Speed Sensor and torque to
specification.
Wheel Speed Sensor air gap is adjusted by adding

and removing shims. Shims are added to increase
gap and removed to decrease gap. No more than 3
shims (per Wheel Speed Sensor) should be used at
one time.
1. Using a suitable feeler gauge, measure the air gap

between the ABS Pulse Ring and the Wheel Speed
Sensor.
ABS Pulse Ring--+--
~ I
r--
n 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.
Wheel Speed Sensor Air Gap (Max)0.079 in (2.00

rnrn)
3 . Remove Wheel Speed Sensor from bracket.

4. Withdraw the speed sensor and remove any
existing shims.
5. Based on air gap measurement, add or remove
shims to achieve the specified air gap.

14.15
BRAKES
ABS MODULE REPLACE MENT 7. Remove the fastener CD securing the side ABS
Module mount.
Do not disassemble the ABS module. The ABS

module is serviceable only as a sealed (pre-bled)
assembly. If ABS module has failed internally, replace
complete assembly.
(
The hydraulic brake system MUST be completely

bled following removal or replacement of the ABS
module. Follow the brake bleeding procedure
outlined in this chapter after ABS module service.
(
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 CD from ABS module
front wheel clamped in a wheel vise. and cap off lines to prevent contamination.
3. California Models ONLY: Remove the
evaporative emissions charcoal canister, if
equipped. Refer to, page 1.10.
4. Remove the swingarm assembly. Refer to , page
12.17 procedure.
5. Remove the voltage regulator. Refer to Regulator I
Rectifier Replacement, page 15.30procedure.
C
6. Remove the fastener CD securing the bottom ABS
Module mount.
C
10. Remove ABS module.
Installation
12. Bleed brake system as outlined in this chapter.
13. Attach Digital Wrench and check for ABS trouble
codes.

14.16
BRAKES
ABS BRAKE SYSTEM BLEEDING

BRAKE FLUID REPLACEMENT/ BLEEDING
PRECAUTIONS
An unsafe condition exists when air is trapped in the
hydraulic brake system. Air in the brake hydraulic
system acts like a soft spring and absorbs a large
Contaminated brake discs or brake pads greatly
1
percentage of the pressure developed by the master
reduce braking performance and increase stopping cylinder. Without this pressure, the braking system
distance. Do not attempt to clean contaminated pads. cannot develop full braking force to allow for safe,
Replace them. Clean the brake disc with brake
controlled stops. It is extremely important to bleed
cleaner. the brakes properly after any brake system work has
been performed or when inspection reveals spongy 14
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).

14.17
BRAKES
ABS BRAKE VACUUM BLEEDER ABS REAR BRAKE BLEEDING

A vacuum 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. (
1. Remove rubber cap from rear caliper bleed screw

CD and place a box end wrench on the screw.
2. Attach a tight-fitting clear hose from the vacuum
bleeder to the bleed screw and apply vacuum.
ABS FLUID CHAN GE

Review Brake Fluid Replacement and Bleeding
Precautions before working with brake fluid.
When bleeding or flushing the system, monitor fluid

\ (
3. Fill rear brake fluid reservoir and leave cover off
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
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.
9. After completing the bleeding procedure a second

time, inspect brake fluid level and add if
necessary.

14. 18
BRAKES
10. Clean the reservoir cover, diaphragm, and 3. Remove rubber cap from bleeder screw G) on
reservoir sealing surface. If diaphragm is front caliper and place a box end wrench on the
extended, return it to normal (flat) position. Install screw.
diaphragm and cover.
11. If pedal is not firm, repeat bleeding procedure and
insect brake system.
ABS FRONT BRAKE BLEEDING

1. Pull brake lever forward to ensure smooth lever
operation. Loosen pivot screw CD if necessary.
4. Attach tight fitting clear hose from vacuum

bleeder to bleed screw and apply vacuum.
5. Hold lever to handlebar or hold firm pressure on
lever, then open bleed screw about 1/ 4 turn.
6. Pump brake lever repeatedly with smooth full
strokes while adding brake fluid to the reservoir as
required. For best results pump the lever at a fairly
2. Remove front brake fluid reservoir cover (J) and rapid rate but avoid pumping too fast or fluid may
leave it off so fluid can be added as it is drawn become aerated. Eventually, the bleeder hose
through the system. should have clear, bubble-free fluid running
through it. Close the bleeder screw.
7. Fill fluid reservoir and install diaphragm and
cover. Torque cover screws to specification.
8. Perform Brake Lever Reserve _Inspection. See

Brake Lever Reserve Inspection, page 14.20.

14.19
BRAKES
BRAKE LEVER RESERVE INSPECTION

This procedure requires use of the Brake Lever Re-
serve Tool (PV-50104).
l. Turn handlebars fully LEIT.
2. Place grommet of Brake Lever Reserve Inspection
Tool PV-50 l 04 on ball end of front brake lever.
(
3. Connect a scale (commercially available) with a
minimum of 25 kg I 50 lb capacity to end of tool.
4. Keep tool centered so it does not touch, hand grip.
Pull on scale to specified force.
Brake Lever Reserve Force: 42 lbs (19 kg)
5. Have an assistant verify brake lever does not

contact hand grip. Clearance must exist at
specified pull force as shown.
6. If lever makes contact with hand grip or bar end,
bleed the front brake system.
(
7. See troubleshooting if bleeding problems persist.

14.20
BRAKES
BRAKE SYSTEM SERVICE

FRONT BRAKE PAD REPLACEMENT 10. Slowly pump lever to set brake pads against disc.
Lever should be firm, not spongy. If lever is
spongy, inspect pad installation, bleed brake lines
Always replace brake pads as a set and always and inspect brake disc.
replace pads in both front calipers at the same time.
11. Install reservoir cover and torque to specification.
1. Remove the set screw, and then remove brake pad
pin CD.
Master Cylinder Reservoir Cover: 13 in-lbs (1.5 Nm)
12. Operate brake lever several times until lever is

firm and pressure can be felt.
After pad installation or any brake system repair,

safely elevate wheel, apply and release brake pedal
or lever 2-3 times and release. Verify wheel turns
freely without drag. If brake drag is evident, do not
operate the motorcycle. Inspect vehicle to determine
cause and then repair as necessary.
2. Push each pad back by hand to gain clearance for

new pads. REAR BRAKE PAD REPLACEMENT
Always replace brake pads as a set.

Brake fluid will be forced back into the reservoir
when pads are pushed back. Remove reservoir cover
and monitor fluid level, or attach a hose to the brake 1. Remove the rear brake caliper mounting pins CD
bleeder screw and open the bleed screw while and remove the caliper.
pushing the pads and pistons back.
3. Remove each pad.

4. Wipe brake disc clean with a shop towel sprayed
with brake cleaner (commercially available).
5. Inspect caliper piston seals for any sign of fluid
leakage. J
cJ
6. Install new brake pads with friction material
toward disc.
7. Insert pin through caliper and through outer pad.
Lay spring in place over pads and press on center
while sliding pin through spring and then through
inner pad. 2.
~-;/
Push each pad back by hand to gain clearance for
new pads.
8. Torque pad retaining pin to specification.
Brake fluid will be forced back into the reservoir

when pads are pushed back. Remove reservoir cover
and monitor fluid level, or attach a hose to the brake
9. Inspect brake fluid in reservoir and set to proper bleeder screw and open the bleed screw while
level. pushing the pads and pistons back.

14.21
BRAKES
3. Remove the set screws CD and pad retaining pins BRAKE DISC INSPECTION
G). Slide the mount bracket © back into the 1. Visually inspect disc for cracks or damage.
caliper, and slide the pads ~ off the end of the 2. Measure brake disc thickness in several locations
guide pins ®· Do NOT remove the guide pins for around disc with a micrometer, and along wear
pad removal. Note orientation of retaining spring. surface and compare to specifications. See , page
14.3.
(6)
(
4. Install new brake pads with friction material

toward disc. C
5. Using the guide pins, install caliper back onto
bracket with mounting fasteners. Install set screws Replace the brake disc if any measurement is worn
and pad pins. Torque fasteners to specification. beyond the service limit.
3. With disc mounted to wheel, inspect for brake disc

runout I warpage with a dial indicator and (
Brake Caliper Mounting Fasteners: 31 ± 4 ft-lbs (42 ±
. 6Nm) compare to specifications. See , page 14.3.
6. Inspect fluid level in the reservoir and adjust as

Runout should be measured 2-4mm in from outside
necessary.
edge of disc.
7. Pump brake pedal slowly several times to set new
pads against disc, until lever is firm and pressure 4. Replace brake disc if dial indicator reading C
can be felt. displays excessive brake disc runout and other
8. Bleed brake system if necessary. possible causes have been eliminated.
FRONT MASTER CYLINDER SERVICE

After pad installation or any brake system repair, CAUTION
safely elevate wheel, apply and release brake pedal
or lever 2-3 times and release. Verify wheel turns Brake fluid and brake cleaners could damage paint,
freely without drag. If rear brake drag is evident, plastics and some rubber compounds. Cover or
inspect pedal clearance. Do not operate the remove plastic and painted parts before working on
motorcycle if drag is still evident after clearance the brake system. If brake fluid is spilled on cosmetic
adjustment. Inspect vehicle to determine cause and surfaces, immediately rinse the area with a mild
repair as necessary. solution of soap and water until all traces of brake
fluid are removed. Be sure master cylinder reservoir
is level before removing cover.

14.22
BRAKES
6. Remove the nut G) and pivot pin® and pull lever

assembly out of master cylinder.
Replace all rubber parts upon assembly.
l. Clean the master cylinder. Attach a drain hose to

caliper bleed screw and place the end in a
suitable container. Drain brake fluid from the front
brake system by slowly pumping brake lever.
2. Remove the RH side mirror from the lever perch.
3. Remove banjo bolt G) and brake line from master
cylinder.
\._)_
7. Remove dust boot (J) and snap ring out of
master cylinder.
,----
/ 1\
~
\ ,~ \
~--
.
(8 )
(7)
'---
,_\/ \ 0 \
b \
/
4. Remove screws CD, clamp, and master cylinder ?~

1~- - \-'
·~ \ . •
from the handlebar.
I \ ~ ----~___,.-· - •
• 0
i .
~ f}:cs ,
1--=-- ~~ .....
/ ~
r---=:, 8. Slide piston ® out with spring. Note spring
orientation for assembly of new spring (new
parts).
/.
( ~g-,\
\ )
~
5. Remove reservoir cover G) and diaphragm ©.
9. Clean master cylinder with isopropyl alcohol and

dry with compressed air. DO NOT soak in alcohol
for more than 30 seconds. DO NOT aim
pressurized air directly at the level sight glass.
10. Inspect cylinder bore and chamfer of bore for
corrosion, scratches, scoring, or pitting. Replace
master cylinder if any of these conditions are
evident.
•
14.23
BRAKES
11. Measure the diameter of the bore. Replace master FRONT CALIPER SERVICE
cylinder if worn beyond the service limit.
CAUTION
Master Cylinder Bore Diameter Service Limit: 0.504 Brake fluid and brake cleaners will damage paint,
in (12.8 mm.) plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on
12. Clean the compensating port and supply port with the brake system. If brake fluid is spilled on cosmetic
compressed air to be sure they are clean and surfaces, immediately rinse the area with a mild
unobstructed. solution of soap and water until all traces of brake
fluid are removed. Make sure the master cylinder
13. Apply a light film of special lubricant from piston
reservoir being worked on is level before removing
kit to each piston seal cup.
the cap.
14. Assemble the piston I spring assembly as shown.
Large diameter of beveled edge on piston cups
face toward spring. C
Replace all rubber parts upon assembly. Keep parts
in order for assembly. The top and bottom pistons in
the c;aliper are not the same size.
1. Remove banjo bolt CD, sealing washers, and brake

hose from caliper assembly and allow it to drain C
into a container. Cover the end of brake line to
prevent debris from entering.
15. Carefully install spring I piston assembly into

master cylinder bore. Work the front piston seal
carefully past the chamfer and into bore. Use care
\ (
not to damage or fold the seal when working it

past the chamfer.
C
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.
2. Remove front caliper mounting studs CD and
remove the caliper.
18. Clean the bore from the retaining ring outward, so
the outer edge of the new dust boot adheres C
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.
20. Apply non-petroleum grease from kit to brake
lever contact surface.
21. Install master cylinder on handlebar. Torque
clamp screws to specification.
3. Cover the brake hose connection on the caliper

and clean the outer surfaces of caliper assembly
with brake cleaner (commercially available) or
isopropyl alcohol. Dry with compressed air.

14.24
BRAKES
4. Remove pad retaining pin G) and brake pads. 12. Measure the outside diameter of each piston in two
spots 90° apart, 5mm from outer edge. Repeat
measurement 5mm from inner edge. Replace
piston if worn beyond service limit at any
measuring point.
Front Caliper Piston Outside Diameter

Std Size: 1.18 in (30.0 mm)
SERVICE IJMIT: 1..177 in (29.9 mm)
( 3 !~--
,,,---... ~ -
'--._/
Install all new rubber parts during assembly. Do not
reuse old seals or boots.
13. Apply special lubricant from service kit to new

piston seals and dust seals.
Pads contaminated with oil or grease must be 14. Apply non-petroleum grease (included in kit) to
replaced as a set. outer surface of all pistons.
15. Install piston seals and dust seals in caliper body.
5. Keep parts in order for assembly in the same bore.
Top and bottom pistons (in each caliper half) have 16. Install pistons in their respective bores.
different diameters.
17. Install brake pads. Torque retaining pin and set
6. Remove each piston with a caliper piston pliers. If screw to specification.
a caliper piston pliers is not available, wrap the
caliper in a shop towel and apply short bursts of
compressed air through the brake line hole and
through the transfer passage to force the pistons
out of the bore.
7. Remove dust seals and piston seals. Use care not
to damage the seal bores.
8. Clean all parts thoroughly with isopropyl alcohol.
Be sure the seal bores are clean, removing all
traces of dirt or dried brake fluid.
9. Clean piston seal and dust seal bores to remove
residue that could cause the pistons to stick,
resulting in brake drag.
10. Inspect each piston bore for corrosion, scratches,
scoring, or pitting. Replace caliper if any of these
conditions are evident.
11. Measure the diameter of each caliper bore.
Replace caliper if any is worn beyond the service
limit.
Front Caliper Bore Diameter
j Std Bore: 1.185 in (30.2 mm)
SERVICE LIMIT: 1.193 in(30.3 mm)

14.25
BRAKES
FRONT CALIPER INSTALLATION REAR MASTER CYLINDER SERVICE

1. Clean mounting surfaces of caliper and fork leg.
CAUTION
2. Apply brake cleaner or isopropyl alcohol to a
clean shop towel and wipe brake discs clean. Brake fluid and brake cleaners will damage paint,
plastics and some rubber compounds. Cover or
3. Separate brake pads and install caliper assembly remove plastic and painted parts before working on
over brake disc. the brake system. If brake fluid is spilled on cosmetic
4. Install caliper mounting studs and torque to
surfaces, immediately rinse the area with a mild C
solution of soap and water until all traces of brake
specification.
fluid are removed. Make sure the master cylinder
reservoir being worked on is level before removing
the cap. Replace all rubber parts upon assembly.
5. Connect brake hose to caliper with banjo bolt and C

new sealing washers. Torque to specification.
1. Remove brake line banjo bolt CD, sealing washers

and brake line. Allow fluid to drain into a
container.
6. Fill and bleed the front brake hydraulic system.
See ABS Front Brake Bleeding, page 14.19.
After pad installation or any brake system repair,

safely elevate the wheel, apply and release the brake
pedal or lever 2-3 times and release. Verify the wheel (
turns freely without drag. If brake drag is evident, do
not operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.
2. Remove screw CD retaining the clevis to the

footpeg.
; ,

14.26
BRAKES
3. Remove mounting fasteners G) from master 12. Install the master cylinder and torque the jamb
cylinder to footpeg. Remove the master cylinder. nut. mounting fasteners, and brake line banjo bolt
to specification.
_ TORQUE
Rear Master Cylinder Jamb Nut: 12 ft-lbs (16 Nm)
Master Cylinder Mounting Fasteners: 8 ft-lbs (11
Nm)
Brake Line Banjo Bolt: 16 ft-lbs (22 Nm)
REAR CALIPER SERVICE

1. Remove the brake pressure switch from the banjo
bolt.
2. Remove banjo bolt CD and sealing washers from
4. Remove clevis©, clevis nut®, pushrod nut ®, and rear caliper and allow fluid to drain into a
dust boot (J). container.
1l
5. Remove internal snap ring followed by piston, 3. Remove caliper bolts CD and lower caliper off of
pushrod, cups, and spring. mounting bracket.
6. Inspect cylinder bore and chamfer on the front of
the bore for corrosion, scratches, scoring, or
pitting. Replace master cylinder if any of these
conditions are evident.
7. Measure the diameter of the bore. Replace master
cylinder if worn beyond the service limit.
Master Cylinder Bore Diameter Service Limit: 0.504
in(12.8mm)
8.
9.
Clean compensating port and supply port with
compressed air to be sure they are clean and
unobstructed.
Clean all parts with clean Indian Motorcycle DOT
4 brake fluid or isopropyl alcohol.
~.....• -::......•
4.
. . •• ,A,A ,oo-., ..
Remove the rear brake pads. Refer to Rear Brake

Pad Replacement, page 14.2 lprocedure.
7
.n ..
.
10. Replace ALL RUBBER PARTS with new. 5. Slide caliper bracket off pins and remove spring
11. Carefully assemble and install the internal master plate.
cylinder components in order. 6. Remove caliper piston.
7. Remove dust seals and piston seals. Use care not
to damage the seal bores.

14.27
BRAKES
8. Clean caliper thoroughly with isopropyl alcohol. 22. Install brake line with new sealing washers and (
Dry with compressed air. Clean seal grooves torque banjo bolt to specification.
thoroughly. Any residue left behind in the grooves
could cause caliper pistons to stick and result in
brake drag.
Banjo. Bolt (Rear
.
Caliper): 16 ft-lbs (22 Nm)
9. Inspect bore and surface of piston for corrosion;·
scratches, scoring, or pitting. Replace caliper 23. Bleed brake system. See ABS Rear Brake Bleeding, (
assembly if any of these conditions are evident. page 14.18.
10. Measure diameter of each bore and piston.
Replace caliper assembly or parts if worn beyond REAR CALIPER INSTALLATION
service limit. 1. Install caliper to rear mounting bracket and torque
to specification.
Rear Caliper Bore Diameter:
Std Bore: 1.185 in (30.2 mm) (
SERVJCE IJMITS: 1.193 in (30.3 mm)
Rear Caliper Piston Outside Diameter: 2. Install brake hose , and brake switch with new
Std Size: 1.18 in (30.0 mm) sealing washers.
SERVJCE LIMIT: 1.177 in (29.9 mm)
11. Install all new rubber parts during assembly. Do

not reuse old seals or boots. Apply special
lubricant from service kit to new piston seals and 3. Fill and bleed the rear hydraulic brake system.
dust seals. See ABS Rear Brake Bleeding, page 14.18.
12. Apply special assembly oil to outer surface of all
pistons. C
13. Install piston seals and dust seals in caliper body. After pad installation or any brake system repair,
safely elevate the wheel, apply and release the brake
14. Install pistons in their respective bore. pedal or lever 2-3 times and release. Verify the wheel
15. Replace caliper pin boot on bracket and on turns freely without drag. If brake drag is evident, do
caliper. Apply special lubricant from service kit to not operate the motorcycle. Inspect the vehicle to
boots and both pins. determine the cause and then repair as necessary. (
16. Assemble bracket to caliper. Remove excess
lubricant.
17. Install spring plate and outer brake pad. Start pad
pin through outer pad.
18. Install inner pad with insulator and backing plate. (
19. Torque brake pad retaining pin to specification.
20. Be sure end tabs of pads are both fully engaged in

the heel plate on bracket.
21. Install caliper to bracket and torque caliper bolts
to specification.

14.28
BRAKES
TROUBLESHOOTING
TROUBLESHOOTING
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 Bearings.
Axle Torque Correctly
Caliper Mount Surface Uneven 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 I Replace
Brake Pedal or Brake Disc Bent or Warped Replace Brake Disc
Brake Lever Mounting Surface of Brake Disc Uneven I 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 I Loose Mounting Hardware Repair as Necessary
Spongy Brake Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
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 I Damaged Hose Replace
Worn Master Cylinder Piston, Caliper Piston(s) Repair I 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)

14.29
BRAKES

Brakes Drag Reservoir Over Filled Adjust Level As Necessary
Excessively or Brake Pedal Or Lever Not Returning Inspect Linkage, Pivots and Mechanism
Self-Apply Completely To Rest Position For Cause Of Binding Or Restricted
(Brakes Inadequate Freeplay Movement;
Overheat) Compensating Port Plugged Measure Pedal Clearance I Adjust
Internal Corrosion of Components (Master Repair or Replace Master Cylinder
Cylinder I Caliper) Replace Damaged Component
Rear Caliper: Corrosion of Sliding Parts, Bent Repair or Replace As Necessary
or Damaged Parts Flush System, Install Correct Fluid
Contaminated Brak e Fluid Repair I Replace Caliper (Corrosion I
Caliper Pistons Sticking Buildup of Residue In Caliper Piston Seal
Rider Error (Operator Riding Brakes) Grooves)
Educate Operator
Brake Squeal/ If noise is minor and inconsistent, some brake Apply non oil-based solvent to a clean
Squeak squeak I squeal is characteristic of disc brakes shop towel and wipe dust I dirt from
and usually caused by dust I dirt on pads and I brake disc.
or brake disc. Repair as Necessary. Inspect Pad
Pad Not Secure in Caliper Installation
Aftermarket (not genuine Indian Motorcycle) Install Genuine Indian Motorcycle Parts
Parts Replace
Worn or Damaged Wheel Bearing(s) Replace
Worn Pads I Disc

14.30
STARTING I CHARGING
CHAPTER IS
STARTING I CHARGING
GENERAL INFORMATION ...... . ..... . ..... . .. . .. . . . ..... . . . . ......... .. . .... .. .... . ... . .... . .......... 15.3
SERVICE NOTES . ... ............ . .. . . . . . . .... . . . . .......... . ....... . ...... .. ................ .. .... . .. 15.3
SPECIAL TOOLS . .... .. ...................... ...... ... .. . . , ..... .. .... . .... .............. .. . ..... . .. . . 15.4
TORQUE SPECIFICATIONS ..... ...... . . ... .......... . .. . .... .. .. . . .... . . ............................ . 15.4
SERVICE SPECIFICATIONS ... ... .. . .. . .. . ...... .. ................ . ... . . .. ... .. . . . ... .. . ........ ... . . 15.5
ASSEMBLY VIEWS .... . .... . ... ..... .. .. ... . . ... ...... ........ .. ... . . ..... . ..... ... .. . . ... ... . ... .... ... . 15.7
STARTERMOTOR / SOLENOID .. . ........... . .. ...... .......... .. ...... . ......................... . ... 15.7
STATOR .... .. . .. . . .... . .. . .. .. . .............. ... . . ........ . .. .. . ..... . . . . . . .. . . . . . .......... . ...... . . 15.8
REGULATOR / RECTIFIER .. ... ............ . ... . ...... . .. . .. .. ....... ...... ... . . .. ......... ....... . .. . 15.9
BATTERY ......... . .. . ...... . ................... ... . .. .......... .. . . . ...... . . .. .. .. . . ............... 15.10
BATTERY SERVICE .......... .. ... .. ... .. . .. . .. .. . . .. ............................ .. .... .. .............. 15.11
BATTERY REMOVAL . . .... . . . .. . ...... . ... . ... ....... ... ............ . .. .. ... ..... . . ......... . ....... 15.11
BATTERY INSTALLATION ..... ............ ........ .. .. .. . . ... .. .... . .. . ........ .. ........ . ... . . ..... 15.11
BATTERYBOXREMOVAL ................. .. .... .. . . . . ...... . .... .... . .... ..... . .... . . . ...... . .. . ... 15.12
BATTERY BOX INSTALLATION ............ . ..... ... ............................ . ...... . ..... . . . .. ... 15.12
BATTERY CHARGING - NEW BATTERY . .. ... .... . .. ... ...... . .... . ............. . .. . . . . ... ... . .... . . 15.13
BATTERY CHARGING - IN SERVICE ..... .. . .. .. .. ....... . ........ . . . .... .. ..... .. .. . . . .. .. . . . . ..... 15.13
BATTERY INSPECTION .... .... . .. . ........... .. .... . . ... ...... . . . . .. .... . .. . .... . .... .. .. . ... .. ... . 15.13
BATTERY TESTING ............. . . .. . .... ... .. .............. . .. . .... .... ......... . .... .. . . . . . . . .... . 15.13
STARTER MOTOR SERVICE ...... ....... .. .... ...... ... .. .. ........ . . ....... ...... .. ..... .. . .... . . .. . 15.14
SAFETY INFORMATION ....... ..... . ....... ..... . . . ....... . .. .. ... ....... . ......... . ... . ........... 15.14
STARTING SYSTEM DIAGNOSTIC TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 .14
STARTER CIRCUIT DIAGRAM .... .. .... ........ . ....... . .. . ....... . . .. . . . .......... . ............... 15.15
TROUBLESHOOTING FLOW CHART I ... . . . . ... . .. . .. .. .... ...... ... .. . ... . .. .. .. ...... .. . . . ....... 15.16
TROUBLESHOOTING FLOW CHART 2 .. . ... . .. . .............. ..... .... . . .... .. .. ................... 15.17
TROUBLESHOOTING FLOW CHART 3 ...... ..... . .. . ... . .. ...... . ............. . ... .. .. . .......... .. 15.18
STARTING SYSTEM TESTS . . .. ....... ... ....... ....... . . . . ... . .. ........ ..... ... . .. . ..... . . . .. ....... . 15.19
BATTERY LOAD TEST . .. . .. .. ..... . .. ...... ................ . ............ . .... . . ... ........ ... . ..... 15.19
STARTER SOLENOID GROUND CIRCUIT TEST ... . ... ... .... . .. ..... . .. ...... . ..................... 15.19
GEAR POSITION SWITCH NEUTRAL INDICATOR TEST . .... . . .. . .. . . .......... . ...... . .. . . . ........ 15.19
CLUTCH SWITCH CIRCUIT TEST .... ..... .. .... . .. .. . . ..... . . .. . .... ........ .. .... ................. 15.20
CLUTCH SWITCH REMOVAL I INSTALLATION ..... . ..... ........ . ........ .... . . . . .. . ...... . .. . ... . 15.21
STARTER SOLENOID POSITIVE CIRCUIT TEST .. . . .... . ...... . . ..... ....... . ... .. . ... ... . .. . .. . .... 15.21
STARTER CURRENT DRAW TEST ... ... . ........... . .. .. .. .. . . ...... . ........ . . . ........... ... . ... .. 15.21
STARTER MOTOR, REMOVAL I INSTALLATION .... . ... .. . .. . . .......... . .... .. ....... ... . . .. .. . .. .. 15.22
STARTER CLUTCH REMOVAL ..... .. .......................... . ..... .. . ....... .. . . ... . ......... . . .. 15.23
CHARGING SYSTEM SERVICE ......... .. . .... .. .. ... . . . . .. . ......... ............. ... . .. . .. . . .... . ... 15.24
TROUBLESHOOTING, CHARGING SYSTEM .. . . ... ......................... .. . . .... .. .............. 15.24
CURRENT DRAIN INSPECTION .. . . . .. ... ... .. . . . ...... ... ..... ... . .. . ..... ... .. . . . ... . .. . .. .. ...... 15.25
REGULATED VOLTAGE I AMPERAGE OUTPUT INSPECTION .... .. ... ..... ....... . .......... .. . . ... 15.25
STATORACVOLTAGEOUTPUTTEST . . ............. . . ......... . ...... . .. ..... ... . .. . . ... .... . ... . . 15.26
STATOR RESISTANCE TEST ......... . .... .. .................... . ... . ... ...... . . ... ................ . 15.27
9926140 R02 - 2015 - 2016 Scout Se rvice Manual

15. 1
STARTING I CHARGING
STATOR WINDINGS TO GROUND INSPECTION .............. .... ............... . ....................... 15.27

STATORREMOVAL ... . ....................... . .................. ... ............ . . . .......... . . .. ..... . . . 15.28
STATOR INSTALLATION ........ . .. . .... . ................................................................ 15.28
FLYWHEEL REMOVAL .......... . ........... . ....... ...... . . . . .. .. . .......................... .. .... . ..... 15.29
RECTIFIER I REGULATOR CONNECTOR INSPECTION ................................................ . . 15.29
DIODE LEAKAGE TEST ........................................... .. ..................................... 15.29
REGULATOR I RECTIFIER REPLACEMENT ............. . ....... .. ..................... . ................. 15.30

15.2
STARTING I CHARGING
GE NERAL INFORMATIO N
SERVICE NOTES Battery Label
All electrical system and component service can be
performed with the engine in the frame.
· . ·- IMPORTANT . . -· , @ANGER / PO I SON

CAUTIONS TO OBSERVE DURING ELECTRICAL
SYSTEM SERVICE
• Always turn off ignition switch before
disconnecting any electrical component.
• Always verify that bullet-type connectors are free
of corrosion, contamination or breaks when
troubleshooting electrical problems.
• Verify that bullet-type connectors are firmly
seated. Listen and/ or feel for a click when
connecting them.
• Ensure to rele ase the lock on lock-type couplers
before disconnecting them to avoid damaging the
connector.
• Pulling on the wires when disconnecting couplers
can introduce problems. Hold the connectors
themselves when disconnecting them, not their
associated wires.
• Inspect each male and female terminal of multi-pin
connectors for corrosion, contamination, loose or
bent pins.
9926140 R02 - 20 l S - 20 16 Scout Service Manual

15.3
STARTING I CHARGING
CAUTION
Battery electrolyte is poisonous. It contains sulfuric WIRE ROUTINGMake sure that all wires are routed
acid. Serious burns can result from contact with skin, correctly away from moving parts, hot exhaust, or
eyes or clothing. Antidote: sharp edges.
• External: Flush with water.
• Internal: Drink large quantities of water or milk. CAUTION
Follow with milk of magnesia, beaten egg, or (
vegetable oil. Call physician immediately. FUSESFuses are in place to protect circuit wiring and
• Eyes: Flush with water for 15 minutes. Call components. Always determine the cause of an open
physician immediately. fuse before installing a new fuse.Do not increase the
value of the fuse to correct the problem.Do not use
Batteries produce explosive gases. Keep sparks, wire, tin foil or other substitutes for fuses.
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always C
shield eyes when working near batteries.KEEP CAUTION
BA'ITERIES AND BATTERY ACID OUT OF REACH ELECTRONIC COMPONENTSSemiconductor parts
OF CHILDREN. used in electronic components will not withstand
The charging system used on the motorcycle is careless handling.Do not drop or strike parts that
calibrated for the maintenance free battery that is contain semiconductors such as the ECM or rectifier/
installed as original equipment. Do not replace with a regulator. Dropping electronic components can
conventional lead-acid battery. Before cause damage to the component.Follow instructions
troubleshooting the charging system, inspect the supplied in this chapter, including chapter 5 (Fuel
battery thoroughly. A discharged, poorly charged or Injection) and chapter 17 (Ignition System), very
faulty battery will make the readings obtained carefully when working on electronic components.
during charging system troubleshooting erroneous Failure to follow instructions may cause irreparable
or difficult to interpret. damage to the part being inspected.
A battery will self-discharge when the motorcycle is C
not in use. Make sure to properly store the battery as
outlined later in this section. SPECIAL TOOLS
Maximum voltage and service life is only achieved
when the battery is properly serviced initially. Make TOOL DESCRIPTION PART NUMBER
sure to follow instructions outlined later in this
Battery Tester PU-50296
section.
Overcharging can be caused by a faulty battery Electrical Tester Kit PV-43526 C
(shorted cell). Test system with a known good
battery when diagnosing an overcharge condition. Relay Bypass PU-49466
New batteries must be properly maintained as Smartlink Module Kit PU-47471
outlined in this section to ensure proper service life.
USB to Serial Adapter PU-50621
· CAUTION (
Even with a good battery, battery voltage can TORQUE SPECIFICATIONS
recover after charging, but under excessive loads the
battery voltage will drop quickly and eventually TORQUE
PART DESCRIPTION
"die". Often the charging system is suspect when it is SPECIFICATION
not the cause of the problem. Always inspect for Battery Box Mount Screw 96 in-lbs (10.8 Nm)
excessive loads if the battery continues to lose its (.
charge. Items such as incorrect wattage bulbs, Battery Hold Down 36 in-lbs (4.1 Nm)
sticking brake light switch(s), continuous low rpm Screw
operation or leaving the lights on without the engine
running for long periods of time can drain a battery Battery Terminal Bolts 36 in-lbs (4.1 Nm)
even if the charging system is operating correctly. Coolant Reservoir Heat 96 in-lbs (10.8 Nm)
Shield Bolt
Regulator/Rectifier to 84 in-lbs (9.5 Nm)
Bracket Nuts

15.4
STARTING I CHARGING
TORQUE TORQUE
PART DESCRIPTION PART DESCRIPTION
SPECIFICATION SPECIFICATION
Regulator/Rectifier 19.0 ft-lbs (25.7 Nm) Stator Cover Screws 15 ft-lbs (20.0 Nm)
Bracket to Frame Bolts
Stator Mounting Screws 88.5 in-lbs (10 Nm)
Starter Terminal Nut 60 in-lbs (6.8 Nm) to Cover
Starter to Engine Mount 88.5 in-lbs (10 Nm) Stator Wire Clip Screws 70.8 in-lbs (8.0 Nm)
Screws
ELECTRICAL SPECIFICATIONS
ITEM SPECIFICATIONS
Electrical (General) Ignition System Distributor-less Transistorized Dual Coil Type
Ignition
Starting System Electric
Charging System Permanent Magnet I 3 Phase I Full Wave
Rectification
Regulator/ Rectifier Solid State Three Phase Voltage Regulator/ Rectifier
Lighting System 12VDC
CHARGING SYSTEM SPECIFICATIONS
ITEM SPECITICATIONS
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 I 70°F) (Black to each other black)
(Disconnect regulator - see test.) 146 milliohms ±20%
Stator Coil Resistance To Ground (Each black wire) Infinity (no continuity)
Regulator/Rectifier Regulated Voltage 14.3- 14.7 VDC
Alternator Output (Amps I Watts) 32A (460 Watts)@ 6000 RPM
Type Leoch:
Voltage 12 Volts DC
Nominal Capacity@ 10 Hr Rate 12AH
Battery
Recommended Battery
Charging Current STD: 1.20 A for 5 to 10 hrs
Cold Cranking Amp Rating 210

15.5
STARTING I CHARGING
STARTING SYSTEM SPECIFICATIONS
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 (OL on Fluke TM 73) (
Resistance: Battery Input Terminal to Insulated Brush Continuity (0 Ohms)
Resistance: Bat. Input Terminal to Starter Motor Case Infinity (OL on Fluke ™ 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

15.6
STARTING I CHARGING
ASSEMBLY VIEWS
STARTER MOTOR/ SOLENOID
\,.,. ; .'
\ • ;',,_ ..
',,, ' \ .,.
>"T . _:.::,.;·:__:):y:'.:- ·.
·- \_
.· . -;,,,,.:<i,f(:.:,
,"':
. "! ··, ··;:- ... .,·"--~-~---
,:..:.· ·- :...·
CD Starter Motor -
CD Nut, Terminal (B+) - MS (QTY.l) 60 in-lbs (6.8 Nm)
G) Terminal Cover -
© Bolt, Starter Motor - MS x 1.0 x 25 (QTY.2) 88.5 in-lbs (10 .0 Nm)
G) Cable, Solenoid to Starter Motor (B+) -

® Battery -
(j) Starter Solenoid -

15.7
STARTING I CHARGING
STATOR
.. .,/· \
;
·.<... )
/ :··,.,.··/--- -~
/ .
....... ,_.-:-· . - .. --~: .

·' ···· ·--- '-
::/.~--·';;.-:.
. ..
CD Stator -
Q) Bolt, Stator - M6 x 1.0 x 35 (QTY.3) 88.5 in-lbs (10.0 Nm)
CD Clip, Stator Wire -

© Screw, Stator Clip - M5 x 0.8 x 10 70.8 in-lbs (8.0 Mm)
(.

15.8
STARTING I CHARGING
REGULATOR / RECTIFI ER
~-- ·,-···· ·- .... ;;·
\. }
/'
/
/
...... ,:
!''
. . .;
i
. / ..
,,
..
.,
~---··
f ?'\....
i-- - - -'s
~
NUMBER PART D ESCRIPTION TORQUE (IF APPLICABLE)
CD Nuts, Hex 84 in-lbs (9 .5 Nm)
0 Regulator I Rectifier, Voltage -

CD Connector, Electrical Regulator I Rectifier -
© Bracket, Regulator I Rectifier -
Ci) Bolt, Regulator Bracket - MS x 1.25 x 35(QTY.4) 19.0 ft-lbs (25.7 Nm)

15.9
STARTING I CHARGING
BATTERY (
(
G) Screw, Battery Hold Down - M 10 x 1.25 x 25 (QTY. l) 36 in-lbs (4.1 Nm)
CD Bracket, Battery Hold Down -

G) Battery -
C
© Screw, Battery Box - MB x 1.25 x 12 (QTY. l) 96 in-lbs (10.8 Nm)
® Screw, Shoulder - M6 x 1.0 x 10 (QTY.4) 96 in-lbs (10.8 Nm)
® Battery Box -
(j) Reservoir, Engine Coolant 84 in-lbs (9.5 Nm) (
® Shield, Heat Coolant Reservoir -
® Bolt, Heat Shield- M6 x 1.0 x 12 (QTY. l) 96 in-lbs (10.8 Nm)
@) Nuts, Self Threading -

15.10
STARTING I CHARGING
BATTERY SERVICE
BATTERY REMOVAL BATTERY INSTALLATION
page 3.9.
2. Rotate the fuse panel to access the battery. Be sure cable ends and battery terminals are clean.
Apply a light film of di-electric grease to terminal
3. Remove the battery hold down bolt CD. bolt threads.
f\ \
1. Carefully install battery with negative terminal
toward front of vehicle.
4. Remove negative (-) battery terminal bolt and

terminal from battery.
5. Remove positive ( +) battery terminal bolt and
2. Connect positive cable to the battery and torque to
terminal from battery CD. specification.
6. Lift battery out of battery box. 3. Connect ground (negative) cable to battery and
""
2 )
_/
4. Apply dielectric grease over terminal areas for
corrosion protection.
3.9.
It may be necessary to push the main harness away

from the battery, toward the RH side of the frame in
order to remove the battery.

15.11
STARTING I CHARGING
BATTERY BOX REMOVAL BATTERY BOX INSTALLATION

1. Place motorcycle in an upright position with the 1. Connect the Load I Tip Over Module connectors
front wheel clamped in a wheel vise. ©.
page 3.9.
3. Remove battery. See Battery Removal, page 15.11.
4. Lift starter solenoid and coolant filler from bracket. (
/--
( 3
\,_./
r
. - -----1
5. Remove rear battery box screws G).
/.,,..---"\
( 4 ;;c----+--
, ... _,.,,...
(
2. Lower the battery box CD into position and align

screw holes. C
3. Install the battery box fasteners CD, G) and torque
to specifications.
6. Remove front battery box screws Q).

C
7. Lift battery box CD to disconnect the load module
connectors ©.
4. Install the starter solenoid.

8. Remove battery box. 5. Install the coolant reservoir filler.
6. Install battery. See Battery Installation, page 15.11. C
7. Install seat assembly. See Seat Removal I
Installation, page 3.9

15.12
STARTING I CHARGING
BATTER Y CHAR GIN G - NEW BATTE RY BATTERY IN SPECTION

1. Charge the battery at 1.2 amps for 5 to JO hours. 1. Remove battery. See Battery Removal, page 15.11.
use a straight rate charger (not load sensing or
2. Inspect battery tray and hold-down bracket for
battery tender type) for the initial charge of a new
damage. Be sure all foam strips are in place on
battery.
battery box .
CAUTION 3. Inspect for cracked or broken battery case.
Do not attempt to quick charge the battery at any
time. CAUTION
Do not remove the battery cap assembly in an
2. Remove battery from charger and let it sit for 30 attempt to inspect fluid level, specific gravity or
I
minutes or longer. attempt to add fluid to battery. After initial servicing,
battery should remain sealed.
Measure voltage with a digital multimeter. If lower 4. Inspect terminals for corrosion. If corrosion is
than 12.5VDC, battery must be recharged again in found, remove battery and clean terminals with a 15
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 15.11 .
battery voltage is still below 12.5 V DC , replace
the battery. 6. Once connections are secure d , apply a thin film of
di-electric grease to terminals.
BATTE RY CHARGING - IN SE RVI CE 7. Install seat. See Seat Removal I Installation, page
1. Measure battery voltage with a digital multimeter. 3.9 .
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
BATTE RY TES TING
given below.
The recommended battery tester for all Indian
CAUTION Motorcycle batteries is special tool PU-50296. See
Special Tools Index, page 1.13.
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 5 to 10 hours. this output a conductance measurement is calculated.
Conductance testing is more accurate than voltage ,
specific gravity, or load testing.
Specification: 1.2 A for 5-10 hours
3. Remove battery from charger and let it sit for 30

minutes or longer.
4. Measure battery voltage with a digital multimeter.
If battery voltage is lower than 12.50 V DC battery
must be recharged again in accordance with step
1 and 2 above.
minutes or more , check the battery voltage again.
If battery voltage is still below 12.50 V DC, replace
battery.
When motorcycle is not used for one (1) month or

more , remove battery and store it in a cool, dry area.
Inspect voltage monthly and charge according to
above instructions if necessary.
9926140 R02 - 2015 - 20 16 Scout Servic e Ma nual

15.13
STARTING I CHARGING
STARTER MOTOR 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.
STARTING SYSTEM DIAGNOSTIC TABLE

SYMPTOM POSSIBLE CAUSE RECOMMENDATION
Starter motor does not turn with Gear Position Switch or circuit Test Gear Position Switch. (
transmission in neutral. Turns with malfunction.
clutch pulled in.
Starter motor does not turn with Clutch Switch or Side Stand switch Test Switches.
transmission in gear and clutch circuit malfunction.
lever pulled in. Turns with
transmission in neutral. (
Starter motor will not turn. Low battery voltage. Poor cable See Troubleshooting Flow Chart I
connections. Main ground loose.
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 Chapter 16
speed, but engine does not start. Engine Problem Chapter 7 - I 0
Fuel Delivery Problem Chapter 5

15.14
STARTING I CHARGING
STARTER CIRCUIT DIAGRAM

Starting Circuit
-Scout
I I
~
40A
Main
Fuse
B
Starter~
f"""y II
II
II
:l I II
GSS
ECM 1
;;
Top
View
l
L
;, 00,M
WH/Yl'
I
1 RD/OK
ECM1 YE/..\'H
==============::::::::'.:~t:-
b=- ::~ ~P:
!
-
~":155 Load
Module In
OB/YE P2 ~;?~~
ECM2 YEI\VH ·: Pl
ECM2
ft::: =====::::::::=:::::::t: F::t.===

lJoG!WH===!=
· =:!=Ii:= i=a==oGNIH~S
1
· - - - P K / BK P7
,~
:ls/
Chassis
Ground
= ~ I====== Da/YE
L.:::===== YE,WH · Pl
Pl

15.15
STARTING I CHARGING
TROUBLESHOOTING FLOW CHART 1 (
iT
est f
B
ttery
!
-+- Fail -+-
Service I Charge I Replace Battery
Inspect Charging System
Pass
t
Does Starter Solenoid Click -+- Yes
(
When Button Is Pushed?
t
No
t
Test Gear Position, Clutch,Sidestand -+- Starter Turns -... !Repair or Replace Switch(es)I
Sto /Run, and Ti over switches · ·
t
I.Bypass
. - - - - - - - - - - - - - - - ~ -+-
Starter Relay Switch Circuit I
Starter Turns _.___ Problem is NOT in High Current Portion of Starting System
------.- Ins ect Switchin Circuit
t
t
Starter Doesn't Turn
~~~~~~~~~~~~
(
IBypass Starter Relay ! -+- Starter Turns !

-.,.. Replace Starter Relay !
t
(
.
t
IBypass Positive Starter Cable I
.
-+- Starter Turns -.,.. Perform Voltage Drop Tests for ( +)
High Current Side of Starter
t
Bypass Ground (.) Side of Starting Perform Voltage Drop Tests for (·)
System -+- Starter Turns _.... High Current Side of Starter
t
I Inspect Starter Motor I -+- Starter Motor Okay -+- ..._Engine or Starter Drive Gears
(
____L_o_c_k_e_d_U~p_ _ _ _..,
C.

15.16
STARTING I CHARGING
TROUBLESHOOTING FLOW CHART 2
These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive ammeter
clamp and a DMM.
!Inspect Battery! --t,.- Battery Condition Poor__.. Service Battery or Replace

· Inspect Charging System
Battery Condition Good
t
! Perform Starter Current Draw Test ! --to-- ! Slow Crank and Low Draw!
t t
ISlow Crank and High Draw I IInternal Starter Problem I --to-- ! Remove Starter Motor and Inspect !
I I I
! Perform(+) Side Voltage Test --to-- Voltage Drop Above Limit --to-- ! Correct Problem and Retest I
!voltage Drop Within li.llowable Limit I
IPerform(-) Side Voltage Test I -.- j Voltage Drop Above Limit I --t,.- ! Correct Problem and Retest!
Ivoltage Drop Within Allowable Limit j
I. Internal Starter Problem I- __.... Internal Starter Problem Found

Rebuild I Re lace Starter Motor
INo Internal Starter Problems Found I

Carbon Build-Up in Combustion Chamber
Engine Compression Excessive Incorrect Valve Timing
or Internal Engine Problems Incorrect Ignition Timing
Internal Engine Problem
9926140 R02 - 20 I 5 - 2016 Scout Service Manual

15.17
STARTING I CHARGING
TROUBLESHOOTING FLOW CHART 3 (

SYMPTOM POSSIBLE CAUSE
Starter clutch malfunction.
Starter motor turns, but engine does not turn. The Starter torque limit clutch slipping.
starter motor can be heard spinning.
Starter gears damage.
(

15.18
STARTING I CHARGING
STARTING SYSTEM TESTS

BATTERY LOAD TEST 5. Working on the vehicle side of the harness, test
1. Load test battery using a commercially available continuity between terminal 2 (black wire) and
battery load tester. Follow the battery load tester chassis ground.
manufacturer instructions.
Although not as conclusive, the following test can be

used to direct troubleshooting efforts if a battery load
tester is not readily available.
r-lffhl:nf 1
') _______
I I
2. Charge battery until open circuit voltage is above

12.5 Volts. L~~----.. 2
3. Install battery and connect battery cables.
4. Connect digital multimeter to battery and keep it
connected for duration of test.
5. Turn ignition key on and move head light high
beam switch to High Beam for 1 minute (without
the engine running).
Resistance should be~ 0.5 0
6. Measure battery voltage.
7. If battery voltage has dropped below 10.5 V DC,
re-charge and re-test battery or replace it. GEAR POSITIO N SWITCH NEUTRAL INDICATOR
TEST
STARTER SOLE NOID GROU ND CIRC UIT TEST Symptoms of a faulty Gear Position Switch may
include:
• Starter motor does not operate when transmission is
Ensure that the motorcycle is secure and that the in neutral,
transmission is in neutral for the following test.
but...
1. Shift transmission to Neutral. • Starter motor does operate when clutch is pulled in.
2. Remove seat. See Seat Removal I Installation, page 1. Place the ignition switch in the · RUN position to
3.9. power up the electrical system.
3. Locate the starter solenoid CD and disconnect the 2. Place engine stop switch in the RUN position.
start solenoid connector Q).
3. Shift transmission into Neutral.
4. Observe neutral indicator light.
I
Jr
{
·-"
, ··· ~- -< .
,r?:.....
/" _l9
4. Set the multi-meter to read resistance and insert

meter leads into the appropriate jacks.

15.19
STARTING I CHARGING
5. If indicator is not lit with transmission in neutral: • Test the gear position switch resistance between the (
• Place the RUN/STOP switch in the STOP position and switch connector terminal 1 and chassis ground.
turn motorcycle power off.
• Roll the motorcycle forward and back enough to
verify that it is in neutral.
• Locate the gear position switch G) wire connector Q)
located near the engine at the rear of the cases
above the voltage regulator.
• Compare reading to the resistance specification.
Gear Position Switch Neutral Resistance

Specification: 10±0.50
6. If resistance reading is not within specified

parameters, replace neutral switch or repair
wiring as necessary.
7. If neutral indicator switch is working correctly and
neutral indicator did not light with the transmission
in neutral; inspect neutral lamp and circuit wiring
for a open/short circuit.
CLUTCH SWITCH CIRCUIT TEST

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. (.
• Set the multimeter to test resistance and insert
meter leads into the appropriate jacks. 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. l
5. Operate clutch lever while observing meter
display.
6. Pull clutch lever to the handlebar. Meter should
display continuity or very low resistance (less than
1 ohm) when the clutch switch closes.
7. Release clutch lever, meter should display 01
(open line).

15.20
STARTING I CHARGING
8. If clutch switch does not test as described inspect 4. Installation is performed by reversing the
clutch switch, clutch switch wiring or mounting of removal procedure.
switch to clutch lever for fault.
9. If switch is mounted correctly and physically STARTER SOLENOID POSITIVE CIRCUIT TEST
operates but does not open and close electrically,
replace switch.
Secure motorcycle on the side stand and place
CLUTCH SWITCH REMOVAL/ INSTALLATION transmission in neutral for the following test.
1. Remove clutch lever G).
1. Place the transmission in neutral.
2. Disconnect positive cable G) from starter motor.
/ '
i\.." / ··, • . ·<·· :, ',

.J ·--- / ·
',v " .~· .....;,;'/.;
\~-1~~~f0;-
2. Disconnect the electrical connectors at the clutch
switch 0 and slide the switch out from the lever
side.
3. Set multi-meter to DC Volts and insert meter leads
in the appropriate jacks.
4. Connect the red meter lead (+) to the positive
starter cable eyelet and the black (-) meter lead to
chassis ground.
5. Place key switch in RUN position to power up the
electrical system and place the STOP/RUN switch
in the RUN position.
6. Press starter button. The meter should display
battery voltage. If voltage is more than .2 volts
below battery voltage, inspect the power supply
circuit.
STARTER CURRENT DRAW TEST

3.
CAUTION This procedure requires the use of an inductive
ammeter to read current draw and a volt meter to
The clutch switch has a locating pin on the bottom monitor battery voltage during the test.
side which slide into the clutch lever perch. Use
caution when removing the clutch switch so the
locating pin does not break off.
Do not allow any part of the jumper cable clamp

Gently pull the clutch switch out of the lever perch to touch the chassis or any other ground.
until the locating pin is free.

15.21
STARTING I CHARGING
CAUTION
•• ·C ·-·
STARTER MOTOR, REMOVAL/ INSTALLATION
Disable the ignition system so that the engine will not
start during this test.
Ensure that the ignition switch is turned off.
• Remove ignition coils and spark plugs. Remove the negative cable at the battery before
• Install test spark plugs into plug caps. removing the starter motor.
• Ground spark plugs against engine.
1. Disconnect negative battery cable. See Battery
1. Remove seat. See Seat Removal I Installation, page Removal, page 15 .11.
3.9.
2. Remove radiator assembly. See Radiator Removal I
2. Inspect the battery. Charge or replace battery as Installation, page 4 .2 2.
necessary before proceeding.
3. Disconnect positive terminal from the starter
3. Place transmission in neutral. motor.
4. Position an inductive ammeter clamp on battery 4. Remove the two fasteners G) from rear of starter
positive cable. motor Q). Slide starter to the RH side of the
motorcycle to release from engine case.
5. Set the multi meter to Volts DC scale and connect
red lead of meter to positive post of battery.
6. Connect black lead of meter to negative post of
(
battery.
(
=
Ii
-+
Solenoid
(
5. Remove starter motor.
6. To install the starter motor, reverse the
removal procedure.
7. Turn the ignition switch ON to power up the
electrical system and observe ammeter. It should 7. Torque the starter mounting bolts to specification.
register negative amps. If it does not, turn the
ammeter probe around. (
8. Place the engine STOP/RUN switch is in the RUN
position, transmission is in neutral, clutch lever
pulled in and that the ignition system is disabled. 8.
9. Press starter switch and crank starter for about 5
seconds and observe both meters and the Hold the lower terminal nut with an open ended
tachometer. (
wrench while tightening the upper nut to avoid
10. The battery voltage should remain above 9.6 volts. damage.
11. The amperage draw of the starter should not
exceed 160 amps. Torque the starter motor positive terminal nut to
specification.
Starter current draw@ 77°F (25°C): '.5:160 Amps
Starter Motor Positive Terminal Nut: 35 in-lbs (4.0

Nm)

15.22
STARTING I CHARGING
STARTER CLUTCH REMOVAL

1. See Starter Drive Removal, page 10.19.

15.23
(
STARTING I CHARGING
CHARGING SYSTEM SERVICE

TROUBLESHOOTING. CHARGING SYSTEM
The battery must be fully charged and in good condition to obtain accurate readings. Battery charging current is
automatically reduced by the regulator I rectifier if the regulator I rectifier unit reaches a critical temperature
(overheated). The system should be cool when testing DC charging output or when testing the regulator I
rectifier to ensure accurate readings. Refer to test procedure for individual charging system components for (
more information.
START
i
! Measure Current Drain! - Incorrect -
Excessive Loads (Acey Draw)
Shorted Wiring
Shorted Compenents
(
(Disconnect any accy items to
i
Correct
see if load disappears)
i
Inspect Regulated Voltage & - ll3.S VDC _ 14 _7 VDC I- Inspect Battery & Battery Connections
Amperage Output · - Perform Battery Load Test
Less than 13.8VDC or

above 14.7VDC
Inspect Voltage Reg/Rect 2-pin C

and 3-pin connector. Inspect BK
wire(-) and BK/RD wire (current
- Reg/Rect Faulty - IReplace Reg/Rect Unit !
path) back to battery(+)
C
j Inspect Stator j - Stator Faulty - !Replace Stator j
i
Stator OK
i
- Faulty Wiring or Connectors
Damaged Rotor Magnet
j Test Reg/Rect Unitj - Reg/Rect Faulty ---,.... IReplace Reg/Rect Unit!

15.24
STARTING I CHARGING
CURRENT DRAIN INSPECTION REGULATED VOLTAGE/ AMPERAGE OUTPUT

IMPORT.ANT · .· INSPECTION
- - .
Current drain should only be measured after all
systems have timed out and gone to sleep. Leave This procedure requires the use of an inductive
power OFF and do not disturb for approximately 12 ammeter to read current draw and a volt meter to
MINUTES for an accurate reading. monitor battery voltage during the test.
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 3.9.
storage).
2. Place the inductive ammeter over the positive (+)
1. Remove seat. See Seat Removal I Installation, page battery cable.
3.9.
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 and 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.
5. Start engine and warm to operating temperature.

6. At 1000 RPM or slightly above; the ammeter
should reach the "break-even" point (no
Do not operate electric starter or meter fuse will be amperage leaving the battery) and the voltmeter
damaged. should be rising toward 14 VDC.
Specification: Break-even point for charging System:
4. With ignition switch off, and after 12 minutes 1500 RPM
have passed, read current drain.
5. If current drain exceeds specifications inspect 7. Increase engine RPM to 2500. The ammeter should
wiring and components for short to ground. rise a slight amount, then stabilize. Volt meter
should read above 14 V DC.
Parasitic Draw Specification (after 12 minutes with
power OFF): 4.5 mA MAX
6. Locate the faulty component or wiring by

disconnecting accessories, wiring connections,
and fuses one-at-a-time while observing current
drain. When current drain falls within
specifications, focus efforts on the last circuit or
component that was disconnected.

15.25
(
STARTING I CHARGING
·,-.p~·. : .. --:: -, . ,. ,. - A . - . . . : " .. .

8. Use results obtained from preceding tests and the ::.·. ,- . - .ea. WARNING .: -
following descriptions to determine if charging
system is functioning properly. CARBON MONOXIDE: Never run an engine in an
CHARGING SYSTEM OPERATING enclosed area. Exhaust contains poisonous carbon
CORRECTLY: Ammeter goes up a small amount, monoxide gas that can cause loss of consciousness
then stabilizes slightly above +O amps. Volt meter and may lead to death. If you must run the engine to
rises toward 14.8 ± V DC, drops off a little and do some repairs, do so in an open area or with an
starts to stabilize. exhaust evacuation system operating.
LOW BATTERY: Amperage continues to rise ,
voltage levels off as battery is absorbing voltage. CAUTION
Charging system may be okay. Need to charge
battery fully or use a good battery and repeat test. VOLTAGE I ARCING: Use caution not to touch any of
Meters will indicate similar reading to the the connections or allow the exposed terminals to
overcharging chart. come close to any other part of the vehicle or other
objects, as an arc may occur.
CHARGING SYSTEM UNDERCHARGING: Ammeter
drops to O or remains below O (negative reading)
at all rpm, volt meter remains the same or goes 1. Disconnect the 3-pin stator connector.
down. Go to voltage drop inspection. 2. Set multi meter to measure AC Volts.
CHARGING SYSTEM OVERCHARGING: Ammeter
3. Connect one lead of the multi meter to pin A CD
rises well above O and remains there or continues
and one lead to pin B Q) on the 3-pin stator
to rise. Volt meter goes well above 14.8 V DC and
connector.
may continue to rise.
EXCESSIVE LOAD: Current levels off or starts to
drop, voltage continues to rise. Load may be
excessive (accessories or shorted components).
Determine if excessive loads are present.
Disconnect accessories and re-test.
(
9. Turn ignition key off.
10. Remove inductive ammeter clamp.
3.9.
(
STATOR AC VOLTAGE OUTPUT TEST ................- .....-.-- ,.--·
.. /,
··-·······················-···-···--
····································-- - ~
,--•"' •......
->.....:
Set multimeter to VAC (alternating current). Engine
cold. Regulator I Rectifier disconnected (2-pin and 3- CAUTION
pin connector). Engine must be running. Be sure to
heed the following Warnings and Cautions. VOLTAGE I ARCINGUse caution not to touch any of
the connections or allow the exposed terminals to
come close to any other part of the vehicle or other
objects, as an arc may occur.
HOT COMPONENTS: The engine and exhaust
4. Start the engine and let it run at idle. Observe the
system become very hot during operation and
multi meter reading.
remain hot for a period of time after the engine is (
shut off. Wear insulated protection for hands and 5. The meter should indicate a minimum reading of
arms or wait until the engine and exhaust system 24 VAC at idle.
have cooled sufficiently before working on the
6. Repeat test for pins A CD & C G).
machine.
(_

15.26
STARTING I CHARGING
7. Repeat test for pins BCD & C CD. 3. Connect one meter lead to pin A G) and the other
lead to pin B CD on the stator connector. Note
No load AC Volts @ 800 RPM: Approx 24 VAC resistance value.
The test results in Steps 6, 7, and 8 can read more

than 24 VAC, but it is important that the reading for
each pair of wires is approximately equal.
8. Increase RPM to 2000. Repeat Steps 4-8.

9. At 2000 RPM the reading should be at least 34
VAC.
The test results obtained in step 10 can read more

than 34 VAC, but it is important that they are all ······-·····- ······--···..-·-
approximately equal.
Stator Resistance: Less than 1 Ohm

No load AC Volts @ 2000 RPM: Approx 34 VAC
4. Repeat test for pins A G) & C CD.
5. Repeat test for pins B CD & C CD.
STATO R RESISTAN CE TEST
6. If resistance values do not match specification,
CAUTION inspect stator and replace as necessary.
The engine must not be running while performing the
following resistance test. STATOR WINDING S TD GROUN D INSPECTION
CAUTION
The engine must not be running while performing the
Set multimeter to measure resistance. Engine OFF following resistance test.
and cold. Regulator Rectifier 3-pin connector
unplugged.
1. Disconnect the 3-pin connector G) from stator. Set multi meter to measure resistance. Engine OFF
and cold. Regulator Rectifier 3-pin connector
unplugged.
l. Disconnect the 3 pin connector G) from stator.
2. Set the multi meter to measure resistance (0) and

insert the meter leads in to the appropriate jacks.

15.27
STARTING I CHARGING
2. Connect one multi meter lead to pin A CD and 4. Remove fasteners CD from stator wire guide CD.
place the other lead of the multi meter in contact
with a good engine ground, observe resistance to
ground reading.
5. Remove three stator bolts CD.

6. Push the rubber harness seal © to inside of stator
cover CT). Remove stator assembly©. (
Stator to Ground (-) Continuity Specifications: Open
Circuit (OL)
3. Repeat test for other two stator leads (CD & CD) to
ground.
4. There should be no connection from stator
windings to ground. C
STATOR REMOVAL
1. Remove stator cover. SeeStator Cover Removal,
page 9. 19.
2. Disconnect the stator connector from the regulator.
C
3. Using a terminal tool or pick tool, remove the three
electrical terminals from the stator connector.
STATOR INSTALLATION
The electrical connector must be removed from the
stator assembly before it can be installed in the motor-
cycle. See Stator Removal, page 15.28 for information
on connector removal.
1. Feed the stator wires through the hole and seat the
rubber harness seal CD in cover.

15.28
STARTING I CHARGING
2. Position the stator CD inside the stator cover G). 7. Install the stator cover. See Stator Cover
Installation, page 9.19
FLYWHEEL REMOVAL
See Flywheel Removal, page 9.20.
RECTIFIER/ REGULATOR CONNECTOR

INSPECTION
1. Remove the regulator I rectifier assembly. See
Rectifier I Regulator Replacement, page 15.30.
2. Disconnect both 2-pin and 3-pin connectors G).
3. Install stator screws © and torque to specification.
3. Inspect pins in the 3-pin and 2-pin connectors

carefully. Check for corrosion, loose pins, poor
connections, or evidence of overheating or other
damage.
4. If the wiring and connectors are undamaged and
appear to be clean and tight, inspect the battery,
stator, and related wiring. Test the regulator I
rectifier for diode leakage.
4. Install the stator wire clip ® and fasteners ®· DIODE LEAKAGE TEST
Torque fasteners to specification.
Engine must be OFF. Perform this test at the regulator

I rectifier 2-Pin connector. Testing at any other point
(between battery and battery cable for example)
could include leakage not attributable to the
5. Insert wire terminals into stator connector housing. Regulator I Rectifier unit.
Note: Verify there is an audible "click" and the
wires cannot be backed out. 1. Disconnect the 2-pin connector at voltage
regulator I rectifier unit.
Wires can be installed into any position on the 2. Install a jumper across the connectors as shown for
electrical connector. Charging performance will not the Bk wire to provide a complete ground path.
be affected.
6. Connect the stator connector to the regulator I

rectifier.

15.29
STARTING I CHARGING
3. Connect meter as shown, with red(+) meter lead

to the RD I BK wire on harness side, and the black
meter lead to the RD I BK wire on the regulator I
rectifier side.
3-Pin cor\nected
4. Compare leakage to specification below.

Specification: C
Leakage: Less than 1.0 mA
REGULATOR/ RECTIFIER REPLACEMENT

1. Disconnect the electrical connectors from the
regulator I rectifier G) .
(
'{;:~\{~~~
:..-·· "
~
:'..,-····· (.
.. '
/.-- ... ·,., ,, .. ,

·.. ( 1 .. . ' ,, ..
-.._/ : \. ,
2. Remove the two nuts CD securing the regulator I

rectifier to the bracket.
removal procedure. (
4. Torque the regulator I rectifier nuts to
specification.

15.30
IGNITION SYSTEM
CHAPTER16
IGNITION SYSTEM
GENERAL INFORMATION .. . .. . . . . . ... . .. . .... ...... ......... . .. .... . . .. .. ............ . .......... . .. . .. 16.2
SERVICE NOTES .................... . ............. . .... .... .................... . . , ................... 16.2
SPECIAL TOOLS ... .... . ... . . .... . .. . ... ........... . .. . . . ...................... ... . .. ....... .... ..... . 16.2
TORQUE SPECIFICATIONS ......... . .. .... ... ... ... ... ... ... .. .... ... . . .... .. ..... ..... .. .. ....... .. . 16.2
SERVICE SPECIFICATIONS .. . .......... .... .. ........ .. .......... . .. .. ... . .. ... ..................... 16 .2
IGNITION SYSTEM SERV1CE ...... . ........................ . . ...... .... . . ... .... .. ... . . ...... ... . ...... 16.3
IGNITION COIL REMOVAL I INSTALLATION ... . ..... . . . ..... . .. .... ................. .. ........... ... 16.3
TROUBLESHOOTING . . . ........ ........ . . ......... . . . .. ... . . ......................... . . . ...... .. .. .. . .. 16.4
BASICS ............................ .. ..... . . . ..................... . .. .. . .. ..... .. . .......... . . ........ 16.4
TEST LEAD ADAPTER KIT . .... .. .. . .... .. .. .. . ... . . .. ....... . . .... ............... .. .................. 16 .4
ECM CONNECTOR MAP .... . ...... . ...... . ... . .. .. .. . .. . . .. .. ... .. .... .. . .... . ..... ... .. ... ......... 16.5
IGNITION SYSTEM TEST FLOWCHART ............. . .............. . ... . ....... ... .. ...... .. . ......... 16.5
BATTERY VOLTAGE INSPECTION TEST 1 ... . .. ........................................... . ..... . . ... 16.6
SPARK INSPECTION TEST 2 .. .. ... .. .. . ...... . . . . ................. .. ... . .. .. .. .. . ... . . ...... . .... . . . . 16.6
IGNITION COIL POWER I GROUND SIGNAL TEST 3 ...... . . . .. .. . ... . . . . ...... . .. .. ...... . .. . .. . . . . . . 16. 6
IGNITION COIL RESISTANCE TEST 4 ................................................................. 16. 7
CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION: . .. ...... .... ... . ..... . .. .... . ... 16. 7

16.1
(
IGNITION SYSTEM
GENERAL INFORMATION
SERVICE NOTES GENERAL PRECAUTIONS
There are many hazards present when working on or • This ignition system is controlled electronically and
around the ignition system. Read and pay close no provisions are available to inspect or change
attention to the following warnings and cautions when ignition timing. A timing light is still valuable as a
working on any component in this section. diagnostic tool.
• Poor connections are the most common cause of
ignition problems. Inspect all connections and
Never run an engine in an enclosed area. Exhaust replace the spark plugs before doing extensive
contains poisonous carbon monoxide gas that can ignition system troubleshooting.
cause loss of consciousness and may lead to death. If • Make sure the battery is fully charged and that the
you must run the engine to do some repairs, do so in charging system is operating correctly.
an open area or with an exhaust evacuation system • A signal from the Crankshaft Position Sensor must
operating. be present at the ECM for spark to occur.
SPECIAL TO OL S
The engine and exhaust system become very hot SPECIAL TOOL PART NUMBER
during operation and remain hot for a period of time Electrical Tester Kit PV-43526
after the engine is shut off. Wear insulated protection (
Digital Multimeter Commercially Available
for hands and arms or wait until the engine and
exhaust system have cooled before working on the Inductive Timing Light Commercially Available
machine.
CAUTION TORUUE SPEC IFICATION S

Some procedures call for the engine to be run in PART I FASTENER TORQUE
order to warm the engine to operating temperature. SPECIFICATION
If this is done the exhaust pipes can "blue" if a
Spark Plug 7.4 ft-lbs (10 Nm)
cooling air stream is not provided by means of a shop
fan directed the exhaust system. Coil to Valve Cover 7.4 ft-lbs (10 Nm)
CAUTION C
SERVIC E SPE CIFICATION S
Parts containing semi-conductors can be easily
damaged if handled carelessly. Do not drop or ITEM SPECIFICATIONS
subject the electronic components to shock loads. Spark Plug NGKDCPRSE
Spark Plug Gap .034 in (.9 mm)

CAUTION Ignition Switch/ Primary 0.6 - 0.8 Ohms± 20 %
Follow the instructions closely when troubleshooting Cables
items in this section. Some electrical components can Resistance Secondary N/A
Values
be damaged if they are connected or disconnected
while the ignition is powered ON and current is 860 Ohms± 10% @ 68°F
Crank Position Sensor Resistance (20°C)
present.
* Spark plug end caps are not removable
,· . -
CAUTION
Using incorrect heat range spark plugs can damage
the engine. Always follow the manufacturer's
recommendations for spark plug heat range.

16.2
IGNITION SYSTEM
IGNITION SYSTEM SERVI CE

IG NITION COI L RE MOVAL/ INSTALLATION
1. Place the IGNITION and RUN I STOP switch in the
OFF/ STOP position.
page 3.9.
page 5.20.
5. Remove the ignition coil fastener G) .
6. Remove the ignition coil electrical connector G)

and lift the ignition coil CD out of the cylinder head.
7. INSTALLATION of the ignition coil is
performed by reversing the removal
procedure. Torque fasteners to specification.

16.3
(
IGNITION SYSTEM
TROUBLESHOOTING (
BASICS TEST LEAD ADAPTER KIT
Before troubleshooting the ignition system, ensure that 1. Tests in this section may include the testing of
the engine STOP/RUN switch is in the RUN position, voltage and I or resistance at the connectors for
the battery is fully charged, and system related fuses various sensor and system components. Use the
are not open (blown). Check visually for corroded, appropriate test adapter lead when performing
loose, or broken connections in critical areas (e. g. these tests at connector pin(s).
sensor connector). Check for loose wire pins in the C
individual sensor connectors and at the ECM 2. Forcing an incorrect or oversized probe into a
(mounted on right side of the battery box). connector may cause inaccurate test results (due
to lack of a solid mechanical connection to the
Don't forget the spark plugs! terminal). It can also damage the connector being
The Ignition System Troubleshooting flow chart (and probed or the connector housing, creating another
the accompanying text) is designed to help you problem which greatly complicates the diagnostic
troubleshoot ignition system problems. It will not lead process. Extreme care must be taken not to
you to faulty or fouled spark plugs. Always inspect introduce problems while probing a connector.
spark plug condition first (and replace if necessary) Electrical Tester Kit: PV-43526
when troubleshooting ignition system problems.
Be sure that the spark plugs are the correct heat range
and are the correct size specification.
C
Extremely high voltage is present in the ignition
system. Do not touch the ignition coils or spark plugs
during test procedures.
CAUTION
(
Once the ECM connector has been disconnected, do
not touch the pins on the ECM. Static electricity from
your body can damage the ECM. Do not attempt to
perform tests on the ECM.

16.4
IGNITION SYSTEM
ECM CONNECTOR MAP

See ECM Connector MAP, page 5.30.
IGNITION SYSTEM TEST FLOWCHART
Inspect Engine,
Check Spark Compression and
Fuel System
Check Spark Plug
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
Test Ignition Coil
OKAY Check
Sensor Pole, NOT OKAY
Timing Wheel Replace the CPS
Teeth, and Wiring

16.5
(
IGNITION SYSTEM
BATTERY VOLTAGE INSPECTION TEST 1 5. Shift transmission into neutral and pull in clutch
1. Remove the seat. See Seat Removal I Installation, lever.
page 3.9.
6. Depress starter button and observe timing light.
2. Set multimeter to measure DC Volts.
7. Determine if timing light flashes without
3. Inspect battery voltage. interruption for both cylinders.
8. Consistent flashes indicate that some secondary
voltage is present. The likelihood of an ignition
related problem is reduced but not eliminated.
Keep the following points in mind:
• There is a threshold voltage and amperage
requirement for timing lights below which they will
not trigger and therefore, not flash.
• Fouled spark plugs may drop secondary voltage so (
low that a timing light will not trigger and therefore,
not flash.
• With no current flowing (open secondary side of the
ignition coil) the timing light will not flash.
• A faulty high tension circuit or poor connection is
one example of an open secondary.
(
9. Replace spark plugs, connect plug wires and re-
test.
10. If timing light does not flash consistently for one or
both cylinders, test ignition coil (Test 3).
IGNITION COIL POWER/ GROUND SIGNAL TEST

3
Power To Ignition Coil
Battery voltage must be present at the ignition coil (Pin
B) when the power button is switched on and the
electrical system powered up.
1. Disconnect the electrical connector from the C
4. If the battery voltage is below 12.5 V DC charge or ignition coil. See Ignition Coil Removal I
replace the battery with a fully charged battery. Installation, page 16.3.
2. Set the multimeter to measure VDC and insert the
meter leads into the appropriate jacks.
When operating the starter with a low battery, the
3. Connect the black lead to ground (on the engine).
voltage available for the ignition coils can drop
below the minimum required to produce spark. 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.
SPARK INSPECTION TEST 2 5. Turn ignition key ON to power up the motorcycle
1. Remove ignition coil(s). See Ignition Coil Removal electrical system and place the STOP/RUN switch
I Installation, page 16.3. in the RUN position.
2. Install secondary ignition cable test adapter 6. Battery voltage should appear on terminal 1 of the
(commercially available) between coil (s) and coil connector (RD wire).
spark plug(s).
3. Connect timing light to secondary ignition cable
test adapter.
4. Turn ignition key ON to power up the motorcycle
and place the STOP/RUN switch in the RUN
position.
9926140 R02 - 2015 -2016 Scout Service Manual

16.6
IGNITION SYSTEM
7. With transmission in Neutral, crank the engine. IGNITION COIL RESISTANCE TEST 4
Battery voltage should again be present on center Ignition Coil Primary Winding
wire.
1. Remove ignition coil. See Ignition Coil Removal I
Ignition Coil Ground Signal Installation, page 16.3
The following steps will test the ECM (Ground)
Signal To Ignition Coil 2. Set the multi meter to measure resistance (Q) and
insert the meter leads into the appropriate jacks.
ECM ground signal must be present at terminal 3
of the ignition coil primary harness connector. The 3. Measure resistance between terminal G) and
signal will appear as a pulse on the meter between terminal G) on the coil. Compare to specification.
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.
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.
14. Repeat the test on the other outside wire in the
connector.
• If no pulse is present, test the Crankshaft Position
Sensor.
If the signal is present on one wire and not the other,
Primary Coil Resistance: 0.6 - 0.8 Q
test related wiring and connections.
• If both signals are present and there was battery
voltage on the RD wire (center terminal) but still no
spark, test the ignition coil windings. (Test 5). CRANKSHAFT POSITION SENSOR (CPS)
RESISTANCE INSPECTION:
See CPS Test I Replace, page 5.42.

16.7
IGNITION SYSTEM
NOTES

16.8
CHASSIS ELECTRICAL
CHAPTER 17
CHASSIS ELECTRICAL
GENERAL INFORMATION ............ ... ...................... . .. . . . .................. . ................ 17.2
SERVICE NOTES .. ....... ...... . . ..... ...................... . .. .... . .. ............... . ............... 17 .2
SPECIAL TOOLS . . .. ................. ... . .. . .. ........................................................ 17 .2
TORQUE SPECIFICATIONS ............. . ............................................................. 17 .2
ASSEMBLY VIEWS . . .. .... . .. . . . .............. ... ................ . ..................... .. ................ 17 .3
HEAD LIGHT . ... ....... . . . ............... . ............ .. ................ .. .... . ....... . . . ... ... . . .... 17 .3
TAIL LIGHT I LICENSE PLATE LIGHT ................................................ . ................ 17.4
FUSE BOX ... . ....... . ............................... . .......... . ....... ... .......... . .. .. . . ...... . ... 17 .5
FUSE BOX ............ .... ...... . .. . ....... .... ........................ .. ................. .... ............ 17.6
FUSE BOX LOCATION ...... . ... . ........ . ................... . ... . .................................... 17 .6
FUSE APPLICATION CHART ....... . . .. ... .. ... ...... ...... . .... .. .... .... .. ....... ......... . .... . .... 17. 7
LOAD I TIPOVER MODULE ....................... .... ... . .... .... . . . . .... .. ............................ 17.9
LOAD I TIP OVER MODULE CONNECTOR MAP ................. . ............. . .... . . . . .. ............ 17 .9
LOAD TIP OVER MODULE REMOVAL AND INSTALLATION ......... . .... . ......... . ........... . . ... 17 . 10
HEADLIGHT SERVICE .. . . .... . .. . ......... . .... . ........... . ... .. .. . ....... . .. . ................. . .... 17.11
HEAD LIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 .11
HORN SERVICE ....................................................................................... 17.12
HORN REMOVAL I INSTALLATION . . ..... .... . . . . .................. ... . .. ... . ............. .. . ... ... 17 .12
TAIL LAMP SERVICE .......................................................................... . . . ..... 17 .13
LED TAIL I BRAKE LIGHT OPERATION ...... . .......... .. .......... .. ..... .. ........ . . .... ...... ... 17 .13
TAIL I BRAKE I LICENSE PLATE LIGHT REMOVAL I INSTALLATION . ..... ................ . .... . .... 17 .13
TURN SIGNAL I HAZARD SYSTEM SERVICE ............... . .................. . .................. ... 17 .15
TURN SIGNAL OPERATION ......................................................................... 17 .15
FRONT TURN SIGNAL REMOVAL I INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 15
REAR TURN SIGNAL REMOVAL I INSTALLATION . . ... . .. ........... ... . . ... .. ...................... 17 .15
INSTRUMENTATION .... . .................... . . ... ........ .. . ........ . .. .... .. ............. . .. . ....... 17.16
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 .16
INSTRUMENT CLUSTER REMOVAL I INSTALLATION ..................... .... ...... . ........ . ... . .. 17 .17
SWITCH TESTING ................ . ........ . .. . .... . ... ... ..... . . . ........ . ............. . . .... .... .. . . . 17.18
BRAKE LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 .18
CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 .19
SIDE STAND SWITCH TEST ................... . .. . ....... . ............... . ......... .. . .... . .. .... ... 17 .19
GEAR POSITION SWITCH TEST ........... . ...... . . ..... .. .. . .. . . .... . . . ........... .... .......... .. 17 .19
BREAKOUT WIRING DIAGRAMS .............. .. .. . ...... . ............ . .. . ............. ... ... . ....... 17 .20
STARTING CIRCUIT WIRING DIAGRAM ......................... . .................. ... ....... . .. . . . 17 .20
IGNITION SYSTEM WIRING DIAGRAM .... . ....... ..... ... . ... ... .................... ... ......... .. 17 .21
THROTTLE CONTROL WIRING DIAGRAM ..... . .................... . ............. . .. . . . ............ 17 .22

17 .1
CHASSIS ELECTRICAL
GENERAL INFORMATION
SERVICE NOTES TORQUE SPECIFICATIONS
Keep the following notes in mind when diagnosing an
electrical problem: PART DESCRIPTION TORQUE
SPECIFICATION
• Refer to wiring diagram for stator and electrical
component resistance specifications. Head Light Retaining 36 in-lbs (4 Nm)
• When measuring resistance of a component that has Ring
a resistance value under 10 Ohms, remember to C
Head Light Mount Pivot 35 ft-lbs (47 Nm)
subtract meter lead resistance from the reading.
Bolt (Adjuster)
Connect the leads together and record the
resistance. The resistance of the component is equal Head Light to Lower 18 ft-lbs (24 Nm)
to tested value minus the lead resistance . Triple Mount Screw
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being Horn Bracket Bolt 96 in-lbs (10.8 Nm)
performed (i.e. 10 A jack for current readings).
Refer to the Owner's Manual included with your Ignition Side Cover Bolts 96 in-lbs (10 Nm)
meter for more information. Instrument Cluster 22 ft-lbs (29.8 Nm)
• Pay attention to the prefix on the multi-meter Mount Screws
reading (K, M, etc.) and the position of the decimal
point. License Plate Bracket to 36 in-lbs (4 Nm)
• For resistance readings, isolate the component to be Fender Nut
l
tested. Disconnect it from the wiring harness or
Load I Tipover Module 84 in-lbs (9.5 Nm)
power supply.
Mounting Screws
Tail Light to Fender 84 in-lbs (9.5)
SPECIAL TOOLS Screw
TOOL DESCRIPTION PART NUMBER Turn Signal Bolt, Rear 18 ft-lbs (24.4 Nm) (
Battery Tester PV-50296 Turn Signal, Front 36 in-lbs (4.1 Nm)
Electrical Tester Kit PV-43526
Smartlink Module Kit PU-47471
USB to Serial Adapter PU-50621
(

17.2
CHASSIS ELECTRICAL
ASSEMBLY VIEWS
HEAD LIGHT
("- ,
I\ __3,,/)
CD Screw, Retaining Ring 36 in-lbs (4 Nm)
CD Retaining Ring -
0) Head Light -
© Nut -
® Screw, Adjuster 35 ft-lbs (47 Nm)
© Headlight Bucket -
(j) Screw 18 ft-lbs (24 Nm)

17.3
CHASSIS ELECTRICAL
TAIL LIGHT/ LICENSE PLATE LIGHT
'
,, rf:i
..
· , ..";:':
/
/
(
,,
<{: .',
"~~
\H. ',\-~ ! "··
j_,,
/
,,,,"'
;
!I ! /'
.' /
_/ . ·..._ ......
"- ·· ~-
5-i::t
'. (. ( \'.
•,, "
(
ITEM DESCRIPTION TORQUE (IF APPLICABLE)
CD Taillight -
CD Lamp, License Plate -
G) Washer (QTY. 2) -
© Nut (QTY. 5) 36 in - lbs (4 Nm)
® Washer (QTY. 3) ·-
® Bracket, License Plate -

17.4
CHASSIS ELECTRICAL
FUSE BOX
.: .. ,
:.~-
~ .,,··,/ •. .. "v ·
.( 1 r_:.,· /<·-
:
'-...
,, ', '
' , -~\_<:~ /
,;·-·" \_'·-·····
\. ·"·.
·• :
·-" ,,.--\
/
('-._,/
3 '
]).~,5
I /
J
\ , ........ __ ___....,.,./
' : r'
1<t
i .
!
!' )
' . '
t i
: ~i Jf;i
ITEM DESCRIPTION TORQUE (IF APPLICABLE)
CD Tab, Fuse Box Mounting -

CD Cover, Fuse Box -
CD Latch, Fuse Box Cover -

17.5
(
CHASSIS ELECTRICAL
FUSE BOX
FUSE BOX LOCATION • The main fuse box CD is located beneath the seat.
There are two fuse locations on the motorcycle "'- '-::::I \
• The main fuse holder G) is located on the rear of the
battery box.

17.6
CHASSIS ELECTRICAL
FUSE APPLICATION CHART
~ )\j~
co 1u . Y)- rr::r~,;u
LJ LJ LJ LJ
CL
680 FAr'~ CHASSIS

STAA1ER RESISTOR 20A 1SA
~ElAY FUEL PUMP ENJG!NrE IHiEADUGHT
~5A 20A ~SA
HEADUGHT FUEL ENiGi~l!IE COO UNG

l PUMP
i
!7!79867
RELAY
RELAY
RELAY FAIN
RELAY
17 1
PIN CIRCUIT DESCRIPTION FROM TO
Al Not Used - -
A2 Headlight Relay Output Fuse Box LH Control
A3 Headlight Relay Coil Power Fuse Box Splice (IGNSW)
A4 Fuel Pump I Ignition Coil Relay Output Fuse Box Splice (FPPWR)
A5 Fuel Pump Relay Coil Power Fuse Box Splice (ENGPWR)
A6 Engine Relay Output Power Fuse Box Splice (ENGPWR)
A7 Engine Relay Coil Power Fuse Box Splice (ENGBRK)
AB Cooling Fan Relay Output Fuse Box Cooling Fan
AS Fan Relay Coil Power Fuse Box Splice (IGNSW)
Bl Not Used - -
B2 Headlight Relay Control ECM 1 Fuse Box
B3 Headlight Circuit Breaker Output Fuse Box CB Fuse BoxB3
B4 Fuel Pump Relay Control ECM 1 Fuse BoxB4
B5 Fuel Pump I Coil Fuse Output Fuse Box C4 Fuse Box BS
B6 Engine Relay Control ECMl Fuse BoxB6
B7 Engine Relay Power Input Fuse Box B7 Splice (ENGBRK)
BB Cooling Fan Relay Control ECM 1 Fuse Box BB

17.7
CH.ASSIS ELECTRICAL
PIN CIRCUIT DESCRIPTION FROM TO

B9 Cooling Fan Circuit Breaker Power Fuse BoxDS Fuse Box B9
Cl Not Used - -
C2 Starter Relay Output Power Fuse Box C2 Start Solenoid
C3 Starter Relay Coil Power Fuse Box C3 Splice (IGNSW)
C
C4 Fuel Pump I Coil Fuse Output Fuse Box Bus 1B Fuse Box C4
(Main Fuse)
C5 Fuel Pump I Coil Fuse Input Main Fuse Fuse Box C5
cs Engine Breaker Output Fuse Box CS Splice (ENGBRKl)
C7 Engine Breaker Input Fuse Box C7 Splice (MFUSE)
C
CB Headlight Circuit Breaker Output Fuse Box CB Fuse Box B3
C9 Fusebox Bus D Input Fuse Box C9 Splice (MFUSE)
Dl Not Used - -
D2 Starter Solenoid Relay Control ECM 1 (El41) D2
D3 Starter Relay Input Power D3 Splice (ENGBRK)
D4 Fuel Sender Resistor Output Fuse BoxD4 Splice (FUELSEND)
D5 Fuel Sender Resistor Power Fuse BoxD5 Splice (ACCR)
DS Cooling Fan Circuit Breaker Output Fuse BoxDS Fuse Box B9
(
D7 Cooling Fan Circuit Breaker Input Splice (MFUSE) Fuse BoxD7

DB Ignition Breaker Output Fuse Box DB Splice (IGNBRK)
D9 Fuse Box BUS D Input Fuse BoxD9 Splice (MFUSE)
(

17.8
CHASSIS ELECTRICAL
LOAD/ TIPOVER MODULE

LOAD/ TIP OVER MODULE CONNECTOR MAP
LOAD I TIP OVER MODULE
co~~NECTOR
P I r~ REFER ENCE
CONNECTOR #I CONN ECTOR #2 CONNEC TOR #3
FRONT FRONT FRONT
VI EW VIEW VIEW
8
IIJ
Ill
IIJ
IIJ
Cl
Cl
Cl
Cl
Deb
IIJ
i!dl
i!dl
Cl l
Cl
Cl !
I
4
I
4 I
DD D D
DD OD
0 0 DD
OD OD
5
8
2
I
(§]
CB ~
~ '
08R - JWPF - VSLE - D 08T-JWPF - VSLE -D 02T - JWPF - VSLE-S

RECEPTACLE HOUSING TAB HOUSING TAB HOUSING
CONNECTOR PIN OUT

CONNECTOR PINOUT FUNCTION PCB PIN OUT WIRE COLOR
CONNECTOR # I 8 WAY 08R-JWPF - VSLE - D
I START SWITCH IN ( TO LOAD MOD) I- I TAN
2 CLUTCH SWITCH IN (TO LOAD MOD) 1-2 GREEN
3 LEFT TURN SiGNAL SWITCH IN <TO LOAD MOD) 1-3 BLUE
4 RIGHT TURN SIGNAL SWITCH IN (TO LOAD MOD) 1- 4 PURPLE
5 FRONT BRAKE SWITCH IN <TO LOAD MODJ 2-1 PINK
6 RE AR BRAKE PRESSURE SWITCH IN ( TO LOAD MOD) 2-2 BROWN
7 NEUTRAL SWITCH IN <TO LOAD MOD) 2-3 ORANGE
8 TIP-OV ER SENSOR SIGNAL RETURN (GROUND) 3-2 BLACK
CONNECTOR #2 8 WAY 08T - JWPF-VSLE-D
I START SWiTCH OUTPUT (TO ECM) 1-5 TAN
2 CLUTCH SWITCH OUTPUT ( TO ECM ) 1- 6 GREEN
3 LEFT TURN SIGNAL SWITCH OUTPUT (TO ECM) I- 7 BLUE
4 RIGHT TURN SIGNAL SWITCH OUTPUT <TO ECM) 1- 8 PURPLE
5 FRONT BRAKE SWITCH OUTPUT (TO ECM) 2-4 PINK
6 REAR BRAKE PRESSURE SWITCH OUTPUT (TO ECMJ 2- 5 BROWN
7 NEUTRAL SWITCH OUTPUT (TO ECMJ 2-6 ORANGE
8 TIP -OVER SENSOR ( TOS J SIGNAL 3-3 WHITE
CONNECTOR #3 2 WAY 02T - JWPF - VSL E- S
I 12+V SWITCH ED LOAD MODULE POWER 3- I YELLOW
2 TIP -OVER SENSOR +5V REF 3-4 RED

17.9
CHASSIS ELECTRICAL
LOAD TIP OVER MODULE REMOVAL AND

INSTALLATION
CAUTION
The negative battery cable MUST be disconnected
before the Load I Tip Over Module can be removed.
-:~-- ··--.
··'
\
(.; -
"• '' •. _.,,
'*,, ,, '!
_ <.:t.f : ~:., \ ~~'.. .·< \~;-;ti-·

·~ \, ; ,
.,· ,~ -
1. Remove seat. See Seat Removal I Installation, page

3.9.
2. Remove the battery box. See Battery Box Removal,
page C
3. Disconnect the three electrical multi-plugs CD from
the load I tip over module and remove module.
removal procedure.
5. Torque load /tipover module mounting screws to C
specification.
Load I Tip Over Module Mounting Screws: 84 in - lbs

(9.5 Nm)

17.10
CHASSIS ELECTRICAL
HEADLIG HT SERVI CE
HEAD LIG HT BUL B REPLACE MENT 3. Disconnect wire harness CD and move rubber
"· ,. ·. : .' :. . · .I MPORTANT . . . grommet G) to allow access to headlight bulb.
Avoid touching a halogen bulb with bare fingers. Oil

from your skin leaves a residue , causing a hot spot
that will shorten the life of the bulb. If a bulb is
touched, clean it thoroughly with denatured alcohol.
1. Remove headlight retaining screw CD.
4. Squeeze bulb retainer and move pins out of way of

bulb.
2. Lift headlight upward to remove from base.
5. Remove Bulb © .

removal procedure.

17 .11
CHASSIS ELECTRICAL
HORN SERVICE
HORN REMOVAL/ INSTALLATION
1. Remove screw CD securing the horn to the frame
bracket.
2. Disconnect the horn electrical connectors CD.
3. Remove the horn.

removal procedure.
5. Torque fasteners to specification.
9926140 R02- 2015- 2016 Scout Service Manual

17.12
CHASSIS ELECTRICAL
TAIL LAMP SERVICE

LED TAIL/ BRAKE LIGHT OPERATION 2. Working from beneath the rear fender, access the
The multiple LED tail I brake lamp functions much like three tail light nuts CD and remove along with
a conventional incandescent tail I brake lamp. LED washers.
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 I Brake Light Power Supply:
When the motorcycle is powered ON, battery voltage
is delivered to the TAIL I BRAKE LEDs on the BN I PINK
wire from the Headlight Relay. Current through each
TAIL LED (WHITE wire) is limited (inside tail lamp
unit) to approximately 250 rnA.
Tail I Brake Light Ground Signal:

The front and rear brake light switches provide a path
to ground through the Load I Over Module to the ECM 3. Lift the tail light assembly CD off of the rear fender
via BLACK I YELLOW wire (rear brake switch) and and disconnect the electrical connectors noting
YELLOW I VIOLET wire (front brake switch). When the their position for reassembly.
ECM receives a grounding signal from either of the
brake switches, ground is provided to the tail I brake
light LED, thus illuminating the light. · -/
When the motorcycle is powered ON, the ECM

provides a ground path to the tail light LED, thus
illuminating the light.
TAIL/ BRAKE/ LICENSE PLATE LIGHT ;;~: .. , ./

REMOVAL/ INSTALLATION
- ifti·· /
/1:-!ir:::- .: •__ ,
The tail and brake lights are LEDs and cannot be •;(' ,: -<::~/ OA
replaced individually. If the lights fail to function = t:::::-: ~: A':.

when activated, and all circuit tests indicate correct
power and ground distribution, the tail / brake light 4. Remove the tail light assembly.
must be replaced as an assembly. The license plate
light can be replaced individually.
5. Remove nuts CD and washers.
i '
I \
i ~
Tail I Brake Light Removal
\ J-
1. Place the motorcycle in an upright position with the ~
9926 I 40 R02 - 20 I 5 - 20 I 6 Scout Service Manual

17.13
CHASSIS ELECTRICAL
6. Remove the license plate light © from the license

plate bracket.
License Plate Bracket to Tail Light: 84 in-lbs (9.5 Nm)
Tail/Brake Light Installation

1. Install the tail light assembly.
2. Install the license plate light.
3. Verify tail lamp harness is secured with tie straps
CD.
4. Verify tail lamp connector CD is positioned as
illustrated.
~-~>~-ff-t~~~b
'.? ~\!
-~~--- ·~_
..........
,(·~ ~
·.:--,
5. Torque all fasteners to specification.

17.14
CHASSIS ELECTRICAL
TURN SIGNAL/ HAZARD SYSTEM SERVICE

TURN SIGNAL OPERATION 2. Remove screw CD and nut Q) to remove turn signal
Turn Signal Auto Cancel Functionality from front fork.
' \
Verify function of the following components for correct ',
turn signal operation.
• Turn Signal Switch
• Hazard Flasher Switch
• Vehicle Speed Sensor
The Auto Cancel Turn Signal Modes

1. NORMAL MODE - Vehicle speed above 14.9 mph
(24 kmh) the auto cancel software records vehicle
when turn signal is activated and equates speed
with a preset distance. After the preset distance is
traveled the turn signal is cancelled.
2. CONTINUOUS MODE - Vehicle speed below 14.9
mph (24 kmh) the turn signals operate indefinitely
until manually cancelled. This mode overrides any
previous auto cancel mode. 3. Installation is performed by reversing the
removal procedure. Torque all fasteners to
3. 90 - DEGREE TURN MODE - Vehicle speed below specification.
14.9 mph (24 kmh) the turn signals operate
indefinitely until speed exceeds 14.9 mph (24
kmh). If vehicle speed remains above 14.9 mph (24
kmh) for approximately two complete ON-OFF
flash cycles, the turn signal cancels.
4. LANE CHANGE MODE - Vehicle speed above 14.9
mph (24 kmh) by pressing and holding the turn REAR TURN SIGNAL REMOVAL/ IN STALLATION
signal switch in the desired direction for more than 1. Remove the tail light assembly. See Tail I Brake I
one ON-OFF flash cycle the turn signals will cancel License Plate Light Removal I Installation, page
immediately once the switch is released. 17.13.
5. HAZARD FLASHER MODE - At any vehicle speed
the hazard flashers operate indefinitely and must
2. Remove bolt CD.
be manually cancelled. This mode overrides any
previous auto cancel mode.
The turn signal I hazard light system does not utilize a
conventional "flasher module", but instead receives a
grounding signal from the ECM. Power to the turn
signals is provided via the IGNITION CIRCUIT
BREAKER located in the main fuse box. Turn Signal
INPUTS & OUTPUTS can be located in the ECM i
Connector Map and Fuse Application Chart. I
See ECM Connector Map, page 5.30.
See Fuse Application Chart, page 17. 7.
FRONT TURN SIGNAL REM OVAL/

INSTALLATION
3. Unplug turn signal connector and withdraw the
1. Locate turn signal connectors inside the headlight turn signal from the tail light assembly.
and disconnect. See steps 1 and 2 of the Head Light
Bulb Replacement procedure to access connectors: 4. Installation is performed by reversing the
Headlight Bulb Replacement, page 17 .11 removal procedure. Torque all fasteners to
specification.
99261 40 ROZ - 20 15 - 20 16 Scout Service Manual

17 .15
CHASSIS ELECTRICAL
INSTRUMENTATION
IN STRUM ENT CLUSTE R LIGHT INDICATES CONDITION
The instrument cluster includes the speedometer,
indicator lamps and Multi-Function Display (MFD). the signal system, the
lamps will flash at
twice the normal rate.
This indicator light
appears when there
.,.,..... . . .
\ ..~),----~ j_i) Low Fuel are 0.5 gallons of
fuel remaining in the
tank.
Illuminates with
A\ Hazard Flashers
hazard flasher
operation. C
The light will remain

on if the tilt sensor
shuts down the
engine. If abnormal
sensor or engine (
.:!lo
.;;
operation is
' Check Engine
detected the light
l ~•. will remain on as
long as the fault
condition exists.
• CD Speedometer Retrieve the error
• 0 Indicator Lights codes for diagnosis.
• Q) Multi-Function Display (MFD)
Units w ith ABS
ONLY: The indicator
remains on until the
For detailed information regarding MODE selection anti-lock system
and Multi-Function Display operation refer to the activates, which
Owner's Manual. occurs when vehicle (
speed exceeds 6
/,~~,
~ ff.\( »
Anti-Lock Brakes MPH (10 km/h).
Indicator Lights R '¥ }j NOT Activated
'\C'-./J When the lamp is
illuminated, the anti-
LIGHT INDICATES CONDITION lock brakes will not
Illuminates when the activate, but the
Neutral
transmission is in conventional brake C
neutral. system will continue
to operate normally.
The headlight switch When metric mode

is set to high beam. Vehicle Speed is selected, speed
This indicator will Km/h Units displays in
High Beam kilometers per hour.
fl.ash if there is a
problem with the low
When standard
or high beam light.
Vehicle Speed mode is selected,
The turn signal MPH Units speed displays in
indicator flashes miles per hour.
when the left, right,
Turn Signal
or both turn signals
(hazard) are active. If
there is a problem in

17.16
CHASSIS ELECTRICAL
Multi-Function Display (MFD) The power switch INSTRU MENT CLUSTER REMOVAL/
must be ON to access the MFD. Use the mode switches INSTALLATION
to toggle through the modes of the MFD and to change
settings in the display. The LH mode switch CD is 1. Remove four speedometer screws ©.
located on the backside of the LH switch cube .
.,.-------~--- . .
~
2. Press tab (I) down to remove the connector from

speedometer.
MODES AVAILABLE
Odometer Engine Speed
/
Trip Odometer 1 Clock
Trip Odometer 2 DC Voltage /
Gear Indicator I
I
Odometer /,
The odometer displays total distance traveled. lt ,· ./
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 3. Installation is performed by reversing the removal
resets to zero. procedure.
Engine Speed
Engine Speed displays in revolution per minute (RPM). Instrument Cluster Mount Screws22 ft-lbs (29.8 Nm)
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.

17.17
(
CHASSIS ELECTRICAL
SWITCH TESTING
BRAKE LIGHT SWITCH TEST 6. Locate the rear brake light switch connector CD.
2. Locate the brake light switch connector (j) on the
right control and disconnect.
C
7. Connect meter leads to each terminal of the rear

brake switch connector ©.
3. Set multi meter to measure resistance. ~

~
~ \r~.. . _r - · \\ ' -
4. Connect meter leads to each terminal of the front ,,. V t \\ -~
brake switch CD. ·;· II\
! ' I
I/.\
/ \ \
- ........ "-
./, \'"---\// \\\ ~

-
/
-~0,;;!
/
I
·
\
\\
\'\'\ \
~
f\ ;r
"~,.
-
..
~ ~:. ...;,·,··
_ . /
(
2 -- /t,f.
"'-.
-···c,.
~1·
t;. ... \
( 4 )
"""
~
.,
/
~
' II
-I
/'
\.J I C
-~ 1
.• ,,, ., ...<,,n,,.;,,/
8. Apply the rear brake.

/
'. 2 )
' Resistance Specification: Continuity with pedal
'-....__/ depressed
(
5. Apply the front brake.

Resistance Specification: Continuity with lever
depressed

17.18
CHASSIS ELECTRICAL
CLUTCH SWITCH TEST GEAR POSITION SWITCH TEST

1. Disconnect clutch switch CD electrical 2 - pin 1. Disconnect the gear position switch CD electrical
connector. connector Q) located at the rear of the engine
above the voltage regulator.
2. Measure the resistance of the switch with lever

pulled to handlebar (less than 1 Ohm resistance) 2. Set multi meter to measure resistance.
and with lever released (01).
3. Connect one meter lead to each of the pins on the
switch connector.
SIDE STAND SWITCH TEST
1. Inspect side stand. Be sure that when the side 4. Watch the resistance readings as the transmission
stand is fully retracted (UP) that the switch plunger is shifted into Neutral. The meter readings be less
is extended and that when the side stand is than 1 ohm with transmission in Neutral and 01 in
extended (down) the plunger is depressed. · all other gears.
2. Remove the voltage regulator bracket to access
the side stand switch connector and disconnect.
See Regulator I Rectifier Replacement, page
15.30.
3. Set multi meter to measure resistance and insert
meter leads into appropriate jacks.
4. Place one meter lead onto each of the side stand
switch terminal pins.
5. Read resistance with the side stand switch plunger
depressed and extended.
Switch Depressed (Stand DOWN): No Continuity
(OL)
Switch Extended (Stand UP): Continuity (Less than
l!!)

17.19
CHASSIS ELECTRICAL
BREAKOUT WIRING DIAGRAMS

STARTI NG CIRCUIT WIRING DIAGRAM
Starting Circuit
-Scout
('
I I
~
40A
Main
Fuse
B
C
I
Battery . . R D ~ O
Start
Solenoid
I
2
DG!WH
BK
I I Ui
w~LH
DBA'E t..J ~ Control
C
BK:WH ?l
II
&
8~)
RD/BK P2
II RH
I E!KM'H P3
~
II Control
YEM'H P<i\
I II
I BKMIH PS ~· ~, ...,,.......... . C
PK [ RU~l/STO? ~~
OG......I , START
IBRAKE
..~,.. , ;
f~~; ........ t.. 'T .. :£:,:j~
ECM 1 - GSS
~
Top .
1J 0·=
View .
-41 " WW'f'E
~:: f' =
'3 ROiBK
ECMl
I
7 ·:. YE/WH
-
BN/YE
svJPK P7 I I Load
Module In
DBtYE P2 ~R9,2
ECM2 VE/WH -· Pl
:-
ECM2
-
~~-
l BN/YE
OG:WH
== =
~
-
OG,WH88
PK/BK
OS/YE
P7
P2
r·
YEMH . Pl
Chassis
Ground

17.20
CHASSIS ELECTRICAL
IGNITION SYSTEM WIRING DIAGRAM

Engine Ignition
-Scout
Front
Injector Engine
Relay
y
Rear
Injector
Front
Coil
m
Ignition ,.., 3 12
;
1
R
Coil e a. r m
l'.t :: ___ Iii( - • •O
Ignition~ 8WH =====~='.:l
ECM 1
- SHLD .~ dl......imijjJ·l]!·fJ·rJ,i,t,1/(rt,P,.f;I"",;-.,.r,AU,iroo••_.._. . VT/PK
l 0 VT/PK
..lt,,l.........,...... GY
t1 a-DG-,
Top
u View
Fuel
Pump
2
l
BK
EK/
'· • hJ !:::::=BN
ECMI
< VTl'!'E
I
8
i
J. L'::!;::!;::!:~~~:l::f::f::I====
Ignition
Switch
Ill II! •
11
•I
L:::=;~;::::::11:!~:l:t:l=l=I====
WH
v,H
56
54 ECM2
EQ./12
Ill 1 : I
Fuse Box ~=~~~~;;l=;l;;,l,;i,:=:=::;:; WH/OB 44
RD
---;:11:: 13
. __ _ _ _ _ OGIBN 19
l
!!:!!===========:::
. ._ _ _ _ _ _ _ _ BK
BK/BU 6
~ ~
~ ~
'
l
t ---------------
~
~
J.
Fuel Pump Chassis
Fuse Ground

17.21
CHA.SSIS ELECTRICAL
THROTTLE CONTROL WIRING DIAGRAM

Engine Throttle Control
-Scout
Throttle
Body
ETC Grip
PIN
(
PEDAL PCSITlON SENSOR 1 R
PPS 1 •5V REFERE.Nce
C
0
~
;:
"E 0~
!;: "' ~
0
~ I "'
z
~
~
a
ea I l!s
~
z
i
,.,
10 20 3 51 51
• 11
It
5 3S 25 3 ,,
ECM2 ECM 1
II I I 11
EC~2 £CM I
Top View

17.22
A Lubrication, Front .. .. .. ..... ..... .... .. .. .. .. ... ..... .... .. .. ...... 2 .18
Brake Lever Reserve Inspection ................. ... .. .. .... .... 14 .20
ABS Module, Replacement .......................... .. .... ....... 14.16
Brake Light
ABS System
Operation Overview ....... .. .. .. .......... ... .. . .. .. ... .... .... 17. 13
.special Tools .. .. ............ . .. .. ..... ..... ......................... 14.3 Removal I Installation ...... ...... ...... ....... ......... ... .. .... 17.13
Air Box
Brake Light Switch
.~~;!{!~~i:~~:::::::::::::::::::::::: ::::::::::::::::::::::::::::1~i
Air. Filter, Replacement.. ....... ..... ..... .... ......... .. .... ......... 2.8
Testing ... ... .. .... . ... ............... .. .......... .. ...... ... ..... .. . 17.18
Brake Pads
Replacement, Front. .. .... ... ... ..... ... ... ... .. ..... .... .. .. ... . 14.21
Replacement, Rear .... ........ ... ....... .. ...... ............ .... 14.21
Animated Wiring Diagrams ... ... .... ............... .. ... ............ 23 Brake Pedal
Assembly .... .. .. ............... . .... .. ................... ............ ... 7 .33
Inspection .. ... ...... .. .... ... ......... .. ....... .. ... ......... ... ... .. 2. 18
Axle Inspection, Front .............. ..... .. ..... .. ........ ......... 11.14 Lubrication .... ...... ... ..................... .. .. .... ......... .. ... ... 2.19
Axle Inspection, Rear ..... ... ...... ... ..... ................. ....... 12.13 Brake System
ABS Brake F1uid Change .... .. .... .. ................. ..... ..... 14.18
ABS General Information .. ..... ... ............... .. ..... ...... 14.12
B ABS Module Replacement.. ..... .... ....... .. .. .. ......... ... . 14. 16
ABS Module, Assembly View .. .. ......... ........ .. ........ .. 14. 11
Balance Shaft ABS System Safety Precautions .... .. ... .............. .. .. ... 14.12
AssemblyView ... ... .......... .. .... .. ... .. ... .. ................. 10.15 Assembly View, Front Brake ....... .. ... ............ ........ .. .. J 4.4
Installation . .............. ... ... ..... .. ................ ... .. ... .... . 1O. l 7 Assembly View, Line Routing . ....... .. .... .. .................. 14.6
Removal. ... . ... . .. .. ....... ... .............. .... ... ... ..... .... .. ... 10.17 Assembly View, Rear Brake ...... ....... .. ....... .. . ... ... ...... 14.5
Service Specifications .... .. .. ...... ...... .... . .......... .. ....... 10.3 Bleeding, Front Brakes ....... ..... ................ .. ... ...... .. 14.19
Special Tools ...... .. ......................... ... . ...... ....... ..... . 10.3 Bleeding, Rear Brakes ..................... .. ... .... ..... ....... 14.18
Battery
Disc Removal I Installation, Front ....... .... ................ 11.14
Assembly View .. ..... ... .. ... .. ... .... ...... ......... .. .. .. .. .... 15.10 Disc Removal I Installation, Rear ... ........................ . 12. 15
Cha rging, In Service .. .. .. .... ... ..................... ........ .. 15.13
Front Brake Pads, Replacement .... .. .. ... ...... ....... ...... 14.21
Charging, New ... ... . .. .... ...... .. .. ..... .. .. ... ...... . .... ..... . 15.13 Front Caliper Installation .. ... .. ... .. ............... . ......... . 14.26
Current Drain Test .. .... .. ................ .... .. ....... ... ....... 15.25 Front Caliper Service ..... ........ .............. .. .. .. ... ... ... . 14.24
Inspection ....... .... .. .. ....... . ...... .............. .. ... ... 2.28, 15.13 Front Caliper, Assembly View ..... .... ...... .. .. ............ .. 14.9
Installation .. ... .... .. ............ . .............. .. .............. ... 15.11 Front Master Cylinder Service .. .. .. ........ .. ....... .. ... .. . 14.22
[;~;;;~~::: ::: ::: : : : : ::::::::::::: ::::::::·~!:H

Safety Precautions ....... ...... ...... ... ... .. ...... ....... ......... 15.3
Lever Reserve Inspection ........ ................... ......... .. 14.20
Precautions ............. .... .... ......... ....... .. .. .. .. ........ .. . 14. 17
Rea r Brake Pads, Replacement . .. . ... .. .. ............ .. .. ... 14.21
Rear Caliper Installation ... ........... ..... ................ .. .. 14.28
~~~~ri; ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::·i~:f ~
Battery Box
Rear Caliper Service ............... ............................ . 14.27
Rear Caliper, Assembly View ....... . .. .. .......... ... ... .... 14 . 10
Rear Master Cylinder Service ....... . .... ... ............... .. 14 .26
~X:!~~!i~.~.::: ::::::::::::::::::::::::::::: ::::: ::::: :: ::::::::::: ::i~: i~
Battery Box, Assembly View ...... .. ...... .. ....... .. .. .. ... .... . 15. lo
Rear Master Cylinder, Assembly View ........... .. ... ..... . 14.8
Service Notes .... .... .......... .. .... ....... ....... ..... ............ 14.2
Service Specifications ...... .. .. .. ................... . ............ 14.3
Battery Charging .................... .. . .. ... ............ ... ........ ... 2 .29 Special Tools ........ . .. ... .. .. .......... .. ... .. .. .. ... ... .......... . 14 .3
Batte.ry Installation ......... ............................... ..... ....... 2 .30 Torque Specifications ... ..... ...... .. ... ......... ..... .. .. .. ... .. . 14.3
Bearing Clearance Inspection ........ .. ........... ...... .. ..... 10.29 Troubleshooting ... .......... .. ..... ............. ............. ... . 14.29
Bearing Selection Vacuum Bleeder ....... .. ....... ... ........ ...... .. .... ... .. .. .... 14.18
Connecting Rod .. ..... ............ .. ......... .. ..... .. ..... ..... . 10.30 Wheel Speed Sensor Adjustment (Air Gap) ... ........ .. 14. 15
Belt Wheel Speed Sensor Replace ment .. .... .. .. ...... .... ..... 14.14
~§~:Jr: ::
Brakes
Brake Pad Inspection, Front. ... .. .. ... .... .. ..... .. .... ....... .. 2.23
Tension Measurement .... .......... .... ... ... .... .. ........... .. . 2.31
m Brake Pad Inspection, Rear ............... .......... ...... ...... 2.23
Brake Pedal, Inspection .. ......... ......... ....... ... ..... ....... 2 . 18
Brake Pedal, Lubrication ............ ......... ........ ......... ... 2. 19
F1uid Level Inspection ...... ..... .... ... ........ ....... .... ... .... 2.22
Front Brake Lever, Inspection ... ..... ......................... . 2 .18
Body
Front Brake Lever, Lubrication ... .. ..... ....... .. ......... .... . 2.18
~;:;:~ :00;:s.:::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~:~ Braking System
ABS Overview of Operation ........... ... .... ... ............ .. 14.13
Brake Bleeding Precautions .. ................ ... ..... .... ........ 14.17 ABS System Components ......... ........... .... .. ..... .. ... .. 14.13
Brake Disc
Break-In, Engine .... .. . .. . ............ .... ....... .. .. ... ... ... .. .. ... .. 2. 7
Removal I Installation, Front .. . ... ............. .. ..... ..... .. . 11 .14 Breather, Inspection .. . ...... . .... .... ... ........................ .... . 2.23
Removal I Installation, Rear ... .... .... ...... ... .. ... ... ..... .. 12.15
Brake F1uid
Changing ........... ............... ...... .. ... ....... .. .. .... ....... 14.18
Brake F1uid Replacement .. ........ .. ... .. ...... ... .. ...... .. .. .. . 14.17 C
Brake Lever
Caliper
Inspection, Front ..... ... ........ .. .. .. ... .. ... .. ...... .... ......... 2.18 Front, Installation .................. ... .. .. .. .. ....... .. ...... .. ... 14.26

IX.I
Front, Rebuilding .... ...... ... .... ... ..... ... .. ...... . .... .. .. ... 14.24 Clutch Lever
Front, Removal ................ . ...... .. .. ... .. .................... 14.24 Free Play Adjustment ..... ....... ... ... .. .. ........ .. ......... .... 2 .17
Rear, Installation ........... .... ....... ... .......... .. ............ 14.28 Lubrication .. . ........ .. ....... ... ..... .. ........................... .. 2.17
Rear, Rebuilding .... ... ... ........................ . ... .. .. .. . .... 14.27 Clutch Pinion Shaft
Rear, Removal. .......... .. ....... . .. ....... .. .............. ...... . 14.27 Assembly View . .... ............ .. .... ... .... . .. .. ..... .... ....... .. . 9.5
Caliper, Front Clutch Rack
Assembly View ........ ........... .... .. .. ...... .. .... .... .. ..... . .. 14.9 Removal I Installation .... .. .... .. .... ..... ... . ..... .. .......... ... 9. 13
Caliper, Rear Clutch Switch
Assembly View ...... .. ..... ... .. .. ....... .. .... ..... ........... .. 14.10 Circuit Test.. .......... .. ·.... ... .. ............. .. . ......... .. ....... 15.20 (
Cam Chain Removal I Installation .. .. .. ..... .. .. ... .. ... ........... ....... .. 15.21
Installation .. ...... .......... ...... . .... .. . .... .. .............. . ...... 7 .15 Testing ... ... ...... .. .... .. ..... ... .. ..... .. ............. . .. ......... 17. 19
Removal. ... ................. ... .... .... ...... .. .. ....... ... .. ......... 7. 15 Coil, Ignition
Service Notes .. ................. .. ........................ .... .. : .. . 7.11 Removal I Installation ....... ..... ...... ........... ................ 16.3
Cam Chain Guide Compression Test (Wet), Engine .. ........ .. .......... ... .. .. .. .. 2.28
Installation .... .. .......... .. ... ...................................... 7 .16 Compression Test, Engine .. ........ ...... ....... ... ... .. ...... ... . 2.27
Lower, Removal. .... .. ....................... .................... .. . 7. 14 Connecting Rod (
Upper, Installation ........ .. ... ..... . .... ... ... ... . ........ .. .. .... 7.22 Bearing Clearance Inspection .... .. ...... .... .. .. ........... 10.29
Upper, Removal .... .. ..... ... ... .. ..... .... ............. .. ......... 7 .11 Bearing Inspection ...... ...... .. .. .... .. .. .. .... .. .. .... .. .... .. 10.29
Cam Chain Tensioner Bearing Selection ............ .. .. .. .......... .. ............ .. .. .. 10.30
Inspection .... . .. .......... .. ... ..... ... ... .... .. ... ...... .. .... .. .... 7 . 11 Inspection .... ........ .. .... ..... .... .......... .. ..... ....... 8.10, 10.27
Installation .......... . .. ............ . ... .. .. ..... ... .. ... . .... ... ..... 7 .21 Inspection, Big End .. ........ .... ..... .. ... .... ....... .... .... ... 10.28
Removal ......... .. .. .. .. .................. .. ... ... ................ .. .. 7.11 Installation .. ... .... .. .. ...... .............. .... .. .. ......... .... ... 10.32
Cam Drive Shaft Removal .. .. .. ... .. ........... .. . .. .... . .. .......... ... .. ... .. ....... 10.27
Installation ... . ... ......... .. .............. ........ ...... .. .. . 7.15, 7.17 Side Clearance ...... .. ......... .. .... ...... .. .... .. .. .......... .. 10.27 [
Removal ................. ... .... ........... ............ . .. .. ........... 7 .14 Connecting Rods
Cam Timing .......................... . .............. .. ..... .. .. .. ....... 7.19 Service Specifications .... .. .. .. .. ............ ...... .... .... .. .... 10.3
Camshaft Controls, Assembly View ....... ... ........ .. ....................... 11.4
Drive Sprocket Installation ....... .... .... .. .... ... ... ....... .... 7 .17 Conversion Chart
Inspection ... .................... .. ....................... .. ........ .. 7.27 Metric .... .. ............................ .. ......................... .... 1.16
Sprocket Removal ....... .... .... . ...... ..... ... ..... ...... ....... .. 7 .12 Conversion Charts ... .... .. ... .. .. ...... ......... . ...... ... .. .. ...... . 1.17
Timing .. .......... ............... .... ........... .. ...... .... ............ 7.9 Measurement ............. ... .. .. .. ... ........ .. ...... .. ... .......... 1.18
Camshaft Sprocket SAE .... .... ... ..... . ...... ....... ....... .. .. .. .. .... .. .... ............ .. 1.16 C
Installation ................... ....... ... ... .. ....... ...... .... .. .. .... 7. 19 Te mperature .. ................ .... ...... ......... .. .. ... ......... . ... 1.18
Timing .. ... ............................ . ... .......... ... ............ ... 7. 19 Coolant Drain I Fill .. .... .... .... .. .... ........ .... .. ...... ... 2.14, 4.20
CamshaftCam Drive Shaft Coolant Fill I Bleeding ... .. .............. ..... ...... ........ .. ...... 4 .22
Drive Sprocket Removal .. ..... ........ ............ .... .......... 7 .13 Coolant Flow Diagram ...... .. ..... ...... ..... ......... . .. ..... .. . .. .. 4.6
Removal ......... .. ............... ..... .. ..... .. .. .... .......... ....... 7.13 Coolant Level Inspection .. .... ...... .......... .......... .... .... .. . 2.10
Charcoal Canister .. .... .... ... .. ... .... ... ..... .. ...... . .... ..... .. .. 2.24 Coolant Strength / Type ....... .... ........ ... .... ... .... ... 2.10, 4.1 9
Charging System Coolant Temperature Sensor ... . ....... ..... .... .. ... .. ... ........ 4.27 C
Output Test. ................. .... ................. ....... ... .. ... .. . 15.25 Cooling System Hoses ..... ... ..... ..... . ... ..... ........... .... ..... 2.12
Service Notes .... .. ...... .. ... ........ ....... ...... . ... .. ........... 15.3 Cooling System Overview .. ..... ........... ... ..... .. ......... .... 2 .10
Service Specifications ....... .. . .. ................................ 15.5 Cooling System Pressure Cap Test .... .... .. ............ 2.11 , 4.20
Special Tools ...... .. ........... ....... ..... .... ....... ........... ... 15.4 Cooling System Pressure Test. .. ....... .. .. ......... .... .. 2.11, 4.19
Torque Specifications ..... ........ .. ................ .. ............ 15 .4 Cooling System Troubleshooting .......... .. .. .... .. ... .. ....... 4 .28
Troublesho oting .. .. .... ......... ... . .... .. .. . ....... .. ....... .... 15.24 Crankcase
Checking Oil Level .. .... ...... ......... ... .... ........... ... .. .. ..... . 2.8 Assembly .. .. .. .. ... ...... ... ..... ......... .. .. ............ ....... .. 10.35
Clutch Assembly View . .. .... .................. ............ .. . ............. 10. 6
Assembly .. .. .. .. .. ... .. .... ..... ... .. .... .......... .. ..... .. ...... ... 9. 16 Assembly, Left Side ... .. ............. ........ .. .. ....... .... ..... 10.33
Assembly View .............. .. .. ..... .. . .. ..... ....... .............. 9 .6 Assembly, Right Side .......... .. .................... .. .. .... ... 10.33
Disassembly .... .... ..... ....... ... ... ... ... .. ... .. .. ...... .... .. .... 9. 14 Bolt Location ..... .... ............ .. ..... . ... ... . ... .. .. .............. 10.8
Inspection ...... ................. ... ...... .. ... .. .. .. . .... ........ .... 9. 15 Disassembly .. . .. .. .. . .. .. .. .. . .. .. . . . . .. . . . . .. .. . . . . . .. . . .. . . . .. . . 10. 21
Installation ...... ............ .. .. ... ...... . .... .. .... . ......... ... .. .. 9. 18 Resealing ..... ... ..... ..... ........ . ............ ... .... .. .... ... .. .. 10.35
Pinion Shaft Bearing Inspection .... .. .... ............ .. ........ . 9.8 Separation .. ........ .. ..... .. ...... . ..... .... ..... ....... . .... .. .... 10.21
Pinion Shaft Installation ...... ... .. .................... .. .......... 9.9 Torque Sequence .... .. ... .... .. .. ........ .. .. .... .... ........ .. ... 10.8
Pinion Shaft Removal. ........ .. .............. . .. .. ................. 9.8 Crankcase Emission Control .... .. ...... .... .. .. .. ............ .. .. 1.10
Pinion Shaft Seal Replacement ..... ........ .. ..... .. .. .. ........ 9.9 Crankcase Ventilation, Inspection .. .. .. .... .. .. ............... .. 2.23
Rack, Removal I Installation ...... ... ......... .. .......... .. .. .. 9 .13 Crankshaft
Removal . ...... . .......... .. ..... ... .......... .. .. . ... ..... .. .. ..... .. . 9. 13 Assembly View ..... ...... ... ... .. ....... ...... ..... .. ... ... .. .. .... 10. 7
Service Notes .. .. ... .... .. ...... .... .... .. .. .. ...... ...... ........ ... 9.2 Cleaning ....... .... ... .. .... .... .. ..... .. .... .. ... .. ... .. .... ..... .. 10.32
Service Specifications ....... ... ......... ....... ...... .. .... ....... 9.2 Inspection ..... .. ..... ......... ... ....... ...... ..... .. ... .. .... .. ... 10.31
Special Tools ..... ... ... .... .. ..... ......... ..... .... .. ........... ... . 9.2 Installation .... ... ........... ........... .... ... ... ...... .. ...... .. .. 10.34
Torque Specifications .. .... ... ... .. . ..... .. ... .. .... .... ... ........ 9 .2 Locking for Service ...... ......... .... .. .. ...... .. .... ............ . 10.5
Troubleshooting ........ ... .. .... ..... .... ... ... ... ...... .. .... ..... 9.22 Main Bearing Inspection ............ .... .. .. ...... .... .. .. .... . 10.32
Clutch Cable Main Bearing Oil Clearance .. ..... .......... ....... .. ... .. ... 10.32
Lubrication .... .. .. .... .... .. ... .. ......... .. ... .. .................... 2.16 Removal ... . .... .. ............ .. .......... . ... .. ... ....... .... ....... 10.26
Removal I Installation .. .. ............. ...... ... .. ... .. .. ..... .. . 11.12 Service Notes .. .......... .... ... .. ....... .. .... ... .. .. . .... ......... 10.3

IX.2
Service Specifications ... .... ..... .. .... .... .. ............... .. ... I 0.3 Specifications ....... .. .. .. ........ .. ...... ....... ....... ............ 2 .31
Special Tools ... .. ........... ........ ...... .... .......... .... ....... . 10.3 Tension Measurement ........... .. .. .. .. .. ..... . .. .. ...... ... .... 2.31
Troubleshooting ... .. ... .. ..... ..... ............. ........... ... ... 10.38 Drive Sprocket
Crankshaft Position Sensor (CPS) Resistance Installation ... .. ..... .... . .. ................... ...... ..... .... ........ 12 .8
Inspection ... ... .. ..... .. .. . .. ............ .... ..... ..... ............... 16 .7 Removal ..... ....... ..... ... . ... .. ........ .... .......... .. ... .... ...... 12 .7
Crankshaft Position Sensor, Test I Replace ........ .. .......... 5.42 Drive Sprocket Inspection .. .. .... .. ..... .... ........ ... .. ..... , .... 12.8
Current Drain, Testing .... ... .. .. ..... .. .. . ....... .. ..... .. ........ 15.25 Drive Sprocket, Cover
Cylinder Removal I Installation ... .. ......... ..... ......... .... .. ..... .. .... 12. 7
Assembly View .... ........ .... ........ .. ...... .... .... ........... .. . 8.4 Driven Sprocket
Bore Measurement. .. ... .. ... .. ... .... ........ ..... .... ...... . .. .... 8.6 Inspection ..... .. ........ ....... .. ........ .. ...... ........... .. ..... 12. I 0
Inspection ....... ..... ...... .... .. ....... .. ..... ... .. ..... ....... ..... . 8. 6 Installation ..... ... .. ....... .. ....... .... ..... .. ........ ..... ..... .. 12.11
Installation .... ...... .... .. ... .. .. .. ... ... .... ... ... .. ....... .... .. ... 8 .12 Removal ....... ....... ... ... .............. ..... .................. .... 12.10
Removal. ...... .. ....... .... .. . .. .... . ... ... ... .... . ......... .. ... .. .. .. 8.5 Driver Foot Pe g Removal I Installation ........ ........... .. ..... . 3. 7
Service Notes ........ .......... ........ ... .... .. ........ .. ........ ... 8.2
Service Specifications .. ... ... .. ... .. .... ... ... ............. ....... 8 .3
Special Tools ... .. ........... .... ................. .......... ... .. .. ... 8 .2 E
Torque Specifications ... .. .. .... .... . ..... .... ... .. ... .. ... .... .... 8 .2
Warp age Measurement .. ... .... ..... .... .... .. . ... .... ........ ... 8.9 ECM
Cylinder I Piston Connector Map ......... ... ...... .. .. ..... .......... ... .. .... ....... 5.30
Trouble shooting ... ...... .. . ... . .... ..... ........ .. ... .... ........ .. 8.14 Connectors ................. .... ...... .. . .... ... .. ... ............ ... . 5.38
Cylinder Head Disconnect ..... ... ......... ....... ..... .. ........ .. .... ... .. ......... 5.38
Assembly .... ... ... .. ... .... .... .. .... ...... .... .. ... ....... .......... 7.33 Pinout Chart ....... ........... ........ ........... ... ... ........... ... 5.30
Disassembly .... .. ... . .. .... .... . ... .. ............... ......... .. .. ... 7 .29 Pinout Testing .... ... ... ....... ..... .............. ....... ... .. ....... 5.38
Inspection ... . ..... .... .. ............... .. .. ......... ..... ... ... . .... . 7 .30 Reflash Procedure .. .. .. .... .. ... .. ...... ...... .. ... .... ..... ...... 5.48
Installation . .. . ............. . .. .. . ... .......... .. .. ... .......... . ..... 7.34 Removal I Installation ... .. .......... ...... .. ......... ... ..... ..... 5 .39
Removal ....... . .............. ... .. .. ... ......... . .. .... .. ..... ... .. .. . 7.27 ECM Connector Map .... .... .. .... ............ .. . .... ........... .. .. 16.5
Special Tools ......... ... .. .. .. ..... .. ......... .. ................... .. 7.3 ECM Replacement Information . .... .... ... .... .. .. ... ... ..... ... . 5 .44
Cylinder Head I Valve Train EFI
Service Notes ........ ...... . ... . .. ... ..... .... .. . ....... ..... ........ 7.3 Service Notes ... ... ...... ... ..... .... ............ .. ..... ...... ... .. .. 5 .3
Cylinder Head I Valves Service Precautions .... ............. ........ ....................... 5.5
Service Specifications .. .. .......... .... ......... ...... .... .. . ..... 7 .4 Service Spe cifications ... ...... .. ......... ..... ...... ... ..... .. .. .. 5 .4
Torque Specifications ....... . ......... ..... ... .. .. ... ..... ......... 7.4 Special Tools .... . .. ...... ............... ............. ..... .... ....... 5.4
Troubleshooting ........... . ........ ... .. ..... .... .. . .. ... .......... 7 .39 Torque Specifications .. ...... .. .. .. ....... ........... ..... ..... .. .. 5.4
Cylinder Head Te mperature Sensor Electrical System
Replacement .......... .. ....... . .. . ............ .... .. .. .. ...... ... .. 5.40 Service Notes .... .. .......... ....... ... .................... ......... 17.2
Test. .. ..... .. . .......... .... ... . ........ ... ....... ..... .. .. .. .... ..... .. 5.40 Special Tools ... ......... ..... ......... .. .. .. .... ... ........... .. .... I 7 .2
Cylinder Head, Exploded View .. .. ............................... 7 .8 Torque Specifications ... ... ...... .. ... ................. .... ... ... . 17.2
Electronic Fuel Injection (EFI)
Sensor Locations .. ....... .............. ...... .. .... .. ... .. ... ...... 5.11
D Electronic Throttle Control Module
Re moval ... ... . .. ..... . .... ........ ..... ..... ........... .... .... ....... 5.42
Diagnostic Trouble Codes (DTC) ............... ....... .......... 5.31 Emission C ontrol Systems .... . ..... ........ ....... ........... ... .... 1.9
Digital Wrench Emission Sources .... ... .. .. ..... ... ........ ... ...... ... .. .... ......... 1.9
Communication Errors ... .... ...... ...... ........... ... ........ .. 5.44 Engine
Diagnostic Connector ... ... .. .... ..... ............ .. ........ .. .. . 5.44 Compression Test. .. ..... ......... .... .......... ...... . .......... .. 2.27
ECM Reflash .. ... .... ... ... .. .... ........................... ... . .. ... 5.48 Compression Test (We t) ........ .. ................. .... ... ... .... 2.28
ECM Replacement .. ....... .... .. . .. ..... .... .. ... .. ...... ... .... .. 5.44 Locking the Crankshaft. ............. ..... .. ... .. .. ....... .. .... .. 10.5
Feature Map .. .. .. ... .. ...... .. .. ....... ........ ...... ...... ... ... ... 5.47 Engine Break-In Procedure ... ...... ...... ....... .... ...... ..... .... 2.7
Guided Diagnostics .............. . .. ...... ..... ...... .... ... ...... 5.44 Engine Installation ...... .... .. .. ..... ... ........ .... ... ... .. ........... 6. 7
Overview ..... ... ...... .. ........ .... .............. ..... .. . .. ... ..... . 5.44 Engine Number Location .... .. ... ........ .. .. ... .................... 1.2
Serial Number Location ....... .. ...................... .. ......... 5.45 Engine Removal
Update Information ........ ...... .. ..... ....... .. ... .... .......... . 5.44 Assembly View .... .. .. ...... .... .. .... ............. .. ... .... ........ 6 .3
Update Process .. ... . ....... .... .. .. ........ .... ...... .. ... .. .. .. ... 5.45 Preliminary Steps ........ ... .. .... ........ .... .. ..... .. .. .. ...... .. . 6.4
Version Updates ..... .. .. .. ... .......... .. .. ...... .... .. ........... . 5.45 Removing Engine from Frame ... ...... .. ........... .. .. .. .. .... 6 .5
Discs, BrakeBrake System Service Notes .. ......... ....... .. .... ....... .. ......... . ... .. .. .... .. 6.2
Disc , Inspection . ............ ... .. . .. ...... ........... .. ... .. .... . 14.22 Service Specifications ....... .. .. .. ... .. .......... ... ........ ..... . 6.2
Inspection .. .... .............. .... ..... .... ..... ............. .... ... 14.22 Special Tools ... .... ..... .......... ...... .... .... .. ..... .... ...... .. .. 6 .2
Drill Sizes Torque Specifications . .. ... ....... .. .... ...... ... ....... ... .. ... ... 6 .2
Metric ....... .. .... ........ ... ... ...................................... 1.16 Engine, Assembly Views
SAE ... ... ..... .... ....... .. ..... ... .... ... ....... .. ......... ... .... .. ... 1.16 Cam Chains ......... .. .. ... .. ... ........ .. .... ........ ... ........ .... . 7.6
Drive Belt Camshafts .. ....... .. ..... ..... .. ...... ....... ...... .. ... ..... ... ...... 7. 7
Adjustment. .... ...... . ... ....... ..... .... ... ... .. ....... .... ....... .. 2.32 Cylinder Head ..... .. ... ................. ........ .... ..... ...... 7. 7-7.8
Alignment .. ... ....................................................... 2.32 Engine, Oil I Filter Change ........ .. .. .. .. .... ........... ...... .. .. 2.9
Inspection .. ..... ... ... .. ... .... .. .. ....... . ...... ... ... ........... .. . 2.31 Engine , Timing .. ..... .. .. . .. .......... ...... .. ..... .. .. ....... ..... .... 7 .9
Installation ... .. .. .. .. .. ............. ............ .. .. .. .... .. ... ...... 12.6 EVAP System ... .. .. ... ... ...... ... ...... .. .... ... .......... .. .... .... .. 2.24
Removal. ...... .. .. ..... ....... .... ....... ... .. ...... .... .. ............ 12.6 Evaporative Emissions Control .... .. ............ .... ..... ........ 1.10
99261 40 R02 - 20 15 - 2016 Scout Se rvice Manual

IX.3
Evaporative Emissions System ..... ............. ...... ..... .. ..... 2.24 Routing, 49 State ..... ..... .. .. ... ... . ......... .... .. ... .. .. . ..... .. .. 5.6
Evaporative System Routing, CA .... ......... .. .. ... .... .. ....... ..... .. .... ... .... ... ..... 5.7
Line Routing, 49 State ..... ... .......... ....... .... ... .... .... ... ... 5.6 Fuel Pressure
Line Routing, CA ... .......... ..... ..... ...... .. .... ..... .. ...... . .. . 5.7 Inspection .. .. ... .. .. ...... .............. ... . .. . .. .... ........ ....... . 5 .19
Exhaust Specification ... ................. ..... ..... ...... .. .. ..... .. .......... 5 .19
Assembly View .. ... .... ..... .. ... .. .... ...... ... .... .......... ..... 5.12 Test ........ .......... .. .... .. .... ...... ...... ....... ... ...... .. .... . .... 5.19
Head Pipe, Removal .... ....... ..... .............................. . 5.1 4 Fuel Pump
Muffler Removal .... ... .. .. ... .... ... . .. . ... . .. ............... ..... . 5.13 Current Draw Test .. .. .. .... . ............ ... ...... ................. 5 .27
Muffler, Installation ....... ..... .... ... .. .... . ... ....... ........ .... 5.13 Installation .... .... . .. ... ..... .. ......... .. ..... .. .. ..... .......... ... 5 .23 C
Exhaust Emission Control . ... ..... ... ... .... ... ... .... ... .. ... ...... 1.9 Pressure Test .... .... ... ... .. ....... .. .... .... ... ... ........ . ....... . 5.19
Exhaust Valve Lash - Tappet Selection Matrix ........ ....... . 7 .38 Removal ... . .. . ...... ... ......... .. ... .. ... ..... ...... ................. 5.21
Supply Voltage Test .. .. .... .. . ..... .... ..... .. ... .. .. .. ... . .. ... .. 5.27
Fuel Rail
F Removal I Installation ..... .... .. ... .. .. ........ ... ... ...... .. .. ... 5.41
Fuel System
Fault Codes .... ..... .... ..... ..... . .... .... .. .. .. ... ..... ... ..... .... ... 5.31 Assembly View . .. ...... . .. ..... ... ...... .. .... .... ... ... ... .. .. .... . 5.8 (
Fender, Front Depressurization .. .. .. ... ...... .. ... .... ... ............ ..... ... .... 5 .20
Installation ...... . .. ... .......... ... .. ..... .......... ...... ... ...... .. 3.10 EFI Overview ... ... ... ....... .. ............ . ...... ...... .. ... ..... .. . 5.29
Removal. ................... .. .... ...... ..... .. ......................... 3.9 Inspection .................. ... .... .. .. ..... .. ... . ........ . .. . ..... ... 2.26
Fender, Rear Line Routing, 49 State .... .. . ... ... .. ... ....... ......... .. ........ .. 5.6
Installation ....... ..... .. ...... . ... . .... ..... ... ... ..... .. ... ......... 3.11 Line Routing, CA .. .... ....... ... .... .. .. ........... ... .. . ..... .. .... 5.7
Removal .... ...... ..... .... ... ..... .. .. ... .. ... .... ...... . .... ...... . .. 3.10 Priming ..... ... .. . ..... .... .. .... .. .. ... .. ...... .. ... ............. .. .. 5.28
Fenders Service Notes .. . ..... .... .. ..... .. .. .... ....................... . .. ... 5.3
Assembly View .. .... ....... ....... ... ... .. .. ... .... ... .. ...... . .. .. . 3.3 Service Precautions ... . .... ...... ... .... ... ..... .... . .. ....... ..... 5.5
Final Drive Service Specifications .... .. ..... ..... ...... .. .... ..... ........ .... 5.4
Troubleshooting ... .... .. ... .. ... .. .. ... . .. ... .... .... .... . .... ... 12.22 Special Tools ... .. .. ... .. ... .. .... ... ... ..... .... .. .... ... . ... .. .. .. .. 5.4
Flywheel Torque Specifications ....... ... ...... ... ... ..... .... . .. .... .. . . .... 5.4
Installation .. .. ... ......... .......... ... ....... ... ... ... . ......... .... 9.21 Troubleshooting .. .. .... ....... ........ .. ........... .... ... .. ....... 5.50
Removal. .... ... .... ... ..... .... .. ... .. ..... ........................ . .. 9 .20 Fuel Tank
Flywheel Removal .. ... ...... .... .. .... . .. . ..... .... ... ..... ... . .... 15.29 Assembly View . ..... ... . .. .. ........ ............ ... . ... ... ........ . . 5.9
Foot Pegs ....... ..... .... ........ ... .... ... ... ... .. ................ .... ... 3.6 Installation ................... .... .... ...... ..... .. .. .. ...... ... ... ... 5 .25
Foot Pegs, Passenger Mounting .. .... .... . ... ... ...... ........... ..... .... ... ... .... . .. .... .. 5.9 C
Installation ... ... ..... ....... ......... ..... ... ................. .. .... .. 3.8 Removal ... . ... ....... . .. . ...... .... .. .. .. .. ... .... ..... ............... 5.20
Removal. ...... ..... ... ..... .. ........ .... ...... ..... ....... ... .. ....... 3.8 Vent Inspection (49 State) ... .. .... .... . .. ..... .................. 2.24
Fork Vent Inspection (CA) . .... .. .... .. .. ...... .... ..... ... ... .. . ...... . 2.24
Assembly .. ........... ...... . .... .. ......... ...... .. .. ... .... ... .... 11 .22 Fuse Box
Assembly View ..... ... ..... ..... . ... .. ......... .. ... ... .. ...... .. .. 11.8 Assembly View .. .. .. ..... ....... . .. . .... .... .... ...... . ...... .. . ... I 7 .5
Disassembly .... ..... ........................ .. .. .... ... .... ...... . 11.18 Fuse Application Chart.. ....... ... .... ......... ..... .. ...... . .... I 7. 7
Installation ... . ... .... .... ..... .. .. . .. ..... .. .... . ..... ...... .. . .... 11.25 Location .. ... .. .... ..... .............. ........ .... ..... ... .. ..... .... . . 2 .34
Removal. ..... .. ... .... ... .......... . ......... .. ... .... .... ...... .... 11.16 Locations .. .... ..... .. .... .... .. ....... .... ..... .. ...... ... ......... .. 17.6
Frame Fuses
Assembly View . ... . ......... .... ........... ... ........ .... ....... .. . 3.4 Location ....... ........ ... ... . .. . .... ... .. .. ... ...... ....... .. ..... .. .. 2 .34
Service Notes .. . ..... ... ...... ....... .......... ..... ... .. ... ... .... .. 3.2 Replacement ... . .. ... ... ... .. .. .... ... ..... .... . ......... .... .... ... 2.34
Special Tools . .... .... ..... .. ..... ... .. ....... ......... ... ......... ... 3.2
Frame Removal I Installation ... .. .. ... ... ... ....... . .. ..... ....... 3.12
Front Axle Inspection ... .. ... .... ..... ....... .. ..... ............... 11.14 G
Front Brake, Assembly View ... ...... ... ..... ...... ...... .......... 14.4 C
Front Fork Gear Position Switch
Inspection ..... ...... . ... .... ... .... ... ... .... ...... .. ..... ....... .. 11.21 Neutral Indicator Test.. .. ... ..... .. .. ...... . .. .. ... .. .. .. ..... .. 15.19
Front Wheel Test ...... ... ...... .. .. ....... . .. ... ... .. . .. .... .. . .. .. ... ..... .... .. .. 17 .19
Assembly View ... ... .. .. ...... ..... .. ... .... ....... ..... .. .... .. . 11.10 Gear Ratios ..... .... ..... .... ... .. .. ..... .. .... ... .... .. ... .. ... .. .. .. .. 10.3
Bearing Inspection .. . .... .. .... . ............................. ... 11.15 Gross Vehicle Weight Rating (GVWR) . ......... .. .... ....... .... 1.6
Inspection . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. 14 Guided Diagnostics ..... ..... .. .... ....... .... ......... ....... .... ... 5 .44
Removal I Installation ..... .. .. ................. ... .. ... .... .. ... 11.13
Front Wheel & Suspension
Troubleshooting ..... .......... .... .. ........ .... ...... ........ ... 11.30 H
Front Wheel!
Bearing Replacement.. .. ...... ..... ... .. .... ... ... ... .... .. .... 11.16 Handlebar
Fuel Filter, Replacement .. . ....... .. .... .... . ... .. ...... ... .. ... .. .. 5.23 Assembly View .. . ... ... .... .. ....... .. ...... .. .. ... ... ... .. . .. . .... 11.6
Fuel Injection Removal I Installation ...... . ..... .... ... .. .... . .... ..... .. ... . . . 11.11
Overview of Operation .... .... .... ... .. ... ....... ... .. .... ...... . 5.29 · Head Light
Fuel Injector Assembly View . ......... ... ..... ... ......... . .... ... ..... ..... .. ... I 7 .3
Removal I Installation ... .... .. ... .... ... ........ .. .... .. . ... ...... 5.41 Bulb Replacement ..... .... .. .. ... .... ... . ..... ... .... .. .... . .. .. I 7 .11
Fuel Injector Resistance Test .. ... ............. .... ... ...... . .... .. 5.41 Head Pipe ............................... ... .. .... ......... ..... .. ....... 5 .14
Fuel Level Sensor, Resistance Test. .... ....... .............. ..... 5.26 Exhaust
Fuel Line Head Pipe, Installation .. .. ... ...... ... . ..... .. ........ ........ 5.15

<..
IX.4
Installation .... ............. ........ . .... ..... ..... ...... ... ... ... .... 5 .15
Headlight
Rear, Rebuilding ....... .. ... ..... .... .. ......... .... ...... ... ... . 14.26
Rear, Removal. .. ... .. .... ... ..... .. .. .. .... ........ .... ... ........ 14.26
Xl-1
Aim Adjustment ............... .... .. ... .. .. ............ ... . ...... .. 2.35 Model Number Designation ........ .. ... .......... ..... .. .... ..... . 1.2
Aim Inspection ...... . .. ... ..... .... ....... ........................ .. 2.35 Model Number Location .. ....... ....... .. ........ ..... ........ .... .. 1.3
Horn Motor Mounts, Assembly View ....... .. .... .......... ... .. ........ 6.3
Removal I Installation ... .. ........ ... ... .. ............... .... ... 17 .12 Muffler
Installation ............................. ........ .. .. . ............. ... . 5. 13
Removal ................ .... ... .. .... . ... .............. ..... .......... . 5. 13
Idle Speed
Adjustment .... . ...... ...... ... .. .. ............. .... ................ .. 2.15
N
Ignition Coil Noise Emission Control ... ... .................. ..... ... ... ........... 1.9
Power and Ground Signal Test ... ................. . .. .......... 16.6
Removal I Installation .... ..... .... .. ... .... ......... .............. 16.3
Resistance Test ... ........ .. .... .. .. ......... .. .... ...... ... ....... . 16.7 0
Ignition Side Cover Removal and Installation .. ....... .... ... 3.11
Ignition System Oil Change
Service Notes .... ....... ................ . ... .. ..... .... ... ........ .. 16 .2 Checking Oil Level ........ . ... .. ... ... .. ............ ....... . ..... .. 2.8
Service Specifications .. ..... . .. ... ........... . .... ..... .... .... .. 16.2 Oil Change, Procedure ....... ... .... ... ... .... .......... ..... . .. ..... 2.9
Special Tools ... ... .... ..... ............ .. ..... .. .. .......... ... ..... 16.2 Oil Cooler
Test I: Battery Voltage Inspection ...... .. .... .......... ....... 16.6 Inspection ...... .... ....... . ... ....... . ............ .. .... .... ..... .... 4. I 7
Test 2: Spark ... ... ..... ..... .... ... ... ... . ......... ... ........ ... .. .. 16.6 Installation ... .. ............... .. .. ...... ........... . ....... ... ... ... . 4.17
Test 3 : Ignition Coil Power and Ground Signal ....... .. ... 16.6 Removal. ... ... ......... .... . ............ .... .. ...... .... .. ... ...... .. . 4. 17
Test 4: Ignition Coil Resistance ........................... .. .. . 16.7 Oil Cooler, Exploded View .... .... ...... ..... ..... .... .. ... ..... ... 4.5
Test Flowchart. ... ....... .. .. .... ........ .......... .. .. .. ..... ... .... 16 .5 Oil Level, Check .... ......... ....... ....... .. ....... .. .. ... .. .. .... . .... 2.8
Testing Precautions ............ ..... . ..... ... .. .. ..... .... ........ . 16.4 Oil Pressure Sensor, Test ................. ..... ..... .. .............. 4.12
Torque Specifications ..... ... .... ... .. .... .. ...... ....... . ........ 16 .2 Oil Pump
Troubleshooting Basics .... ... ..... .... ................ ........ .. 16 .4 Installation .. . ....... ... .... ... .. ..... .. ... . .. .......... ...... ........ 4.14
Inspection ... .. ... ...... ......... ... ......... .. ...... . .. 2.26 , 7.33, 12.13 Oil Pump, Exploded View ... .... .... ..... ...... . .... .... ............ 4.8
Instrument Cluster Oiling System
Overview ... .......... ................ ..... . ... ..................... I 7 . 16 Cooling System ............ ........ ............ ... . ... ............. .. 4.3
Instrument Cluster Removal and Installation .... ....... ... . I 7. I 7 Oil Flow Diagram ......... ....... .... .. ....... .. ... ........ ... ..... 4. 11
Instrument Panel ...... . .. .. ..... . .. .. ..... .. ... .. ........ . .... ........ 3.11 Oil Pressure Test .... ..... ... ............. ..... ...... ........ ....... 4.12
Intake Manifold, Removal I Installation ................ .... ... .. 5.19 Service Notes .. ..................... .. .... .. .. .... ....... ... ......... 4.2
Intake Valve Clearance - Tappet Selection Matrix .. .. ... ... 7 .3 7 Service Specifications ..... ..... ........ .... .. ... .. ...... ... ... ... . 4.3
Special Tools .. .. ..... ... ........... .... ... .. ..... .. .... . ... ... ..... .. 4.2
Torque Specifications ......... . .. ........ ... .... .. ....... .... ...... 4.3
L Troubleshooting .... .. ... ... ........ .. .... ..... .... ....... ... ........ 4.2
Oiling System, Assembly Views
License Plate Light Cooling System ................. . ... ..... .. . .... ........ ... .... .. ... . 4.5
Assembly View ...... .. ..... ....... ........ .. ... ...... .. .... .... .... 17.4 Lubrication System .. .. ....... ...... .... . .. .. ..... ....... . .... ...... 4.8
Removal I Installation ......... ...... .. ..... ... .. .... .. ... ...... . I 7. 13 Output Shaft Seal Replacement .. .... . ...... ..... ........ .. ....... 12.8
Load I Tip Over Module
Connector Map .. . ... ..... .... ...... .... .. ............ ... .. .. ....... 17.9
Load I Tipover Module .. .......... . .. ... ........ ... ... .. ..... .... ... 5.43 p
Load/Tip Over Module
Removal I Installation ..... ..... .... .... . ............. . ..... ..... I 7. 10 P-Codes ......... . .. .. ........ ......... ..... ...... ... ... ... .. . ..... ... .... 5.31
Paint
Color, By Model .. ...... .. .......... .... ...... .. ... .. ..... ........... 1.8
M PCV System, Inspection .... ...... ..... ........ .... ............ .. .. .. 2.23
Pinion Shaft, Clutch
Main Bearing Bearing Inspection .. .... .. ........ .. ..... ............... .... ... .... 9.8
Inspection .. ........ ... .. .... . .. ... ... ....... .. .. .. .. ..... ... . ..... . 10.32 Installation ..... ...... ... ..... .......................... ............ ... 9.9
Oil Clearance Inspection .. .............. . ... . ....... ...... .... 10.32 Removal ................ ... ... ... ... .. ........... ......... .... .... ..... . 9 .8
Maintenance Seal Replacement. ............ ... ..... .... .. ........... .... ......... 9 .9
Engine Break-In Procedure ... .... .. .. .. .. .... ................. .. 2. 7 Piston
Service Notes ... .. .. .... .... .... .. ........ ... .. .. .......... .......... 2.7 Assembly View .. .... .. ... ....... .. .... ....... ........ .. ..... ... ... .. 8.4
Special Tools .. ... ... .... ... ... ..... .. ..... ... .. ........ ......... .. .. . 2. 7 Clearance Worksheet. .. .... . ... .. .... .. ..... ....... .. ........... .. 8. 7
Table ........ .... .................................... .... .. .............. 2.5 Inspection ..... .. ... . .......... .... .... ......... ... ... ........... ... .. . 8.9
Maintenance, Specifications ... ... ... .... ... .... ................. ... 2.3 Installation ......... ... ........ ....... . ........ ... .... .......... .. . ... 8.11
Manufacturer Label Location ..... ........ ........ ... ....... .... .... 1.3 Profile & Orientation .. ..... ... ... .. ..... .. ....... ... .... ...... .. ... 8.5
Master Cylinder Removal .... ....... . ........... ..... ..... ...... ... ..... .. ... .. ...... .... 8.9
Assembly View, Rear ... ........... ... ............ . .. . .... .... .. .. 14.8 Service Notes .... .. ... ..... .. ......................... .......... ..... 8.2
Front, Rebuilding .... .. ... .............. ... ....... .... .......... . 14.22 Service Specifications ... ......... ... .. ..... ...... .... ........ ..... 8.3
Front , Removal. ... ....... .. ... ... ... ... ......... ... .. ......... . .. . 14.22 Special Tools ................. .. ... ... .............. ..... .. ...... ..... 8.2

IX.5
C
Torque Specifications .. ...... ... ... .... .... ..... .... ............... 8.2 Removal .. .... . ............ .. ..... .. ..... ... .... ......... .. .... ........ 4.13
Piston Pin Seat
Inspection ....... ... .... ... .... . .... .... .. .. ....... .. ... .............. 8.10 Assembly View .. .. ...... ........ ........... ... . ... ........ ... .... ... 3.3
Piston Ring Removal I Installation .. ..... .. ..... .. ... ... .. .. ... ... .... ... ... ... . 3.9
Inspection ........ ......... . ..... ... ... .... .. ........ .. .... .. .......... 8.9 Sensor Diagnostics . .. ....... .... ... ....... ... .. .... ........ ....... .. . 5.38
Installation ...... ...... ... ... ....... ....... .. .. ..... .. ... ....... ...... 8. 11 Sensors, Location .... ... .. .......... .. .. .. .... .. .. .... .. . .. ... .... .. .. 5.11
Profile & Orientation .. ... ....... .. ........ .. ... .... ... ... ..... ..... 8.5 Service Notes
Removal. ....... ...... ...... .. ........... ................ ............ ... 8.9 Body .. ... .. ... ... .... ... ......... ................... . .. . ......... ... .... 3.2
Pressure Lubrication Oil Pump Installation ... .. .. ..... ........ 4.15 Brake System ............. ................... .. .. .. .... . ..... .. .... .. 14.2 ('
Pressure Oil Pump Removal ... ... ..... . ...... . .. .................. 4.14 Clutch .... ... .... ................... . ... .... ... ........ .. ...... .... ..... 9.2
Primary Cover Crankshaft .... ... ..... ........ . .... .... .... .. .......... .. ..... .. ..... 10.3
Assembly View .... . ......................... ..... .......... .. .. ... . . 9.3 Cylinder ... ..... ........... .... . ... .. ... ..... .. .... ... .. ... ....... .. ... 8.2
Installation ..... .. ... ..... .. .. ... .. ... .... .... .... .. ............ .. ..... 9. 7 Cylinder Head I Valve Train .... .. ..... .. ............ .... . . ...... 7.3
Primary Drive EFI ......... ..... ...... ... ...... .. .... ... .. ... ................... .. . .... .. 5.3
Service Notes .. ..... .. .. .. . ..... ... .. .. ...... ......... . .............. 9.2 Electrical System ......... ..... ... ... ....... ..... .............. . .... I 7 .2
Service Specifications ... ........... ... .. .. .. . ... ... .. ............. 9.2 Engine Removal .. .... . ... ..... ....... ........ ... .... ... ......... ... . 6 .2 (
Special Tools .. .... .. ....... .... .... ....... ....... .. . ........ ......... 9.2 Front Suspension . ... .... .. .... .. .. .. .... ............. ... . .. ... ..... 11 .2
Torque Specifications ..... ................ . ........... .... .... ... .. 9 .2 Front Wheel .................... .......... .... .. ...... .... .. ......... 11.2
Troubleshooting ... ...... .. ........ .. . .......... .. ..... ...... .. ..... 9.22 Fuel System ..... ...... .................. .. ..... .. ............ .... .. ... 5.3
Primary Drive Cover Ignition System .. ..... ...... ... .... .. ........ .. .. .. ... .... .. .... ... . 16.2
Removal. .. .. .... .. .. .. ........... .... ..... .. ............... .... ... .. ... 9. 7 Maintenance ........ . ........ .. .... ... ... ..... .. .... .... .. .... .. ...... 2.7
Priming the Fuel System ... .... ... ... .. ...... .... .... .... .. ......... 5.28 Oiling System .. . .......... ... ..... .. ...... ...... ... .... ...... . .... .. . 4.2
Publication Part Numbers .. ... ....... ... ....... ........ ............. I . 7 Piston .... .. ...... ... ... .... ........... .. .... .. ...... .. .... ... .. ... . ... .. 8.2
Primary Drive .. ..... ... ........ ..... ..... .... ... .. .... . .. .... .. ..... . 9.2 C
Rear Suspe nsion ...... ... ......... ... ... ....... . ..... ... . ........... 12.2
R Rear Wheel ... ...... . .......... .. ..... ... ... .... ..... ... .. ... ...... .. 12.2
Starting System .. ... .. ....... ..... ... ....... ........ ... ...... ...... . 15.3
Radiator ...... ....... .. .... ....... ..... . .. . .... ...... ......... ... ....... .. 4.22 Tires ......... ..... ...... ..... ..... ... . ......... ... ... ... ........ ........ 13.2
Radiator Inspection I Cleaning ....... .. ........ ... ........... .... 2.13 Transmission ....... .. ..... . .... .. ........ .... ... .. ... ........ . ... .. . 10.3
Rear Axle Wheels ... .... .... . ..... ....... ..... ... .. ... .. .... .. ......... ... . ...... 13.2
Inspection ............. ......... .. .......... .. . ... ... ..... ...... .... 12.13 Service Specifications ... ..... ... ....... ... .. ..... ........ ....... .... 13.2
Rear Brake, Assembly View .. ... ........ ..... .. ..... . ............. 14.5 Balance Shaft . ... .. .. ...... .... ... ..................... . .. .. .... .. ... 10.3 C
Rear Sprocket Inspection ... .. .... ... .. .. .............. ........... 12.10 Brake System ... ............ .... ... ......... ... .. .......... ...... .... 14.3
Rear Sprocket Installation ... . ................... ... .... .... .. .... 12.11 Charging System .. ... ... ..... .... ... ... ....... . .......... ......... . 15 .5
Rear Sprocket Removal ........ . ..... ..... .... ... .... .............. 12. l 0 Clutch .... .... .. ....... .... ..... .. ... ....... .... .. . ..... ......... . ...... 9.2
Rear Wheel Connecting Rods .... .. .... ...... ... . ..... ..... ....... .. . .. ... . .. ... 10.3
Bearing Inspection .... .... ... ..... . .... .. .... . .... .............. 12. 14 Crankshaft ..................................... .... .... .. . ......... .. 10.3
Bearing Replacement ...... ....................... .. ...... ... ... 12.14 Cylinder ........... ...... ..... ....... ... ...... ... ... ... ..... .. ... ...... 8.3
Inspection ............ ....... ..... ... ..... .. ... ........ ..... ........ 12.13 Cylinder Head I Valves ..... . .... .. ..... ... ... .... .... ... ... .. .... 7.4
Removal I Installation ......... ..... . .......... .. ........ .. ..... . 12. 12 EFI .... .... ... .............. .. . ...... .. ..... .. .. .... ...... .. ... .... ....... 5.4
C
Rear Wheel and Suspension Engine Removal .... ... ...... .... ... ... ... . .. ... ..... ... .. ...... .... . 6.2
Assembly View ................ .... ... ...... .... .. ....... ..... ... ... 12.4 Front Suspension .... ..... . ... .............. .. ............. ..... .... 11 .3
Special Tools . .......... ........ .... ... ... ..... .... .... .... ..... .. ... 12.2 Front Wheel .. .. .... . ...... . ... ... .. .......................... ... ... . 11.3
Torque Specifications .. .......... ..... ... ... ..... . .... ... ... ...... 12.2 Fuel System ... .. . ........ ...... ...... ........ ..... .......... ... . .. . ... 5.4
Rear Wheel, Assembly View ............................... . ...... 12.5 Ignition System .. .... ...... .. ...... ........................ ...... . .. 16.2
Reflash Authorization ................. ..... .. . .... ... .... ... .. ... .. .. 5.48 Oiling System ... ..... ... .. ..................................... ...... 4.3
Regulated Voltage Test.. .... ........ .. ... ... . ...... ....... . ...... . 15.25 Piston .... ....... .... ... .... ......... ... . ............ .. .... ........ .. ... . 8.3 (
Regulator I Rectifier Primary Drive .. .. ... .... .. .. ...... . ... ..... ... ..... .... .. ... .. .. .. .. . 9.2
Assembly View ... ... .............. ... . .... ...... .... ... ....... ..... 15.9 Rear Suspension ... .... ........... ....... ..... .. .. ............ ... ... 12.3
Bracket, Replacement ..... .............. ... .... ... ...... ...... . 15.30 Rear Wheel ... .............. .. .. ............ .. ... ... ................ . 12 .3
Connector Inspection .. .. .......... ....... .. ..... ..... ... .. ..... 15.29 Starting System ... .. ... ..... ..... .. ... .. .. ........ ........... . ...... 15.5
Diode Leakage Test ... ........................ ... ........... .... 15.29 Tires ... .. ...... .. ... ... . ............... ....... .. ......... ........ ...... . 13 .2
Replacement .................. .... . .... ....... ........... .... .... . 15.30 Wheels .. .. . ... . .... ....... .. . ... ... ..... .. .. ...... ......... .... .... . .. 13.2
Ride Height Shift Arm Removal/Installation .. .. ... ............ .... .. .. .. ...... . 9 .12
Adjustment .... .... ............ .... ... .. .... ....... ....... ... ... ...... 2.38 Shift Drum
Inspection .... .... .... .... .. . ................ ......... ... ....... ..... . 2.38 Assembly View .... .. ....... ...... ... ..... ..... . ....... . .. . ..... .. I 0.14
Rings Inspection .. ............ .... ..... .... .. .. .. ... . ............ .. ....... 10.24
End Gap Measurement.. .. .. ..... .. ............................... 8.9 Removal. ..... .. .. ... ........... .... ...... ....... .... ........ ........ 10.23
Installation ... .. ....... ... ........... .... ... .. . ...... ..... ............ 8.11 Shift Fork
Profile & Orientation .. .... .... ... ... .. ... ..... .... ......... .. .... .. 8.5 Assembly View . .. ..... ...... ...... ... ........................... . I 0.14
Removal. .. .... ... . ....... .. .. ...... .. ... ... .. ... .. ....... .. .... . ..... .. 8.9 Removal. .. .......... ....... .... ........ ..... . .... . .. ... ... ....... ... 10.23
Shift Pedal
Adjustment .... .... .... .... .. ... ... ......... ..... ... .. .. .. ..... .... .. . 2 .21
5 Inspection ......... ........ ..... .... .... .... ... .. ... ... ... .... ..... .. . 2 .2 1
Shift Ratchet
Scavenge Oil Pump Inspection ... ...... ... ...... ....... ... .... .. .... ..... ........ ...... .. . . 9.9

IX.6
Installation ...... ... ......... .... .... .... ... .. ..... .. ....... ........ .. 9. I I
Removal . .... .... ..... .. ...... . .... ... ..... ....... .. ......... ........... .9.9
Drive Gear, Inspection .... .. ..... .. .. .. .. ..... ... .... .... ... ... 10.19
Drive Gear, Installation ... ..... ... .. ............................ 10.20
Xl-1
Shift Shaft Seal, Replacement. .................. ......... .. .... .... 9.12 Drive Gear, Removal ........ ..... .. ..... .......... .. ... . ...... . . 10.19
Shifting Installation .. ............ ... ..... ......... .. ............ ... .... . .... 15 .22
Troubleshooting ....... .. .... ... .. . ....... . .... ........ . ....... .... . 9 .22 Removal .... .... ....... ..... ........ ....... .. ...... .... ... ........... 15.22
Shock Absorber Safety Information ...... .. ...... .. ................ ... .... .... .... 15. 14
Inspection ..... . .. . ............. ... ........... .. ........ ... .. ....... 12. 15 Starter Solenoid
Installation .... . .. . .... .................. ............ ............... 12.16 Ground Circuit Test ...... .. .. ........... ..... ....... .... .... .... 15.19
Removal ...... ... .. . ..... ... .............. ..... ......... ............ . 12.15 Positive Circuit Test ... ... ....... . .... .... .......... ..... .. ... ... 15.21
Shock, Rear Starting Circuit
Preload Adjustment ........ .. .... ....... ........ .. .... .. ........ .. 2.38 Starting Circuit Wiring Diagram . .. .. ... ... ...... ... . .. ..... . 17 .20
Preload Inspection . ........... .. .. ........ .................. .. ..... 2.38 Starting System
Side Stand Switch Circuit Operation ........ ... ......... .. .. .......... ........ ... ... 15.15
Test ... .. ...... ........ .. .... . .................. .. ... ... ......... ...... 17. 19 Diagnostic Table ....... ... .... . .. .......... ... ..... ......... . .... 15.14
Side-stand Service Notes ...... ..................... .... ... ......... .... ..... ... 15.3
Inspection ...... ... . ......... . ................. .. .. ......... ..... .... . 2 .35 Service Specifications ... ... ...... ... .... .... ..... ............ .... 15.5
Lubrication .. ........ .. ... .. .. ..... .. ...... ... ...... ...... .... .... ... . 2.36 Special Tools .... . .. ....... .......... .. ...... ... ....... .. ..... ...... . 15.4
Removal I Installation ...... .... .... ...... ........... . .. .. ..... ... . 2.36 Torque Specifications . .... ... ..... ..... . .... ........ .. .. .... .... .. 15.4
Spark Plug Troubleshooting . ...... ......... ... ...... . .... ......... ..... ... ... 15.17
Gap . ... .... ...... . .. . ...... .... . .... ...... ... . .. ... .. ................... 2.26 Troubleshooting, No Crank .... .. .... .... .... ..... .... ... .... . 15.16
Inspection ... ... .. . .... ....... ....... ........ .. ..... .. ...... .... ...... 2.26 Troubleshooting, Starter Drive ...... . ... ... . .. .... . ....... ... 15.18
Installation .... ... .... .. ... ...... . ..... .... . ... ... .... ............... . 2.27 Wiring Diagram ... .. ... ... ........... ... .. .... ........ ..... ...... 15. 15
Removal . ... . ... .... .... .... ... ...... .. ... ... ......... ... .. ............ 2.26 Stator
Special Tools ... .. ..... .......... ....... ... .. .. ........ ... .... .. .... ... . I . 13 Assembly View .. .... ...... ..... .. ........ .. .. ..... .... ..... .. .. .... 15.8
ABS System .. ... .. .......................... ...... .... ..... ...... .... 14.3 Ground Continuity Test .. ...... . ..... .... .... .. ........... . .... 15.27
Balance Shaft .... ... . ........ ... ..... ... ........ ... ... .. ... .......... 10.3 Installation ..... .......... ......... .. ... ... ..... ....... ...... .. . .... 15.28
Body ......... ............ ........ .. .. ........ ..... .. .. ... . .. ... ....... .. 3.2 Output Test. ....... ... .... ....... ... . .... ........ ........ . .... ...... 15.26
Brake System .... . ... .. .. .. .. .. . .... ....... ... . ..... .. ..... .... .. .. .. 14.3 Removal ...... ... ..... .. ... .. .... ........... ..... .. ..... .. .. .. ... .... 15.28
By System ........ .. ... .. .. ... .. . .... .... .. ..... ... ............ .. ..... 1. 11 Resistance Test ...... ... ......... ..... ........... .. ..... .... ...... 15.27
Charging System ... .... . .... ............ .... ... ...... ... ... ...... .. 15.4 Stator Cover Installation .... ..... ... . ....... ....... ...... ..... ... ... 9 .19
Clutch .. ·...... ........ ... . ..... ...... . ......... ... .. ........ ..... ..... .. 9.2 Stator Cover Removal. .. . ... . ....... .... .............. .. ..... ........ 9.19
Crankshaft ..... .. ... .. ..... ........ . ....... .......... .. . .... . .... .... 10.3 Steering Head
Cylinder .. ......... .... .. .. .... .. .. .... ... ..... .. ...... .... ... ... .... .. 8.2 Bearing Adjustment .... ... ........ .... ....... ..... ...... ........ 11.27
Cylinder Head I Valves ... ... ...... . .. . ... .. ....... . ... .. ....... .. 7 .3 Bearing Inspection . .. ... ..... .. ... ...... ........... ..... .... ...... 2.37
EFI .... ... ....... ... ... .... .......... .. . ... ... . ..... .... ... . .... . .. .. .. .. . 5.4 Storage
Electrical System .... .... .. . .. ..... .. .. ........ ...... ..... ... ... ... . 17 .2 Battery ... ... ..... .... ... .. ..... ... .... . ... ........ .... ..... ... ... ..... . 2.29
Engine Removal .... .. ... ..... .. .. . .... . .. .. ... ......... ..... ... ..... 6.2 Suspension
Frame ... ... ..... .... ... . ..... ... ....... .. . ....... .... ... ...... .. .. .... .. 3.2 Assembly View, Front .. .. .. ..... ... ................ ....... ...... . 11 .8
Front Suspension ...... ..... .. ... .... .. ... .......... . .... .... ... .. .. 11.2 Suspension, Front
Front Wheel .. ...... .......... .. . ... .... .. .. ... .... .......... ........ 11.2 Fork Assembly ... .. ... .. .... ..... ..... ................ .......... .. 11.22
Fuel System ... .... ..... ..... .. ... .. . ... .... ......... .. ................ 5.4 Fork Installation ... .. ... .. .. ... ... ...... ... ........... .... ..... ... 11 .25
Ignition System ...... ......... ...................... ..... ...... .. ... 16.2 Fork Removal.. .. .. ....... ... ... ..... ... ....... .... ............. .. . 11.16
Locating .................... .... ......... .... ......... .. .. . ..... .. .. .. . 1.11 Service Notes ........ ... .. ... .. .. ... ... ....... ..... .. ..... ... . .... .. 11.2
Maintenance ... .. .. ..... ..... .. .. ..... ... .. .. ... .... ......... ... ...... 2.7 Service Specifications .... .... ... ........ ... ... ..... ...... .. ...... 11.3
Oiling System .... ..... .. .. ... ...... .. ...... ........ . .... .. .... . .. .... 4.2 Special Tools ....... ..... .... ... .... .. .. .. . .. .... ..... ....... .. .. .... 11.2
Ordering Information .... ....... . ... ..... ........ .. ...... .... .. .. . 1.12 Torque Specifications .... ........ ... .................. .... .... .... 11.2
Piston ....... ... .. ... ..... ................. ..... ... ............. ......... 8.2 Suspension , Front Fork
Primary Drive .... ..... .... .. .... ... ... .... .. ......... ... .. .. .. . ... ... 9.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . 11 . 18
Rear Wheel and Suspension .... ... ... .. ....... .. .. . ... ..... .... 12.2 Suspension, Rear
Starting System ................. .. . ... . .... .... ...... .... .. .. ....... 15. 4 Service Notes ... .. ... .. .... . ....... .... ......... . ... .... ... ....... .. 12.2
Transmission ... .. .... .... .... .. ... ....... . ....... .... ... ..... ...... . 10.3 Service Specifications ... . .... ... ...... .. ........ ....... ... . ... ... 12.3
Specifications .. .... ... ... .. .. ..... . .. ..... ..... ............ ........ ..... 1.4 Troubleshooting ...... .... .. ... ...... ...... ..... .. ... .... ... ...... 12.21
Sprocket Swing Arm
Drive, Installation .... ... .. . ..... .. ... . .. . ...... ........ ...... .... .. 12.8 Inspection .. .. ....... .. ... ....... .... ... ...... .. .............. ... ..... 2.37
Drive, Removal ...... ... .. .... ... ........ . .. ........ . ... ... . ........ 12.7 Swingarm
Driven, Inspection ........ .. ..... . ......... .... . .. ... .. ....... .. . 12 . I 0 Assembly View ..... .... .. .. ......... ............................... 12.4
Driven, Installation . .. .. .... ... ..... .. ..... ....... .. ...... .... ... 12 .11 Bushing I Bearing Replacement ... ........ .. ..... ..... ..... . 12.18
Driven, Removal .... .... . ... ............. . .......... .............. 12.10 Installation ................. .... .. ... ........... .. .. ......... ....... 12. 19
Inspection, Rear ...... ..... ..... ......... .. ........ ...... .... ...... . 2.34 Removal ... ............... .... ... ... .. .... .. ....... ..... ....... ...... 12.17
Sprocket, Drive , Inspection ... . ........... ........ .. ... ... . ........ 12.8
Stake Nut Installation ..... . .... ... ........ ...... .. . ...... . ... . ...... 10.37
Starter T
Solenoid, Ground Circuit Test ...... ... .... .. .. .. ... ..... ... .. 15.19
Starter Motor Tail Light
Assembly View .. ....... ..... .. .. ........... .. ......... .... . .. ..... . 15. 7 Assembly View ........... .... .. . .. .... .. . ............. .. ....... .... 17 .4
Current Draw Test ... .... .. .. .. ........... ... .. . ..... .. .. .. .. .... 15.21 Operation Overview .... ..... ... ..... ... .. ... .. ..... .... ........ 17 . 13

IX.7
Removal I Installation .. ............... .. ... ...... ...... ......... 17 .13 Triple Clamp
Thermostat ........ .. .. . .................. ... .......... ................. . 4.26 Assembly View . .............. ......... .... .. .... ... ........ ... ... .. 1 1. 7
Thermostat Housing Cover Removal I Installation ......... . 3.12 Bearing Adjustment ........ .. ............ .... ................... 11.27
Throttle Body Installation ....................... .... ............ .. .... ....... ... .. 11.27
Removal I Installation .. .. .. ....... ........ . ...... .. ... ............ 5.42 Removal ..................................... ... ..... ................ 11.26
Throttle Control. ......................................... : ....... .. .. 17.22 Troubleshooting
Timing Components, Exploded View .... .. .. ................ . .. 7 .6 Brake System .. ....................... ...... ..... ... ..... .......... 14.29
Timing Marks ........................................................... 7. 9 Crankshaft .................. .......... .. ... . ... ....... .. ..... ...... 10.38
Tire &Wheel Final Drive ................................. .... .................... 12.22
Troubleshooting .................................................. 13.10 Front Wheel & Suspension .................................... 11.30
Tire Removal, General. ......... .. ................................... 13 .4 Rear Suspension ........... .... ....... ...... .. .. ................ .. 12.21
Tire Wear Patterns ...... ........... ... ..... ......... ... ..... .... .... .. 13.3 Rear Wheel ................ .... ... .... .... .. ..... .. ....... ......... 12.2 1
Cupping .. . .... ......... ....... ..... ... ...... ... .... .... ... : ...... '. ... 13.3 Tire & Wheel ..................... .. ........ ........ .... .. ......... 13.10
Tires . ... ... .... . ... ................................................ 13.4-13.5 Transmission ........ ... .......... ...... ...... ..................... l 0.38
Balance Dots ................... ............................. .. ....... 13 .5 Turn Signal
Balancing ......................................... .................... 13. 7 Front, Removal I Installation ... ...... ...... ... ................ 17 .15
Directional Arrows .. ........ ... ..... ...... .... ..................... 13.5 Operation Overview ................................... .. ....... 17 .15 C
Inflation I Precautions ... ....... .. ................................ 13.5 Rear, Removal I Installation (All Models) ..... ... ... . ..... 17.15
Information ........................................................... 1.3
Inspection .... . .... .......... ...... .. ............. .. ..... .. .... ....... 2.15
Ozone Cracking ... . ...... ............. ................ .. .. ......... 13.3 V
Pressure ............... ..................... ....... ....... ..... .. ..... . 2. 15
Repair Precautions . .. ............... .......... .. ............... .. .. 13.8 Vacuum Bleeder ..................................................... 14.18
Service Notes ............................ .. .. .. ..................... 13. 2 Valve Clearance Adjustment ...... .. .............................. 2 .39
Service Specifications .. .. .... .. .............. .... ................ 13. 2 Valve Clearance Assembly .... .. ..... ...... ................ . ...... 7 .24
Size Specifications ............................. .. .. .. .. ............ 2.15 Valve Clearance Inspection .......... ... ......... .... . ......... .... 2.39
Specifications .......... ............. ........ ... .... .. ........ . ....... 1.3 Valve Cover
Tread Wear ................. ....... ... .... ........................... 13.3 Installation ........................................................... 7 .23
Valve Stem Installation, Metal .............................. .. .. 13.9 Removal ............................................................... 7 .23
Valve Stem Installation, Rubber .. .. .. .. .......... ............ . 13 .9 Valve Guide
Valve Stem, Inspection ...... ....... ...... ........................ 13.9 Removal I Installation ............. ... ...... ........ .. .. ... .. ...... 7 .33
TMAP Sensor Valve Seat (,
Overview ............. .. .. ....... ....... ...... .... ................. ... 5.39 Inspection .. .. .. ......................... .. ........... .. ........ .. .. .. 7 .33
Replacement ...... ... .... ... ............... .. .. . .... .... ...... ... ... 5.39 Valve Seat Reconditioning ........ ... ............. ........... ....... 7 .33
Tools, Special ..................... .. ... .. ....................... . ...... 1.13 Valve Spring, Free Length .. .... ................ ..... .. .. ....... . ... 7 .30
Torque Specifications .... .... ...... .... .................. ......... .... 3.2 Valve Stem
Brake System ............. ......... .. .... ............... .. ...... ..... 14.3 Inspection .... .. ................. .... ................................. 13 .9
Charging System ... ....... .............. .... ....... ...... .. ........ 15.4 Installation, Metal ............ .... ............ ........ .... .......... 13.9
Clutch .... .. .... .. ....... .. ............................................. 9 .2 Installation, Rubber ................. ..... ............ .. ........... 13.9
Cylinder ....... . .... .... .................. ... ...... .................... 8 .2 Valve Timing ............................ .... .............. .. .. .. .. ..... 7. 19 C
Cylinder Head I Valves ........................................... 7.4 Valve Train
EFI ... ... .. ........ ................ ....................... ..... ......... .. 5.4 Special Tools ......................................................... 7 .3
Electrical System ................................................... 17 .2 Valves
Engine Removal .. ............... ............ ........................ 6.2 Inspection . .. .. ...................... .... ... ...... .. .................. 7 .31
Front Suspension ........... .. ...................................... 11.2 Wear Patterns ........... ...... ...... .... ............................ 7 .32
Front Wheel ........... ............... ... ............................ 11.2 Valves, Exploded View ... ........ .... .. ... ........................... 7.8
Fuel System .... .......... ....... ................... .... ............... 5 .4 Vehicle Identification Number .. .... .... .. .... ..................... 1.2 (
Ignition System ... ..... ............................................. 16 .2 VIN Decoder .................. .. ... .................... ................. 1.2
Oiling ·System ............ .... .. .. ..... ...... ...... ..... ... .. ....... .. 4.3 VIN Location .... .................. ...... .. ... ..... .. ..................... 1.3
Piston ............................... .... ...................... ..... ..... 8.2 Voltage Output Test ............... .... .. .. ........ ...... .. .. ....... 15.25
Primary Drive ....... ... ................. .. ...... ..................... 9.2 Voltage Regulator
Rear Wheel and Suspension ............ .. .. .. .................. 12 .2 Assembly View ..... ......... ... .. ..... .... ..... .. ........... . ...... 15. 9
Starting System .. .. ............................................... .. 15 .4
Trademark Information .. ............................................... 2
Transmission
Assembly View ... ..... .. ....................... ......... .. ....... 10.10
w
Gear Ratios ... .... ... .......... ...................................... 10.3 Water Pump .. ... ............. ........ .. .... .... ............ .... ... 4. 7, 4.23
Gear Train ........................ ........ .......................... 10.16 Wheel
Inspection . ... ............. .. ................ .......... ............. 10.24 Inspection ... . ........................... ... .......... .... .... .... .... 13.8
Installation .... ..... .. .......... ....... ..... ........................ 10.34 Wheel Bearings
Power Flow .... .... .. ............ ... ..... .... .. .. .. ... .. ...... ... ... 10.16 Inspection, Front ............... .. ....................... ........... 2.37
Removal. .. .... ...... .. .......................... .. ......... ..... . ... 10.23 Wheel Speed Sensor
Service Notes ... ....... .............. ...... ....... .... .............. 10.3 Adjustment (Air Gap) .............. ...... .. ..................... 14.1 5
Special Tools ... ..... .. ........ ... .......... ......................... 10.3 Replacement ........................................ .............. 14.14
Troubleshooting .. .... ....... ................. .. .. ....... ......... 10.38 Wheel, Front ................. .... ........ .. ... ... ... ................ .. 11.10
Transmission 5 Spd I Sixty ............... ........................ 10.12 Bearing Inspection .......................... .. ................ .. 11.15

IX.8
Bearing Replacement. ... ..... ....... .. ..... ......... .... ....... 11.16
Inspection .... ................ ... .................... .... ... ..... ... 11. 14
Removal I Installation ..... ... ... .. ................ .. .... ..... .. . 11.13
Service Notes ...................... ....... .. ... ..... ... ......... ... . 11 .2
Service Specifications .............................. ... .. .. ...... . 11.3
Special Tools ... .... ... ... .. .......... ......... .......... ............ 11. 2
Torque Specifications ........... . ........ ...... ...... ......... ... . 11.2
Wheel, Rear
Assembly View .............. ............. ........ ..... ..... ........ 12.5
Bearing Inspection ........ .. .... ...... ...... .. ..... ............. 12.14
Bearing Replacement .............. ....... .............. ... ..... 12.14
Inspection .................... ..................... ............ .... . 12. 13
Removal I Installation .... .... .. .. ...... . ...... .. .... .... ........ 12.12
Service Notes .......... ...... .. .. .......... .. ... ............... .. ... 12. 2
Service Specifications ... ... ... .......... ...... .... .......... .. ... 12.3
Troubleshooting .... .. ... .. . ....... .... .... ......... ...... ........ 12.21
Wheels
Service Notes .................. . .. . .... ......... .. . .. ... ... ......... 13.2
Service Specifications ..... .. ........ .......................... .. . 13. 2
Wire Diagrams ............. ..... .. ... .. ............ ....... ....... . .... ... 23
Wiring Diagram
Animated, Overview .. ...... . .. ..... ........ .. .... ...... .. .......... 23
Ignition System ... ... ....... .. ..... .......... ...... ..... .. ... .. .. . 17 .21
.)

IX.9
C
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CHAPTER 1: GENERAL I SPECIFICATIONS

CHAPTERS: FUEL DELIVERY I EFI I EXHAUST

CHAPTER 7: CYLINDER HEAD I VALVES

CHAPTER 9: CLUTCH I PRIMARY I SHIFT

CHAPTER 11: FRONT WHEEL I SUSPENSION

CHAPTER 13: TIRES

CHAPTER 17: CHASSIS ELECTRICAL

9926140 R02 - 2015 - 2016 Scout Service Manual

GRP MY TYPE MODEL LINE DISP NET MARKET COLOR

ENGINE NUMBER LOCATION

VEHICLE IDENTIFICATION NUMBER (VIN)

Vehicle Descriptors Vehicle Identifiers

World Mfg. ID Chee-

* Model Year: E = 2014; F = 2015; G = 2016; H = 2017

9926140 R02 - 2015 - 2016 Scout Service Manual

TIRE INFORMATION LABEL

9926140 R02 - 2015- 2016 Scout Service Manual

992 6140 R02 - 201 5- 201 6 Scout Service Manual

Fuel System Suspension

9926140 R02 - 2015 - 2016 Scout Service Manual

Exceeding the gross vehicle weight rating of your

The maximum load capacity of your motorcycle is the

9926140 R02 - 2015 - 2016 Scout Service Manual

PUBLICATIONS AND TECHNICAL LITERATURE

2015 Indian 9925346 9924343

2016 Indian 9926140 9926136

2016 Indian 9926140 9926136

J 9926140 R02 - 2015 - 2016 Scout Service Manual

MODEL PAINT COLOR PAINT MODEL PAINT COLOR PAINT

Nl5MSAOOBA Thunder Black P-266 Nl6MSBOOCA Thunder Black P-266

Nl5MSAOOCA Thunder Black P-266 Nl6MSBOOABJ Wildfire Red 676

9926140 R02 - 2015 - 2016 Scout Service Manual

9926140 R02 - 2015 -2016 Scout Service Manual

CRANKCASE EMI SS ION CONTR OL EVAPORATIVE EMI SS ION CONTROL

9926 140 ROZ - 201 5 - 20 16 Scout Service Manual

9926140 R02 - 2015 - 2016 Scout Service Manual

TOOL ORDERING INFORMATION

HOME I HOWTOORDER I ORDERfORM I WARRAmY I CONTACTUS I CREDITAPPUCATION I ~ \IIEWCART

9926140 R02 - 2015 - 2016 Scout Service Manual

SPECIAL TOOLS INDEX

Belt Tension Meter Crankcase Separator Tool Crankshaft Locking Pin

9926140 R02 - 2015 - 2016 Scout Service Manual

Relay Bypass Tool Smartlink Module Kit Swingarm Bushing Tool

9926140 R02 - 20 15 - 2016 Scou t Service Manual

Cup Adapter Engine Stand Adapter Fork Oil Seal Driver

Water Pump Seal Installation Tool Fork Seal Installation Tool

9926140 R02 - 2015 - 2016 Scout Service Manual

#5-44 #37 1-8 7/ 8 8xl.25 17/ 64 0.265 17/ 64

#6-40 #33 1 1/8-7 63/ 64 9xl.25 5/ 16 0.3125 5/ 16

#8-32 #29 1 1/8-12 13/ 64 lOxl.25 11/32 0.3437 11 / 32

#8-36 #29 1 1/ 4-7 1 7/ 64 lOxl.50 R 0.339 11/32

#10-24 #24 1 1/4-12 1 11/64 l lxl.50 3/ 8 0.375 3/ 8

#10-32 #21 1 1/ 2-6 1 11/32 12xl.50 13/ 32 0.406 13/ 32

#12-24 #17 1 1/2-12 1 27/ 64 12xl.75 13/ 32 0.406 13/32

#12-28 #15 1 3/ 4-5 1 9/16

9926140 R02 - 2015 - 2016 Scout Service Manual

9926140 R02 - 2015 - 20 16 Scout Service Manual

9926140 R02 - 2015 - 2016 Scout Service Manual

p (3 .14159) x R2 x H (height) = Cylinder

9926140 R02 - 2015 - 2016 Scout Service Manual

9926140 R02 - 2015 - 2016 Scout Service Manual

9926140 R02 - 2015 - 2016 Scout Service Manual

9926 140 R02 - 20 15 - 2016 Scout Service Manual