Required Tools and Supplies
- 10mm Socket
- Phillips Screwdriver
- Flat-Head Screwdriver
- Ratchet
- Torque Wrench
- Brake Rotor Measurement Tool
- Flashlight
- All-Purpose Grease
- Eye Protection
- Nitrile Gloves
- Shop Rags
Note: Indian Roadmaster PowerPlus Dark Horse model shown. This procedure is applicable to Indian Challenger, Pursuit and Chieftain PowerPlus.
To inspect and maintain the brake system on your Indian Roadmaster PowerPlus, follow these steps:
1. Position the motorcycle on level ground in the fully upright position. Position the handlebars so that the fluid reservoir is level. Wipe the fluid container and the area around the reservoir cover with a clean cloth.
2. If the fluid level is low, inspect the brake pads. If pads are worn beyond the service limit, inspect the brake system for leaks.
3. To add fluid, remove the reservoir cover screws with a Phillips screwdriver. Remove the cover, diaphragm plate, and diaphragm. Note: Do not allow brake fluid to contact painted surfaces or paint damage may occur.
4. The fluid level should be above the minimum indicator mark near the sight glass. Add brake fluid as needed. Do not overfill.
5. Reinstall the diaphragm plate, diaphragm, cover and screws. If the diaphragm is extended, return it to its neutral (flattened) position. Torque the fasteners to 13 in-lbs (1.5 Nm).
6. Wipe away any fluid spills. Check for signs of brake fluid leaks around hoses, fittings, reservoir and brake calipers. Check for deterioration of hoses.
7. Lubricate the pivot pin and brake lever hinge point.
8. Remove the bottom nut with a 10mm socket.
9. Remove the pivot pin using a flat-head screwdriver and pull the brake lever out.
10. Clean off any old grease or dirt from the pivot pin and brake lever.
11. Lubricate the pivot pin and brake lever hinge point with all-purpose grease.
12. Clean any old grease from the brake lever bracket and lubricate with all-purpose grease.
13. Reinstall the brake lever and align the pin hole.
14. Reinstall the pivot pin fully and torque to 8.85 in-lbs (1 Nm).
15. Reinstall the nut and torque to 53 in-lbs (6 Nm).
16. Clean any residual grease off the bike and ensure proper operation of the brake lever.
17. Inspect the banjo bolts on the inside of the master cylinder for leaks.
18. Follow the brake lines from the front junction block to the front brake calipers, looking for any leaks, kinks or damage.
19. Inspect the connections at the front brake calipers for leaks.
20. Inspect the brake discs for nicks, scratches, cracks or other damage. Inspect the thickness of each brake disc at four or more locations around the disc. The minimum thickness for the front brake discs is 4.5 mm. The minimum thickness for the rear brake discs is 6.5 mm. If any disc is worn to the minimum thickness at the thinnest point, or if a disc is damaged, see your dealer for replacement.
21. Clean the discs if minor squeaks develop due to dirt or dust. Apply brake cleaner to a clean shop towel and wipe the discs. DO NOT allow brake cleaner to contact painted or plastic parts. Read all precautions on the label.
22. Inspect the front and rear brake pads by positioning the motorcycle on the side stand with the handlebars turned to the left.
23. If needed, use an inspection mirror, positioned at the front side of the caliper, to view the friction material.
24. Inspect each front brake pad on both sides of the front discs.
25. Inspect each rear brake pad on both sides of the rear disc.
26. Replace brake pads when the thinnest point of the friction material has worn to 1.0 mm. Please see your dealer for this service.
27. When checking brake pad friction material thickness, check each brake caliper for dampness or stains from leaking or dried brake fluid. If inspection reveals signs of fluid leakage, do not operate the vehicle. See your dealer for service.
28. Move to the rear brake fluid reservoir near the rear brake pedal on the right side of the vehicle.
29. Ensuring the bike is level, inspect the fluid level, using a flashlight as needed.
30. If the fluid level is low, wipe the fluid container and the area around the reservoir cover with a clean cloth.
31. Remove the cover, diaphragm plate, and diaphragm with a Phillips screwdriver. The fluid level should be above the minimum indicator mark near the sight glass. Add brake fluid as needed. Do not overfill.
32. Reinstall the cover, diaphragm plate and diaphragm and torque to 13.3 in-lbs (1.5 Nm). If the diaphragm is extended, return it to its neutral (flattened) position.
33. Wipe away any fluid spills. Check for signs of brake fluid leaks around hoses, fittings, reservoir and brake calipers.
For more information, see your authorized Indian Motorcycle Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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