INDIAN MOTORCYCLE EQUIPMENT LISTING

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Filed Under (Indian) by admin on 28-11-2010

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INDIAN MOTORCYCLE, INC. EQUIPMENT LISTING QTY DESCRIPTION SERIAL # 1 VIPER VT-25 CNC LATHE FANUC 18-T CONTROL MACHINE CENTER 3398080101 1 MIGHTY COMET MILLING 3VHG 98017/98025 1 SHARP MILL PACKAGE LMV 9 X 42 61124334/61124335/31124336 1 VIPER V-1000G CNC MILL MDL VMC 206506 1 CLAUSING C12AX KHS BANDSAW INV328172 LC889967 1 CNC ROTARY HYDRAULIC TUBE BENDING MACHINE – HMT 992L3055 3 AXIS 005B 1 JANCY COLD SAW T315 21006 1 KALAMAZOO AH9W BANDSAW GEI TECHNOLOGY SOLIDWORKS & PDM WORKS, EASTMAN M9000 STATIC TABLE SYSTEM 1 MITUTOYO CORDINATE MEASURING MACHINE 1006804 2 KHS JET DRILL PRESS 2 MOTOMAN -SK16 ROBOT S99354/S994351 LOT TENNESSEE RAND – SCOUT SWING ARM MANUAL WELD FIXTURE, CHIEF SWING ARM MANUAL WELD FIXTURE, SCOUT REAR STRUT MANUAL WELD FIXTURES, CHIEF REAR STRUT MANUAL WELD FIXTURE, ERGONOMIC TOUCH UP AND REPAIR STANDS – BOTH CHIEF & SCOUT INDIAN MOTORCYCLE, INC. EQUIPMENT LISTING QTY DESCRIPTION SERIAL # 1 CROWN FORKLIFT SC4040-35 ISLE PICKER TROJAN BATTERY HOBART CHARGER FORKLIFT – SC4040-35 BATTERY 63257 CHARGER 100C62388 1 CROWN FORKLIFT SP3210-210 1 NISSAN ELECTRIC FORKLIFT – MODEL PE30Y CSPO1-9A1555 1 NISSAN ELECTRIC FORKLIFT – MODEL PE50YSC CWPO2-9C2180 1 NISSAN LIFT TRUCK MODEL P50LP – USED KP50YLP-901370 CROWN FORKLIFT ISLE PICKER 1A206705 KOMUTSU FORKLIFT 506718A 2000 CHEVY FLATBED

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Indian Rocker Arm End Play Rear Cylinder/ Front Cylinder Installation

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Filed Under (Indian) by admin on 12-11-2010

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Rear Cylinder 1Rotate the engine so that the rear piston is at Top Dead Center (TDC), compression stroke, so no load is on the valves. 2Using a 3/16″ allen wrench, remove the four screws securing the rear cylinder rocker cover. 3Remove the cover and inspect both O-ring seals. Discard if damaged or worn. 4Push both rocker arms towards the valve end support bracket (A) and using a feeler gauge check the gap between the rocker arms and the pushrod end support bracket (B). NOTE: The Rocker arm end play specification should be between 0.003″ to 0.012″. 5 Compare the measurement to the specification an determine whether adjustment is necessary. If the end play is within specification, adjustment will not be required. Refit the rocker cover (instructions 14 to 15) and carry out the same inspection on the front cylinder . If the measurement is outside the specification, adjustment will be required and shimming will be necessary (follow the remainder of these instructions). Adjustment 6Using a 1/4″ allen wrench remove the 4 screws securing the rocker shaft assembly.Refit the LH support bracket and reposition the complete assembly on the rocker base. Make sure that the three dowels are in place and the slots in the rocker shafts are properly aligned with the mounting screw holes in the RH support bracket. 11Clean the threads of the 4 support bracket screws and apply Blue Loctite to the first 4 threads. 12Fit the 1-3/4″ screws into the LH support bracket (A) and the 2″ screws to the RH bracket (B). Torque all screws in cross pattern to 16-20 foot-pounds. CAUTION: The rear piston must be at TDC, compression stroke, when tightening the support bracket screws. 13Re-check the rocker end play to ensure it is within specifica- tion. 13Lubricate the two O-rings with clean engine oil and refit them in the grooves in the rocker base. 14Refit the rocker cover.

Indian Vintage Engine Guards Installation Instructions

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Filed Under (Indian) by admin on 31-10-2010

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1Place the jack under the motorcycle and raise the rear wheel. Motorcycles with an IMC Lowering Kit should remove the upper shock bolt. This lowers the swingarm allowing better access to the lower footpeg/rear guard bolt. 2Using a 3/16″ allen wrench, remove 5 screws securing the center fairing and remove both halves of the fairing. 3Using a 1/4″ allen wrench remove the screw securing the forward saddlebag mounting bracket. 4 Locate the spacer from the kit (62-239) and fit between the frame and the saddlebag mounting bracket. 5 Clean the threads of the removed screw, apply Blue Loctite 242 to the first 4 threads and refit. Tighten to 29 foot-pounds. Motorcycles without Passenger Foot-pegs 6Remove the plastic caps covering the foot-peg mounting holes on both sides of the frame. 7 IMCRW0195 3 Motorcycles with Passenger Foot-pegs 7From inside the frame and using a ratchet with 3/8″ hex bit and 18″ extension, remove the passenger foot-peg bolts. Discard the allen bolt (see previous page for photo). Left Hand Engine Guard 8Fit the rubber bushing/damper (62-241) to the mounting on the saddlebag bracket. Position the split in the rubber at the bottom. 9Position the LH engine guard (62-235) on the left side of the motorcycle, locating the upper bracket over the rubber bushing/damper on the middle saddlebag mounting bracket. CAUTION: Ensure the split in the rubber bushing/damper is positioned at the bottom when locating the upper bracket

1999-2002 Indian Motorcycle Mirror Housing Removal and Replacement

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Filed Under (Indian) by admin on 31-10-2010

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1. Remove seat. 2. Disconnect battery. 3. Remove handlebar cover on top-center of handlebar. 4. Remove left-side clutch-bracket assembly. This exposes an access hole on the underside of the handlebar. 5. Pass the end of the Signal® mirror wires through one of the small holes located on the underside of the clutch-bracket assembly housing. 6. Take piano wire/fish tape and insert at the access hole located on the underside of the handlebar to the center of the handlebar (center handlebar cover removed). 7. Fasten the end of the Signal® mirror wires to the piano wire/fish tape and pull through the handlebars to the center opening. 8. Pull excess wire through the handlebars leaving approximately 2″ of extra wire at the mirror side. 9. Re-assemble clutch-bracket assembly allowing the Signal® mirror wire to wrap around the outside edge of the cover assembly into the underside access hole. Secure Signal® mirror with enclosed 1.5″ long 5/ 16 ” – 24 Allen head bolt. 10. Loosen throttle assembly side and slide back to expose access hole. DO NOT REMOVE THROTTLE ASSEMBLY. Proceed to pass the Signal® mirror wire through the handlebar at the opposite side and re-assemble the throttle assembly. 11. Run both sets of wires under the fuel tank along the topside of the frame to the battery compartment. 12. Connect both black wires to the enclosed ring connector for connection to the battery ground terminal. 13. Locate the male/female electrical connector that is located behind the battery. This wiring assembly is for your tail lamp assembly for braking and turning (see photo). 14. Make sure the harnesses are routed securely to the wire connectors and enough slack is left for splicing or soldering. Cut the heat shrink into (4) equal pieces (approx. 2″ each). 15. Slide the heat shrink over the passenger side Signal® mirror wire. Solder the Right Signal® mirror wire to the Brown wire. Slide the heat shrink over to cover the soldered area. Heat the shrink tube into place with a heat shrink gun or hair dryer. 16. Repeat sliding the heat shrink over the driver side Signal® mirror wire. Solder the Left Signal® mirror wire to the Purple wire. Slide the heat shrink over to cover the soldered area. Heat the shrink tube into place with a heat shrink gun or hair dryer. 17. Connect ground and positive battery connections. 18. Re-install seat.

INDIAN MOTORCYCLES footboard cover Installation

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Filed Under (Indian) by admin on 31-10-2010

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INSTALLATION Tools – Drill and 1/4″ bit – 5/32 Hex Key (included) – 7/16″ Wrench – Needle Nose Pliers 1. Use needle nose pliers to loosen footboard cover and rotate forward out of the way. 2. Using the HEEL GUARD as a template, place in rear corner of metal base plate. Be careful to align the rod with the inside edge of the base plate. Mark the holes first. 3. Drill 1/4″ holes. Print Instructions
Heelguard Installation 4. Use the enclosed bolts and locking nuts to secure the HEEL GUARD. 3. Reinstall the footboard cover

INDIAN MECHANICAL- TO- ELECTRONIC SPEEDOMETER CONVERSION KIT INSTALLATION

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Filed Under (Indian) by admin on 31-10-2010

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Speed Sensor Requirement Identification Certain motorcycles are not equipped with a port that will accept a Transmission Speed Sensor. Those models will require a Rear Wheel Speed Sensor. To determine which sensor is required, follow the following procedure: Determine if you have a mechanical speedometer 1. The mechanical speedometer is around 2 ¼” in diameter. 2. On the axle on the left side of the front wheel, there will be a 2″ diameter ‘donut like’ part that the axle passes through. This is the speedometer drive. Attached to the speedometer drive and extending back and up under the fuel tank will be a housed cable. This is the speedometer drive and cable to drive the mechanical speedometer. 3. If these conditions are true, you have a mechanical speedometer. Determine which speedometer drive sensor you need. You must determine if your transmission will accept the transmission sensor. If not, you will need the rear axle sensor. 1. On the top, right, rear of the transmission, will be a 1″ by 1/2″ (approximately) cover held in by one bolt. 2. If you find this then REMOVE the bolt and over. 3. If after removal of the cover you find a larger hole underneath, then you can use the transmission sensor. Figure 1—Transmission Sensor Port (Inset Shows Cover Removed) 4. If you have no cover, or under the cover is not a hole, then you need the rear axle sensor. Be sure to look closely and under the gasket under the cover. 5. If you have no sensor hole, then you need to make sure you have the rear wheel sensor. Contact Thunder Heart Performance if you need to exchange your sensor for a different one. 1.3 Preparation and Painting of the Console Your console is made of Lexan®, which is a clear, durable plastic. It can be painted on the inside (so that outside scratches will not affect the paint), or on the outside. For the best paint results, thoroughly clean the console only with the following cleaners

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