Always wear safety glasses and nitrile gloves when servicing your Indian Motorcycle. To inspect and maintain the brake system on your Indian Roadmaster, follow these steps:
1. With the aid of an assistant, position the motorcycle on level ground in the fully upright position.
2. Starting at the front reservoir, position the handlebars straight ahead to ensure an accurate reading.
3. Check the fluid level through the sight glass with a flashlight. The fluid should be above the minimum indicator mark on the sight glass.
4. Before adding fluid, wipe the area with a clean cloth.
5. Then remove the two cover fasteners with a Phillips screwdriver.
6. Lift the cover off and set aside.
7. Then remove the diaphragm. Do not allow brake fluid to contact painted surfaces, or paint damage may occur.
8. Add fluid as needed. Do not overfill. A 12-ounce bottle (355 mL) of DOT 4 Brake Fluid is part number 2880016.
9. Then reinstall the diaphragm, cover and fasteners. Torque the fasteners to 14 in-lbs (2 Nm).
10. Clean any residual fluid off the vehicle to prevent paint damage.
11. Next, lubricate the pivot pin and brake lever hinge point.
12. Start by removing the bottom nut with a 10mm socket.
13. Then remove the pivot pin with a flat-head screwdriver.
14. Pull the brake lever out.
15. Clean off any old grease or dirt from the pivot pin and lever hinge.
16. Lubricate the pivot pin and brake lever hinge point with all-purpose grease.
17. Reinstall the brake lever and align the pin hole.
18. Reinstall the pivot pin fully.
19. Then reinstall the nut. Torque to 59 in-lbs (6.6 Nm).
20. Clean any residual grease off the bike.
21. Ensure proper operation of the brake lever.
22. Next, inspect the banjo bolts on the inside of the master cylinder for leaks.
23. Move down to the caliper covers and remove the two acorn nuts and washers on each side with a 13mm socket.
24. Using a 10mm socket, remove the inside fastener from each cover and remove the covers from the motorcycle.
25. Follow the brake lines from the front junction block to the front brake calipers, looking for any leaks, kinks or damage.
26. Inspect the connections at the front brake calipers for leaks.
27. Position an inspection mirror at the back side of the caliper to view the friction material. Replace when the thinnest point of the friction material has worn to the service limit indicator groove. The service limit is 1mm (0.04 inches).
28. 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 at any point. The service limit is 4.5mm (0.18 inches).
29. Inspect the front ABS tone ring for damaged teeth and the wheel speed sensor for excessive debris.
30. Reinstall the caliper cover and cover fastener. Torque to 84 in-lbs (9.5 Nm).
31. Then reinstall the nuts and washers. Torque to 18 ft-lbs (24 Nm).
32. Next, move to the rear fluid reservoir near the rear brake pedal on the right side of the bike.
33. Ensuring the bike is still level, check the fluid level with a flashlight. The fluid level should be above the minimum indicator mark on the reservoir body.
34. Before adding fluid, wipe the area with a clean cloth.
35. Then remove the two cover fasteners with a Phillips screwdriver.
36. Lift the cover off and set aside.
37. Then remove the diaphragm. Do not allow brake fluid to contact painted surfaces or paint damage may occur.
38. Add fluid as needed. Do not overfill.
39. Reinstall the diaphragm, cover and fasteners. Torque the fasteners to 7 in-lbs (1 Nm).
40. Clean any residual fluid off the vehicle to prevent paint damage.
41. Next, inspect for leaks on the banjo bolts at the rear master cylinder.
42. Follow the rear brake line from the rear brake reservoir to the ABS module.
43. Remove the left upper side cover by pulling the corners evenly out to disengage each tab from the rubber grommets.
44. To remove the left saddlebag:
- First, disconnect the saddlebag lock connector near the seat.
- Next, press the lid latch release button and lift the lid.
- Then remove the two saddlebag fasteners with a 6mm Allen socket.
- Finally, tilt the saddlebag out and lift up to remove.
45. Continue by following the rear brake lines to the rear caliper banjo bolt, looking for any leaks, kinks or damage. Also, ensure the brake line retainers are properly secured.
46. Then inspect the rear brake pads and rotors, and replace any that are worn to their minimum thickness. The rear rotor service limit is 0.26 inches (6.5mm).
47. Also, inspect the rear ABS tone ring and wheel sensor.
48. If inspection reveals a need for service or replacement, see your authorized Indian Motorcycle Dealer.
49. Next, begin reinstalling the saddlebags by placing them on the muffler brackets.
50. Reinstall the saddlebag fasteners. Torque to 18 ft-lbs (24 Nm).
51. Then reconnect the electrical wiring if necessary and ensure the saddlebags are mounted properly.
52. Finally, align the three side panel grommets and reinstall each upper side panel.
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.