Required Tools and Supplies
- 10mm Socket
- 12mm Wrench
- Ratchet
- Torque Wrench
- 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 maintain the clutch lever and adjust the freeplay on your Indian Roadmaster PowerPlus, follow these steps:
1. Park the motorcycle on a flat surface, fully extend the side stand and ensure the vehicle is stable.
2. Turn the key or ignition switch to the OFF position and remove the key. If equipped with a keyless fob, remove the fob from the proximity of the vehicle.
3. Begin by verifying proper routing and smooth movement of the cable. Inspect for damage to the external casing and inspect exposed cable wire for fraying, kinks or corrosion. Replace any cables that are damaged, sticky or sluggish.
4. Locate the clutch cable adjuster nut located on the bottom of the clutch cover on the engine. Loosen the lock nut with a 12mm wrench.
5. Turn the cable adjuster nut completely inward to provide maximum lever freeplay.
6. Remove the nut and pin. Disconnect the clutch cable from the clutch lever with a 10mm socket.
7. Remove any old grease and dirt from the lever and housing. Lubricate the clutch lever and pin with all-purpose grease. Note: During installation of the lever, be aware of the internal clutch switch. Improper assembly can cause damage to the switch.
8. Reconnect the clutch cable. Reinstall the lever pin and nut and torque to 48.7 in-lbs (5.5 Nm).
9. Reconnect the clutch cable to the clutch cover on the bottom of the engine.
10. To adjust the freeplay, begin by positioning the handlebars in the straight-ahead position.
11. The clutch cable adjuster nut is located on the bottom of the clutch cover on the engine. Loosen the lock nut.
12. Turn the cable adjuster nut inward or outward until the clutch lever freeplay is 0.5-1.5 mm as measured at the clutch perch.
13. While holding the cable, tighten the adjuster lock nut securely with a 12mm wrench and torque to 48.7 in-lbs (5.5 Nm).
14. Verify that the safety switch activates properly. The engine should not start in gear with the clutch lever released. Never test the clutch safety switch by attempting to start the motorcycle in gear unless the rear wheel is raised off the ground. Note: The starter interlock switch is dependent on the clutch lever freeplay being set correctly to ensure activation of the clutch safety switch.
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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