2001-2004 Indian Spirit Roadmaster Service Manual

2001 to 2004 Indian Spirit Roadmaster Service / Repair / Workshop Manual

Provided in PDF form, in English Language.

Includes wiring diagram.

• This is supplied as a genuine Indian workshop manual, consisting 309 of pages.

This covers the 2001, 2002, 2003 & 2004 years, but may also be largely appropriate for later years, please check before buying.

Sample pages are shown in the second product images.

 

Features Following Chapters...

1. General Information

2. Troubleshooting

• Chassis - Brakes & Chassis
• Engine - Symptom Relates Diagnostics & Basic Engine Tests
• Emission - Evaporative System Checks
• Ignition - Spark Plug Condition & Electrical Ignition Diagnostics
• Carburetor 
• Transmission & Drive - Transmission & Clutch
• Electrical - Electrical Troubleshooting Charts, Battery Testing, Battery Charging, Ground Path Tests, Current Draw/Leak Test, Regulator/Rectifier Current Leak Test, Charging System Tests, Starting System Tests, Wiring Circuit Test

3. Front Suspension Service

• Fork Oil Replacement
• Fork Tube Procedures

4. Steering Component Service

• Steering Stem Inspection & Adjustment
• Steering Stem Disassembly & Assembly

5. Rear Suspension Service

• Shock Absorbers
• Swingarm

6. Wheel & Tires Service

• Front Wheel Removal & Installation
• Rear Wheel Removal & Installation
• Hub Bearing Cleaning & Inspection
• Wheel Sprocket & Brake Rotor Removal & Installation
• Wheel Rim, Hub & Spokes Inspection
• Tire Inspection & Pressure Check
• Tire & Tube Replacement

7. Brake System Service

• Brake Fluid Level & Condition
• Brake Pad Replacement
• Brake Caliper Service
• Brake Rotor Service
• Master Cylinder Service
• Hydraulic Brake Line Replacement
• Replacing Brake Fluid & Bleeding System

8. Frame & Accessories Service

• Seat Removal & Installation
• Fender Removal & Installation
• Dash Removal & Installation
• Front Turn Signal & Headlight Procedures
• Fender Mounted Light Procedures
• Floorboard & Buddy Peg Removal & Installation
• Mirror Assembly Removal & Installation
• Kickstand Removal & Installation
• Chassis Frame Inspection & Repair

9. Air Cleaner Service

• Air Filter Element Removal & Installation
• Air Cleaner Assembly Removal & Installation

10. Fuel System Service

• Fuel Filtration Maintenance
• Fuel Line Inspection & Replacement
• Throttle Control Inspection & Maintenance
• Fuel Tank Removal & Installation
• S&S E Type Carburetor 
• Air Leaks
  
• Carburetor Removal & Installation
• Carburetor Maintenance
• Carburetor Rebuild

11. Ignition System Service

• Spark Plug Replacement
• Ignition Coil & Spark Plug Wire Replacement
• Ignition Trigger Plate/Rotor Removal & Installation
• Ignition Module Replacement
• Ignition Timing Check & Adjustment

12. Lubrication System Service

• Engine Oil & Filter Replacement
• Cleaning the Tappet Screen
• Oil Line Inspection & Replacement
• Oil Pump Removal & Installation
• Oil Tank Removal & Installation
  

13. Emission Control System Service

• Evaporative System
• Carbon Canister Removal & Installation
• Air Valve Removal & Installation

14. Engine Removal & Installation

• • Tools Required
  • Removing Chassis Components & Engine Accessories
  • Engine Removal
  • Engine Installation
  • Installing Chassis Components & Engine Accessories

15. Engine Disassembly & Assembly

• Rocker Box Procedures
• Pushrod & Tube Removal & Installation
• Pushrod Adjustment
• Cylinder Head Procedures
• Cylinder & Piston Assembly Procedures
• Alternator Rotor/Stator Removal & Installation
• Lifter Block Removal & Installation
• Ignition Trigger Plate/Rotor Removal & Installation
• Cam, Breather Valve & Pinion Gear Removal & Installation
• Crankcase Disassembly & Assembly

16. Primary Drive Service

• Primary Chain Inspection
• Primary Drive Removal, Installation & Adjustment

17. Rear Drive Service

• Rear Drive Belt Inspection, Removal & Installation
• Rear Wheel Alignment & Drive Belt Tension Adjustment
• Engine & Transmission Alignment

18. Clutch Service

• Clutch Lever & Cable
• Clutch Inspection & adjustment
• Clutch Removal & Installation
• Clutch Disassembly & Assembly
  

19. Transmission Service

• Transmission Shift Control Linkage Maintenance & Adjustment
• Transmission Oil Change
• Transmission Removal
• Transmission Installation
• Transmission Disassembly
• Installation of Shafts into Trapdoor
• Shift Fork Inspection & Installation

20. Starting System Service

• General Information
• Starter Drive Pinion Assembly
• Starter Motor
• Starter Relay

21. Charging System Service

• General Information
• Battery & Cables
• Alternator Replacement
• Voltage Regulator Replacement

22. Chassis Electrical

• Electrical Equipment Check
• Speedometer & Warning Light Replacement
• Electronic Control Module, Access/Replacement
• Road Light Replacement
• Handlebar Switch Replacement
• Circuit Wiring Repair

23. Specifications

• Dimensions & Weights
• Brake Torque Values
• Wheel & Tires Torque Values
• Front Fork & Suspension Torque Values
• Rear Swingarm & Suspension Torque Values
• Frame & Accessories Torque Values
• Engine Fits & Tolerances
• Engine Fastener Torque Values
• Primary, Clutch & Final Drive Torque Values
• Transmission Torque Values
• Electrical Component Torque Values
• Lubricants & Fluids
• Sealants & Threadlock Compounds

24. Assembly & Drawings

• Chassis Wiring Diagrams
• Ignition System Diagram
• Lubricant Flow Diagram
• Transmission Power Flow Diagrams
• Engine Parts & Assembly Drawings

25. Tools & Equipment

26. Index