Description
Official Indian Motorcycle Service Manual for the PowerPlus 108
This is the complete 2020-2022 Indian Challenger / Pursuit Service Manual (PN 9940277 R04), the same reference used by certified Indian Motorcycle Master Service Dealer technicians. It is a comprehensive, factory-authorized workshop guide covering all systems, diagnostics, and repairs for the 2020 to 2022 model years of the Indian Challenger and Pursuit. Whether you are performing routine maintenance, complex engine overhauls, or electrical diagnosis, this manual provides the correct procedures, torque specifications, and service data required to do the job right.
File Details
- Manual Type: Factory Service / Workshop Manual
- Brand: Indian Motorcycle
- Models: Indian Challenger & Pursuit (2020, 2021, 2022)
- Engine: PowerPlus 108 (1768cc, 11.0:1 compression)
- Document Number: 9940277 R04
- Publication Date: 2022
- Language: English
- Page Count: 753
- File Format: Digital PDF (Instant Download)
Chapters Covered
This manual is structured into ten main chapters, each covering a major system of the motorcycle in full technical detail. The depth of information is designed for professional-level service and repair. Key sections include:
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the â2020-2022 Indian Challenger & Pursuit Factory Service Manual – PDF Downloadâ are as follows:
+2020-2022 Indian Challenger / Pursuitp. 1
Forewordp. 1
Revision Index 9940277p. 3
Feedback Form – Service Manual (9940277)p. 4
+CHAPTER 1 : GENERAL / SPECIFICATIONSp. 6
+VEHICLE INFORMATIONp. 7
Model Number Designationp. 7
Vehicle Identification Number (VIN) Designationp. 7
Engine Number Locationp. 8
VIN / PIN Locationp. 8
Manufacturer Labelp. 8
Tire Information Labelp. 8
+GENERAL SPECIFICATIONSp. 9
2020 Model Specificationsp. 9
2021 Model Specificationsp. 12
2022 Model Specificationsp. 15
+VEHICLE LOADINGp. 19
Gross Vehicle Weight Rating (GVWR)p. 19
+PUBLICATIONS & TECHNICAL LITERATUREp. 20
Publications Part Numbersp. 20
+EMMISIONS INFORMATIONp. 21
Emission Control Systemsp. 21
Emission Sourcesp. 21
Exhaust Emission Controlp. 21
Noise Emission Controlp. 21
Crankcase Emission Controlp. 21
Evaporative Emission Control (California and International Models)p. 21
+SPECIAL TOOLSp. 22
Using Special Toolsp. 22
Tool Ordering Informationp. 22
Special Tools Indexp. 23
+REFERENCEp. 27
Master Torque Tablep. 27
SAE Tap Drill Sizesp. 34
Metric Tap Drill Sizesp. 34
Decimal Equivalentsp. 35
Fahrenheit To Celsiusp. 36
Measurement Conversion Chartp. 37
+CHAPTER 2 : MAINTENANCEp. 38
+MAINTENANCE QUICK REFERENCE GUIDEp. 39
Specifications – Maintenancep. 39
Indian Motorcycle Service Products and Lubricantsp. 40
Maintenance Intervalsp. 41
+GENERAL INFORMATIONp. 54
Service Notes â Maintenancep. 54
Special Tools â Maintenancep. 54
Break-In Procedurep. 54
+ROUTINE MAINTENANCE PROCEDURESp. 55
Air Filter Replacementp. 55
Engine Oil & Filter Changep. 55
Engine Oil Levelp. 57
Tire Pressure / Specificationsp. 57
Brake Fluid Level Inspectionp. 58
Spark Plug Inspection / Gapp. 59
BATTERY CHARGING AND MAINTENANCEp. 59
Fuse Replacementp. 64
Headlight Aim Inspectionp. 64
Headlight Aim Adjustmentp. 65
MAJOR MAINTENANCE PROCEDURESp. 66
+CHAPTER 3 : ENGINE / COOLING / EXHAUSTp. 68
+ENGINE / COOLING / EXHAUST MAINTENANCEp. 71
Coolant Level Inspectionp. 71
Idle Speed / Fast Idle Speedp. 71
Spark Plug Removalp. 71
Spark Plug Installationp. 72
Engine Compression Testp. 72
Engine Compression Test (Wet)p. 73
Crankcase Ventilation Systemp. 73
+AIR CLEANER SERVICEp. 75
Air Filter Replacementp. 75
Inlet Adapter Removal / Installationp. 75
Inlet Tube Replacementp. 76
+ENGINE REMOVAL / INSTALLp. 77
+GENERAL INFORMATIONp. 77
Service Notes â Engine Removal / Installp. 77
Service Specifications â Engine Removal / Installationp. 77
Special Tools â Enginep. 77
+ASSEMBLY VIEWSp. 78
Engine Brackets / Fastenersp. 78
+ENGINE REMOVAL / INSTALLATIONp. 81
Preparation For Engine Removalp. 81
Removing Engine From Framep. 82
Engine Installationp. 84
+LUBRICATION / COOLINGp. 88
+GENERAL INFORMATIONp. 88
Service Notes â Coolingp. 88
Troubleshootingp. 88
Special Tools â Coolingp. 88
Service Specifications â Coolingp. 89
+ASSEMBLY VIEWSp. 90
Filter Adapterp. 90
Oil Flow Diagramp. 91
Lubrication Systemp. 92
Water Pump Assembly Viewp. 94
Cooling Systemp. 95
Thermostatp. 96
Radiatorp. 97
Torque Sequence â Lubrication / Coolingp. 98
+OIL PRESSURE INSPECTIONp. 99
+OIL PUMP SERVICEp. 100
Oil Pump Removal / Installationp. 100
+TRANSMISSION FEED RAILp. 102
Transmission Feed Rail Removal / Installationp. 102
+COOLING SYSTEM SERVICEp. 104
Coolant Drain / Fill / Bleedp. 104
Radiator Removal / Installationp. 105
Coolant Recovery Bottle Removal / Installationp. 107
Water Pump Removal / Installationp. 108
Thermostat Removal / Installationp. 110
Thermostat Disassembly / Assemblyp. 111
+CYLINDER HEAD / VALVESp. 112
+GENERAL INFORMATIONp. 112
Service Notes â Cylinder Headp. 112
Special Tools â Cylinder Headp. 112
Service Specifications â Cylinder Headp. 113
+ASSEMBLY VIEWSp. 115
Cam Chainp. 115
Camshaftsp. 116
Cylinder Headp. 117
Camshaft Timingp. 118
Torque Sequence â Cylinder Head / Valvesp. 119
+CAM CHAIN SERVICEp. 120
Locking the Crankshaft for Servicep. 120
Flywheel Removal / Installationp. 121
Cam Chain Tensioner Removalp. 122
Cam Chain Removal / Installationp. 122
Cam Chain Tensioner Inspectionp. 126
Camshaft Sprocket Removal / Installationp. 126
Cam Chain Tensioner Installationp. 127
Cam Chain Guide Removalp. 127
Cam Chain Guide Installationp. 128
+CAMSHAFT SERVICEp. 129
Camshaft Removalp. 129
Camshaft Inspectionp. 145
Camshaft Installationp. 145
+CYLINDER HEAD SERVICEp. 149
Breather Assembly Removal / Installationp. 149
Valve Cover Removalp. 150
Valve Cover Installationp. 151
Cylinder Head Removalp. 151
Rocker Arm Assembly Removal / Installationp. 152
Rocker Arm Assembly Inspectionp. 153
Cylinder Head Disassemblyp. 153
Cylinder Head Inspectionp. 154
Valve Spring Free Length Inspectionp. 154
Valve Inspectionp. 154
Valve Inspectionp. 156
Valve Guide Removal / Installationp. 157
Valve Seat Inspectionp. 157
Valve Seat Reconditioningp. 157
Cylinder Head Assemblyp. 158
Cylinder Head Installationp. 158
Troubleshooting, Cylinder Head and Valve Trainp. 160
+CYLINDER / PISTONp. 162
+GENERAL INFORMATIONp. 162
Service Notesp. 162
Special Tools â Cylinder / Pistonp. 162
Service Specifications â Cylinder / Pistonp. 163
+ASSEMBLY VIEWSp. 164
+CYLINDER / PISTON SERVICEp. 165
Piston Ring Profile And Orientationp. 165
Cylinder Removalp. 167
Cylinder Inspectionp. 167
Cylinder Bore Measurementp. 167
Piston To Cylinder Clearance Worksheetp. 168
Cylinder Warpage Measurementp. 169
Piston & Piston Ring Removalp. 169
Piston & Piston Ring Inspectionp. 170
Piston Pin / Pin Bore Inspectionp. 170
Piston Ring Installationp. 171
Piston Installationp. 171
Cylinder Stud Replacementp. 172
Cylinder Installationp. 172
Troubleshooting, Cylinder / Pistonp. 173
+EXHAUSTp. 175
Exhaust Systemp. 175
+EXHAUST SERVICEp. 177
Muffler Removal / Installationp. 177
Resonator Removal / Installationp. 178
Headpipe Removal / Installationp. 179
+CHAPTER 4 : FUEL DELIVERY / EFIp. 182
+GENERAL INFORMATIONp. 184
Service Notesp. 184
Special Tools â Fuel Delivery / EFIp. 185
Service Specifications â Fuel Delivery / EFIp. 185
+FUEL DELIVERY / EFI MAINTENANCEp. 186
Fuel Tank Vent Inspectionp. 186
Evaporative Emission Control System â 50 State / INTLp. 188
Fuel Rail Inspectionp. 189
+SERVICE PRECAUTIONSp. 190
EFI System Precautionsp. 190
+EVAP SYSTEMp. 192
EVAP System Overviewp. 192
EVAP Conditions and Symptomsp. 193
Carbon Canister Removal / Installationp. 193
Purge Valve Testing / Replacementp. 194
+ASSEMBLY VIEWSp. 195
Fuel Line Routing â 49 Statep. 195
Fuel Line Routing â 50 Statep. 196
Fuel Systemp. 198
Air Boxp. 200
Sensors – Powertrain Managementp. 201
+FUEL DELIVERY SERVICEp. 202
Intake Manifold, Removal / Installationp. 202
Fuel Pump Pressure Inspectionp. 202
Fuel System Depressurizationp. 203
Fuel Tank Removal (2020)p. 204
Fuel Tank Removal (2021)p. 206
Fuel Pump Removalp. 209
Fuel Tank Vent Inspectionp. 210
Fuel Pump Installationp. 210
Fuel Tank Installation (2020)p. 213
Fuel Tank Installation (2021+)p. 215
Fuel Tank Harnessp. 218
Fuel Level Sensor Resistance Testp. 219
Fuel Pump Supply Voltage Testp. 220
Fuel Pump Current Draw Testp. 221
Priming The Fuel Systemp. 221
+EFI SERVICEp. 222
Fuel Injection System – Overview Of Operationp. 222
Rear Cylinder Deactivationp. 222
ECM Connector Mapp. 223
Trouble Codesp. 225
Sensor Diagnosticsp. 233
ECM Pinout Testingp. 233
ECM Removal / Installationp. 234
Temperature & Manifold Absolute Pressure Sensor (TMAP)p. 234
Cylinder Head Temperature Sensor, Test / Replacep. 236
Ambient Air Temperature Sensorp. 238
Fuel Rail Removal / Installationp. 238
Fuel Injector, Removal / Installationp. 238
Fuel Injector Resistance Testp. 240
Crankshaft Position Sensor, Test / Replacep. 241
Knock Sensor Test / Replacep. 242
Throttle Body Removal / Installationp. 244
Cylinder Misfire Detectionp. 251
+CAN DIAGNOSTICSp. 252
CAN (Controller Area Network) Diagnostic Overviewp. 252
+DIGITAL WRENCHp. 253
Special Toolsp. 253
Digital WrenchÂŽ Software Overviewp. 253
Guided Diagnosticsp. 253
Diagnostic Software Versionp. 253
ECM Replacementp. 253
Guided Diagnostic Availablep. 254
Digital Wrench Diagnostic Connectorp. 254
Digital Wrench Communication Errorsp. 254
Digital WrenchÂŽ Serial Number Locationp. 255
Digital Wrench Version and Update IDp. 255
Digital Wrench Updatesp. 256
Digital Wrench Feature Mapp. 257
Engine Controller Reprogramming (Reflash)p. 258
Throttle Learn Procedurep. 259
Polaris Mobile Digital WrenchÂŽ (PMDW)p. 259
+TROUBLESHOOTINGp. 261
Fuel System Troubleshooting, Part 1p. 261
Fuel System Troubleshooting, Part 2p. 262
Fuel System Troubleshooting, Part 3p. 263
Fuel System Troubleshooting, Part 4p. 264
+CHAPTER 5 : CLUTCH / PRIMARY / SHIFTp. 266
+GENERAL INFORMATIONp. 267
Service Notes â Clutch / Primary / Shiftp. 267
Special Tools â Clutch / Primary / Shiftp. 267
Service Specifications â Clutch / Primary / Shiftp. 268
+CLUTCH / PRIMARY / SHIFT MAINTENANCEp. 269
Clutch Cable Inspection / Lubricationp. 269
Clutch Lever Lubricationp. 270
Clutch Lever Free Playp. 270
Shift Pedal Inspection / Lubricationp. 271
Shift Pedal Adjustmentp. 272
+ASSEMBLY VIEWSp. 273
Primary Coverp. 273
Clutch Pinion Shaftp. 274
Primary Drive Gearp. 275
Clutchp. 276
Clutch Plate Assembly Viewp. 277
+SERVICE PROCEDURESp. 278
Primary Cover Removalp. 278
Clutch Pinion Shaft Removalp. 279
Clutch Pinion Shaft Bearing Inspectionp. 279
Clutch Pinion Shaft Installationp. 280
Shift Ratchet Removal & Inspectionp. 281
Shift Ratchet Installationp. 282
Shift Shaft Bearing & Seal Replacementp. 283
Primary Cover Installationp. 284
+CLUTCH SERVICEp. 285
Clutch Rack, Removal / Installationp. 285
Clutch Removalp. 286
Clutch Disassemblyp. 287
Clutch Inspectionp. 288
Clutch Assemblyp. 289
Clutch Installationp. 290
+PRIMARY DRIVE GEAR SERVICEp. 291
Primary Drive Gear Removalp. 291
Primary Drive Gear Installationp. 292
Flywheel Removal / Installationp. 293
Troubleshooting, Clutch / Primary / Shiftp. 295
+CHAPTER 6 : TRANSMISSION / CRANKSHAFTp. 296
+GENERAL INFORMATIONp. 297
Service Notes â Transmission / Crankshaftp. 297
Special Tools â Transmission / Crankshaftp. 297
Service Specifications â Transmission / Crankshaftp. 298
+ASSEMBLY VIEWSp. 300
Crankcasep. 300
Crankshaftp. 303
Crankcase Torque Sequencep. 304
Transmissionp. 306
Shift Drum / Shift Forkp. 308
Balance Shaftp. 309
Gear Trainp. 310
+BALANCE SHAFT SERVICEp. 313
Balance Shaft Removalp. 313
Balance Shaft Installationp. 313
+STARTER DRIVE SERVICEp. 315
Starter Drive Removalp. 315
Starter Drive Inspectionp. 315
Starter Drive Installationp. 315
+CRANKSHAFT SERVICEp. 316
Crankcase Separationp. 316
Transmission Removalp. 318
Transmission Inspectionp. 319
Crankshaft Removalp. 322
Connecting Rod Side Clearance Inspectionp. 322
Connecting Rod Removal / Identificationp. 323
Connecting Rod Inspection (Big end)p. 323
Connecting Rod Bearing Inspectionp. 324
Crankshaft Inspectionp. 325
Connecting Rod Installationp. 326
Crankshaft Cleaningp. 327
Main Bearing Inspectionp. 328
Main Bearing Oil Clearance Inspectionp. 328
Left Crankcase Assemblyp. 329
Right Crankcase Assemblyp. 331
Crankshaft Installationp. 333
Transmission Installationp. 333
Crankcase Assemblyp. 335
Stake Nut Installationp. 337
Troubleshootingp. 338
+CHAPTER 7 : FRAME / BODYp. 340
+GENERAL INFORMATIONp. 341
Service Notes â Frame / Bodyp. 341
Special Tools â Frame / Bodyp. 341
+ASSEMBLY VIEWSp. 342
Fenders / Seatp. 342
Framep. 343
Floorboardsp. 345
Side Panelsp. 349
Seatp. 351
Fairingp. 353
Lower Fairingp. 360
Saddlebagsp. 362
Trunkp. 364
+BODY / FRAME SERVICEp. 366
Side Cover (Upper), Removal / Installationp. 366
Side Cover (Lower), Removal / Installationp. 367
Floorboard Removal / Installationp. 368
Passenger Foot Pegs Removal / Installationp. 370
Passenger Foot Pegs Removal / Installation (2022+)p. 370
Seat Removal / Installationp. 371
Seat Removal / Installation (Touring)p. 372
Trunk Removal / Installationp. 372
Trunk Lock Replacementp. 373
Highway Bar Removal / Installationp. 375
Front Fender Removal / Installationp. 376
Rear Fender Removal / Installationp. 377
Fairing Disassemblyp. 379
Fairing Removal / Installationp. 389
Lower Fairing Removal / Installationp. 392
Front Casting Removal / Installationp. 392
Midcast Removal / Installationp. 394
Ride Command Display Removal / Installationp. 397
Speedometer / Tachometer Removal / Installationp. 398
+CHAPTER 8 : STEERING / SUSPENSIONp. 400
+STEERING / SUSPENSION MAINTENANCEp. 403
Drive Belt Inspectionp. 403
Drive Belt Tension Measurementp. 403
Drive Belt Tension – Specificationsp. 404
Drive Belt Adjustmentp. 405
Sprocket Inspectionp. 407
Steering Head / Front Wheel Inspectionp. 407
Swing-Arm Inspectionp. 407
Rear Shock Preload Inspectionp. 408
Rear Shock Preload Adjustmentp. 409
E-Preload Adjustmentp. 410
Shock Analysisp. 411
Sidestand Inspectionp. 411
Sidestand Removal / Installationp. 412
+FRONT WHEEL / SUSPENSIONp. 413
+GENERAL INFORMATIONp. 413
Service Notes â Front Wheel / Suspensionp. 413
Special Tools â Front Wheel / Suspensionp. 413
Service Specifications â Front Wheel / Suspensionp. 414
+ASSEMBLY VIEWSp. 415
Handlebar Controlsp. 415
Handlebarp. 417
Front Fork Assemblyp. 419
Triple Clampp. 421
Front Wheelp. 422
+SERVICE PROCEDURESp. 424
Handlebar Removal / Installationp. 424
Clutch Lever Assembly Removal / Installationp. 424
Throttle Control Removal / Installationp. 425
Clutch Cable, Removal / Installationp. 426
Front Wheel, Removal / Installationp. 427
Front Axle Inspectionp. 427
Front Wheel Inspectionp. 428
Brake Disc Removal / Installationp. 428
Front Wheel Bearing Inspectionp. 429
Front Wheel Bearing Replacementp. 429
Front Fork Removalp. 430
Front Fork Disassemblyp. 431
Fork Seal Removal / Tube Disassemblyp. 434
Front Fork Inspectionp. 436
Front Fork Assemblyp. 437
Fork Oil Filling / Level Settingp. 438
Front Fork Installationp. 442
Triple Clamp Removalp. 444
Front Fork Lock Removal / Installationp. 445
Triple Clamp Installation / Steering Head Bearing Adjustmentp. 446
Troubleshootingp. 448
+REAR WHEEL / SUSPENSIONp. 450
+GENERAL INFORMATIONp. 450
Service Notes â Rear Wheel / Suspensionp. 450
Special Tools â Rear Wheel / Suspensionp. 450
Service Specifications â Rear Wheel / Suspensionp. 451
+ASSEMBLY VIEWSp. 452
Rear Suspension (2020+)p. 452
Rear Suspension (2022+)p. 453
Rear Shock / Pushrodp. 454
Rear Wheelp. 455
Drive Sprocketp. 456
Rocker Assemblyp. 457
+DRIVE BELT SERVICEp. 458
Drive Belt Inspectionp. 458
Drive Belt Removalp. 458
Drive Belt Installationp. 458
Drive Belt Adjustmentp. 459
+DRIVE SPROCKET SERVICEp. 461
Drive Sprocket Cover, Removal / Installationp. 461
Drive Sprocket Removalp. 461
Drive Sprocket Inspectionp. 462
Drive Sprocket Installationp. 463
+DRIVEN SPROCKET SERVICEp. 464
Driven Sprocket Removalp. 464
Driven Sprocket Inspectionp. 464
Driven Sprocket Bearing – Replacementp. 465
Driven Sprocket Installationp. 465
+REAR WHEEL SERVICEp. 466
Rear Wheel Removal / Installationp. 466
Rear Axle Inspectionp. 468
Rear Wheel Inspectionp. 469
Rear Wheel Bearing Inspectionp. 469
Wheel Bearing Replacementp. 470
Brake Disc Removal / Installationp. 470
Shock Absorber Removalp. 471
Shock Absorber Inspectionp. 471
Shock Absorber Installationp. 472
+SWING-ARM SERVICEp. 473
Swing-Arm Removalp. 473
Swing-Arm Bushing / Bearing Replacementp. 474
Swing-Arm Installationp. 477
+REAR SHOCK SERVICEp. 479
2020-2021p. 479
2022+p. 484
+TROUBLESHOOTINGp. 488
Troubleshooting, Rear Wheel / Suspensionp. 488
Troubleshooting, Final Drivep. 489
+TIRESp. 490
+GENERAL INFORMATIONp. 490
Service Notes â Tiresp. 490
Special Tools â Tiresp. 490
Service Specifications â Tiresp. 491
+TIRE INSPECTIONp. 492
Tire Wear Patternsp. 492
Ozone Crackingp. 492
Front Tire Cuppingp. 492
+TIRE PRESSURE MONITORING SYSTEM (TPMS)p. 493
TPMS Overviewp. 493
TPMS Sensor Replacementp. 493
TPMS Activationp. 494
+TIRE REMOVALp. 496
Tire Changing, General Informationp. 496
Tire Removalp. 496
+WHEEL INSPECTIONp. 498
Visual Inspection & Runoutp. 498
Tire Repair Precautionsp. 498
+VALVE STEMp. 499
Valve Stem Inspectionp. 499
Valve Stem Replacementp. 499
Tire Installationp. 500
Tire Balancingp. 501
Troubleshootingp. 502
+CHAPTER 9 : BRAKESp. 504
+GENERAL INFORMATIONp. 506
Service Notes â Brakesp. 506
Special Tools â Brakesp. 506
Service Specifications â Brakesp. 506
+BRAKE MAINTENANCEp. 507
Front Brake Lever Inspectionp. 507
Front Brake Lever Lubricationp. 507
Front Brake Lever Reachp. 508
Brake Pedal Inspectionp. 508
Brake Pedal Lubricationp. 508
Front Brake Pad Inspectionp. 509
Rear Brake Pad Inspectionp. 509
+ASSEMBLY VIEWSp. 510
Front Brake Systemp. 510
Rear Brake Systemp. 512
Brake Line Routingp. 514
Front Master Cylinderp. 519
Rear Master Cylinderp. 520
Front Brake Caliperp. 521
Rear Brake Caliperp. 522
ABS Modulep. 523
Wheel Speed Sensor, Frontp. 524
Wheel Speed Sensor, Rearp. 525
+ANTI-LOCK BRAKES SYSTEM (ABS) SERVICEp. 526
ABS System Safety Precautionsp. 526
ABS General Informationp. 526
ABS System Componentsp. 527
ABS Overview Of Operationp. 527
ABS Trouble Codesp. 528
ABS and Low Battery Voltagep. 534
Wheel Speed Sensor Replacementp. 535
ABS Module Replacementp. 537
+ABS BRAKE SYSTEM BLEEDINGp. 540
Brake Fluid Replacement & Bleeding Precautionsp. 540
ABS Brake Vacuum Bleederp. 540
ABS Fluid Changep. 541
ABS Rear Brake Bleedingp. 541
ABS Front Brake Bleedingp. 543
Brake Lever Reserve Inspectionp. 544
+BRAKE SYSTEM SERVICEp. 545
Front Brake Pad Replacementp. 545
Rear Brake Pad Replacementp. 546
Brake Disc Inspectionp. 547
Front Master Cylinder Servicep. 548
Front Caliper Servicep. 550
Front Caliper Installationp. 551
Rear Master Cylinder Servicep. 552
Rear Caliper Servicep. 553
Rear Caliper Installationp. 555
Brake Line Replacementp. 556
Brake Pressure Sensor Removal / Installationp. 559
Brake Pressure Sensor Testp. 560
Troubleshooting â Brakesp. 561
+CHAPTER 10 : ELECTRICALp. 564
+ELECTRICAL MAINTENANCEp. 568
Batteryp. 568
Battery Removalp. 569
Battery Installationp. 569
+STARTING / CHARGINGp. 570
+GENERAL INFORMATIONp. 570
Service Notes â Starting / Chargingp. 570
Special Tools â Starting / Chargingp. 572
Service Specifications – Starting / Chargingp. 573
+ASSEMBLY VIEWSp. 574
Starter Motor / Solenoidp. 574
Statorp. 575
Battery Boxp. 576
+BATTERY SERVICEp. 578
Battery Removalp. 578
Battery Installationp. 578
Battery Box Removal / Installationp. 579
BATTERY CHARGING AND MAINTENANCEp. 581
Battery Charge Port Removal / Installationp. 585
Battery Inspectionp. 586
+STARTER MOTOR SERVICEp. 587
Safety Informationp. 587
Starter Motor, Removal / Installationp. 587
Starting System Diagnostic Tablep. 588
Troubleshooting Flow Chart 1p. 589
Troubleshooting Flow Chart 2p. 590
Troubleshooting Flow Chart 3p. 590
+STARTING SYSTEM TESTSp. 591
Battery Load Testp. 591
Starter Solenoid Positive Circuit Testp. 591
Starter Solenoid Ground Circuit Testp. 592
Starter Solenoid Resistance Testp. 592
Clutch Switch Circuit Testp. 593
Clutch Switch Removal / Installationp. 593
Starter Current Draw Testp. 594
Starter Clutch Removalp. 595
Gear Position Switch Testp. 595
+CHARGING SYSTEM SERVICEp. 597
ACG Cover Removal / Installationp. 597
Stator Removal / Installationp. 597
Regulated Voltage / Amperage Output Inspection (All Models)p. 599
Current Drain Inspectionp. 599
Stator AC Voltage Output Testp. 601
Stator Resistance Testp. 602
Stator Windings To Ground Inspectionp. 602
Flywheel Removal / Installationp. 603
Regulator / Rectifier Replacementp. 604
Rectifier / Regulator Connector Inspectionp. 605
Diode Leakage Testp. 605
Troubleshooting, Charging Systemp. 606
+KEY FOBp. 607
Key Fob Overviewp. 607
Key Fob Operation and Programmingp. 608
Key Fob Authenticationp. 610
Key Fob Troubleshootingp. 610
Alarm System Overviewp. 612
+IGNITION SYSTEMp. 613
+GENERAL INFORMATIONp. 613
Service Notes â Ignition Systemp. 613
Special Tools â Ignition Systemp. 613
Service Specifications â Ignition Systemp. 613
+SERVICEp. 614
Spark Plug Removalp. 614
Spark Plug Inspection / Gapp. 614
Spark Plug Installationp. 615
Ignition Coil Removal / Installationp. 615
+TROUBLESHOOTINGp. 617
Basicsp. 617
Test Lead Adapter Kitp. 617
ECM Connector Mapp. 617
Ignition System Test Flowchartp. 618
Battery Voltage Inspection: Test 1p. 619
Spark Inspection: Test 2p. 619
Ignition Cable Resistance: Test 3p. 619
Ignition Coil Power & Ground Signal Test 4p. 620
Ignition Coil Resistance: Test 5p. 621
Crankshaft Position Sensor (CPS) Resistance Inspection:p. 621
+CHASSIS ELECTRICALp. 622
+GENERAL INFORMATIONp. 622
Service Notes â Chassis Electricalp. 622
Special Tools â Chassis Electricalp. 622
+ASSEMBLY VIEWSp. 623
Wiring Harness Routing / Retentionp. 623
Headlight Assembly Viewp. 626
Tail Light / License Plate Lightp. 627
+POWER SUPPLYp. 628
Power Supply Removal / Installationp. 628
Power Supply Connector Mapp. 629
+FUSE BOXp. 631
Fuse Box Locationp. 631
Fuse Application Chartp. 632
+VEHICLE CONTROL MODULE (VCM)p. 635
Vehicle Control Module (VCM) Overviewp. 635
Vehicle Control Module (VCM), Removal / Installationp. 635
VCM Connector Pinoutp. 638
+WIRELESS CONTROL MODULE (WCM)p. 643
WCM Overviewp. 643
WCM, Removal / Installationp. 644
WCM Pinoutp. 646
+HEADLIGHT SERVICEp. 647
Headlight Replacementp. 647
Headlight Warning Indicatorsp. 648
+FOG LIGHT SERVICEp. 648
Fog Light Removal / Installationp. 648
+LOWER FAIRING SERVICEp. 648
Lower Fairing Harness Removal / Installationp. 648
+HEADRESS SERVICEp. 649
Headress Removal / Installationp. 649
+WIRING HARNESSp. 650
Wiring Harness Replacementp. 650
Wire Harness Connector Identificationp. 653
HARNESS PINOUTSp. 665
HARNESS PINOUTS (2022)p. 677
+HORN SERVICEp. 690
General Overviewp. 690
Load Side Testingp. 690
Switch Side Testingp. 690
Horn Removal / Installationp. 690
+TAIL LIGHT SERVICEp. 691
LED Tail / Brake Light Operationp. 691
Tail / Brake / License Plate Light, Removal / Installationp. 691
+TURN SIGNAL / HAZARD SYSTEM SERVICEp. 693
Turn Signal Operationp. 693
Front Turn Signal, Replacementp. 693
Rear Turn Signal, Replacementp. 694
+SWITCH CUBEp. 695
Switch Cube Replacementp. 695
Switch Cube Replacement – 2021+p. 696
Switch Cube Pinoutp. 696
+THROTTLE CONTROLp. 698
Throttle Control Removal / Installationp. 698
Throttle Control Pinoutp. 699
+INFOTAINMENT SYSTEMp. 700
Speaker Removal / Installationp. 700
Antenna Module Overviewp. 701
Antenna Module Removal / Installationp. 701
+INSTRUMENTATIONp. 702
Instrument Clusterp. 702
Instrument Cluster Pinoutp. 706
+RIDE COMMAND DISPLAYp. 709
DISPLAY CONNECTOR PINOUTp. 709
Ride Command Diagnostics / Troubleshootingp. 713
GPS / CELL ANTENNA TROUBLESHOOTINGp. 714
+CRUISE CONTROLp. 716
Cruise Control Overviewp. 716
Cruise Control Diagnosticsp. 717
Security Alarmp. 718
+POWER WINDSHIELDp. 720
Power Windshield Operationp. 720
Power Windshield Motor, Removalp. 721
Power Windshield Motor, Installationp. 722
+SEAT / TRUNKp. 723
Heated / Cooled Seatp. 723
Seat / Trunk Harnessp. 724
+CELL MODEMp. 726
Cell Modem Overviewp. 726
Cell Modem Replacementp. 726
Cell Modem Troubleshootingp. 727
+GEAR POSITION SWITCHp. 728
Gear Position Switch Replacementp. 728
Gear Position Switch Testp. 729
+INERTIAL MEASUREMENT UNIT (IMU)p. 730
IMU Overviewp. 730
IMU Replacementp. 730
+SWITCH TESTINGp. 732
Brake Light Switch Testp. 732
Clutch Switch Testp. 732
Side Stand Switch Testingp. 733
+ELECTRICAL DIAGNOSTICSp. 734
Electrical Service Notesp. 734
Digital Multi-Meter (DMM) Notesp. 734
Static and Dynamic Testingp. 734
Connector Probing Guidelinesp. 735
Testing Continuity / Resistancep. 736
Testing For A Short To Groundp. 737
Testing For A Short To Voltagep. 738
Testing for Intermittent Conditionsp. 738
Testing Current Flow (Amperage)p. 739
Testing Parasitic Drawp. 739
Current Draw – Key Offp. 739
Testing Voltage Dropp. 741
- Chapter 1: General / Specifications – Model designation, VIN decoding, engine and VIN location, 2020-2022 specification tables (dimensions, weights, capacities, tire pressures, engine data), master torque table, special tools reference, and conversion charts.
- Chapter 2: Maintenance – Complete scheduled maintenance intervals from 500 miles to 50,000 miles, service procedures for engine oil and filter change, spark plug inspection and gap, battery charging and maintenance, brake fluid level inspection, headlight aiming, and drive belt inspection/adjustment.
- Chapter 3: Engine / Cooling / Exhaust – Engine removal and installation, lubrication system service, oil pressure test, oil pump service, cooling system drain/fill/bleed, radiator and water pump removal/installation, thermostat service, cylinder head and valve train disassembly/inspection, camshaft timing, cam chain and tensioner service, exhaust system (headpipe, resonator, muffler) removal/installation, and full cylinder/piston service.
- Chapter 4: Fuel Delivery / EFI – Fuel system depressurization, fuel tank removal and installation, fuel pump and level sensor testing/replacement, evaporative emission (EVAP) system service, throttle body and intake manifold removal/installation, fuel injector removal and resistance test, TMAP, CHT, and knock sensor diagnostics, plus Digital Wrench and CAN bus diagnostics.
- Chapter 5: Clutch / Primary / Shift – Clutch cable inspection, lubrication, and free play adjustment, primary cover service, clutch pinion shaft removal/installation, clutch rack removal/installation, complete clutch disassembly/inspection/assembly, and shift mechanism service.
- Chapter 6: Transmission / Crankshaft – Crankcase separation, transmission removal/inspection (input/output shaft, shift forks, shift drum), connecting rod and crankshaft inspection/installation, bearing clearance inspection, transmission assembly and crankcase resealing procedures.
- Chapter 7: Frame / Body – Disassembly and assembly instructions for all body panels, side covers, floorboards, seat, saddlebags, trunk, fenders, fairing, lower fairing, and front casting/midcast components, including torque specifications for all fasteners.
- Chapter 8: Steering / Suspension – Drive belt inspection and tension adjustment, sprocket inspection, steering head inspection, handlebar and front fork service (including fork oil level and seal replacement), triple clamp removal/installation, rear shock absorber removal/rebuilding, swing-arm service, and tire & wheel inspection.
- Chapter 9: Brakes – Front and rear brake pad inspection/replacement, brake disc inspection, front and rear caliper overhaul, master cylinder service, full ABS system service including module replacement, wheel speed sensor replacement, and detailed ABS brake bleeding procedures.
- Chapter 10: Electrical – Starting and charging system service (battery, stator, regulator/rectifier, starter motor), keyless ignition key fob operation and programming, ignition system, wiring harness routing and connector identification, fuse box application, VCM and WCM module pinouts, Ride Command display, headlight, fog light, turn signals, taillight, horn, speakers, antennas, and comprehensive electrical diagnostics.
What This Manual Enables You to Do
This factory service manual provides the ultimate technical authority for the 2020-2022 Indian Challenger and Pursuit. With this document, an experienced mechanic can confidently perform any major or minor repair, from valve clearance and camshaft timing to transmission overhaul and engine teardown. It includes all critical data: correct torque values for every fastener, precise mechanical clearances, fluid capacities, diagnostic trouble codes (DTCs), and comprehensive wiring diagrams. This manual is the definitive resource for maintaining and restoring these high-performance touring motorcycles to factory standards.
Why This Manual Matters
Working on a modern Indian motorcycle requires accurate information and procedures. An incorrect torque, a missed step, or a faulty diagnosis can result in costly mistakes, unsafe operation, or damaged components. This factory manual eliminates the guesswork by providing the exact knowledge and specifications required by trained professionals. It is a critical investment for any independent shop, serious enthusiast, or owner who wants to perform their own service and repairs with confidence.
Get Your Manual Now
This is a complete digital PDF file, ensuring instant access after purchase. No physical shipping delays and no waiting â the manual is ready to download and use immediately on your computer, tablet, or smartphone. It is fully printable for use in the workshop. Secure your copy of the 2020-2022 Indian Challenger & Pursuit Factory Service Manual today and have the industry’s leading technical resource at your fingertips.
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