Tools and Supplies Required:
- Shop Rags
- Brake Rotor Measurement Tool
- 10mm Socket
- All-Purpose Grease
- Phillips Socket
- Torque Wrench
- Phillips Screwdriver
- Flat-Head Screwdriver
- Safety Glasses
- Nitrile Gloves
Always wear safety glasses and nitrile gloves when servicing your Indian Motorcycle. To inspect and maintain the brake system on your Indian Challenger, follow these steps:
1. Park the motorcycle on level ground in the fully upright position.
2. With the handlebars pointing straight ahead, inspect the fluid level in the front brake reservoir through the sight glass. A flashlight can be used to illuminate the reservoir in dark areas.
3. If fluid is needed, clean the area with a clean cloth.
4. Then remove the two cover fasteners with a Phillips screwdriver.
5. Lift the cover off and set aside.
6. Then remove the diaphragm and set aside. Do not allow brake fluid to contact painted surfaces, or paint damage may occur.
7. Add fluid as needed. Do not overfill. A 12-ounce bottle (355 mL) of DOT 4 Brake Fluid is part number 2880016.
8. Reinstall the diaphragm, cover and fasteners. Torque the fasteners to 84 in-lbs (10 Nm).
9. Clean any residual fluid off the vehicle to prevent paint damage.
10. Next, lubricate the pivot pin and brake lever hinge point.
11. Start by removing the bottom nut with a 10mm socket.
12. Then remove the pivot pin with a flat-head screwdriver and pull the brake lever out.
13. Clean off any old grease or dirt from the pivot pin and brake lever.
14. Lubricate the pivot pin and brake lever hinge point with all-purpose grease.
15. Then clean any old grease from the brake lever bracket and lubricate with all-purpose grease.
16. Reinstall the brake lever and align the pin hole.
17. Reinstall the pivot pin fully.
18. Then reinstall the nut. Torque to 52 in-lbs (6 Nm).
19. Clean any residual grease off the bike and ensure proper operation of the brake lever.
20. Next, inspect the banjo bolts on the inside of the master cylinder for leaks.
21. Follow the brake lines from the front junction block to the front brake calipers, looking for any leaks, kinks or damage.
22. Inspect the connections at the front brake calipers for leaks.
23. Position an inspection mirror at the back side of each caliper to view the friction material. Replace when the thinnest point of the friction material has worn to the service limit indicator groove.
24. Measure the thickness of each front brake rotor at four or more locations. Replace any rotor that is damaged or worn to the minimum thickness of 4.5mm (0.18 inches) at any point.
25. Next, move to the rear fluid reservoir near the rear brake pedal on the right side of the bike.
26. Ensuring the bike is level, inspect the fluid level, using a flashlight as needed.
27. If fluid is needed, clean the area with a clean cloth.
28. Then remove the two cover fasteners with a Phillips screwdriver.
29. Lift the cover off and set aside. Do not allow brake fluid to contact painted surfaces, or paint damage may occur.
30. Then remove the diaphragm and set aside.
31. Add fluid as needed. Do not overfill.
32. Reinstall the diaphragm, cover and fasteners. Torque the fasteners to 15 in-lbs (2 Nm).
33. Clean any residual fluid off the vehicle to prevent paint damage.
34. Next, inspect for leaks on the banjo bolts at the rear master cylinder.
35. Follow the rear brake line from the reservoir across the bike and back to the ABS module.
36. Continue to the rear caliper banjo bolt, looking for any leaks, kinks or damage.
37. Then inspect the rear brake pads and rotors. Replace any that are worn to their minimum thickness. The rear rotor service limit is 6.5mm (0.26 inches).
38. If inspection reveals a need for service or replacement, see your authorized Indian Motorcycle Dealer.
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.