NHTSA ID Number: 10209966
Manufacturer Communication Number: ISA-21-01
TSB/Document Date: 2022-04-06
Summary
Indian
Motorcycle found that some 2022 Chief models can exhibit a noise in the front of the motorcycle when operating slowly on rough or bumpy road conditions. The sound can be difficult to properly diagnose as it may resemble a metallic clicking in the front headlight area. The sound is coming from the bypass valve within the front suspension and occurs when switching between compression and rebound. The sound can be amplified by the fender shape on some motorcycles. The sound does not affect the performance of the motorcycle. Indian Motorcycle has released a service kit with new upper fork with a revised bypass valve to correct the noise.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 9 of 19
10. Gently pry out dust seal and clip.
14. Tilt the tube down and remove the damper tube u.
11. Compress the fork.
15. Using a slide hammer action, separate the inner fork
tube from the outer leg.
12. Looking down from the top of the fork, insert special
tool PF-53122 to hold the damper tube.
16. Remove hydraulic lock i from the outer leg.
13. Finish removing bottom cartridge bolt and washer
from step 2.
17. Discard inner fork tube and bushings.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 10 of 19
F O R K A S S E M B LY
4. Install the inner fork tube assembly into the lower
tube.
NOTICE
Clean all parts prior to assembly.
1. Install NEW washer q, NEW upper bushing w, and
NEW lower bushing e onto NEW inner fork tube.
5. Looking down from the top of the fork, insert special
tool PF-53122 to hold the damper tube.
2. Install the damper tube r into the NEW inner fork
tube (2209304).
3. With the damper tube sticking out of the bottom of
the inner fork tube, install the hydraulic lock t.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 11 of 19
6. Install NEW cartridge washer (2208096) and NEW
cartridge bolt (7527865). Torque to specification.
8. Using the smaller diameter of fork seal installer
(PV-49494), drive in the NEW main seal (2208947).
TORQUE
IMPORTANT
Fork Cartridge Fastener
22 ft-lbs (30 N·m)
Note orientation of seal during installation.
Correct
7. To properly seat the busing and washer, use fork seal
installer (PV-49494) to seat the bushing and washer.
Incorrect
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 12 of 19
9. Install spring clip y
14. With the fork compressed, the oil level should be
4.53 inches (115 mm) from the top of the inner fork
opening. Use special tool PV-59000A for an accurate
measurement.
10. Using the larger diameter end of (PV-49494), install
the NEW dust seal.
15. Install spring mount u, main spring i, upper and
lower spring seats o, and spring spacer a.
11. SUPER CHIEF / CHIEF BOBBER =Install the fork
cap carefully by hand.
CAUTION
Do not use impact to install the cap as damage may
occur.
12. Compress the inner fork into the outer leg and stand
the assembly upright.
13. Pour fork oil (PN: 2208093) into the inner fork and
cycle to purge out any air.
MEASUREMENT
starting oil volume = 550mL
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 13 of 19
16. Install fork cap s.
TORQUE
Fork Cap:
15 ft-lbs (20 N·m)
17. Repeat removal and repair procedure for the second
fork tube assembly.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 14 of 19
F R O N T F O R K I N S TA L L AT I O N
3. Install and hand tighten the triple clamp pinch
fasteners. q.
IMPORTANT
Clean the fork tubes and the clamping surfaces of the
triple clamps to remove any oil or grease prior to
installation.
IMPORTANT
Do not operate the front brake lever with the calipers or
wheel removed.
1. Install one fork tube assembly into lower triple
clamp.
4. Torque fasteners to specification.
TORQUE
Fork Triple Clamp Fasteners (Lower):
Step 1: Tighten bearing lock by following its tightening
procedure.
Step 2: Tighten bottom bolts on lower triple clamp.
Step 3: Tighten top bolt on lower triple clamp.
Step 4: repeat step 2.
Step 5: Repeat step 3.
Step 6: Final Torque Pinch fasteners to 17 ft-lbs (24 N·m)
2. Continue to slide tube through lower triple clamp and
into upper triple clamp. Stop when the top of the fork
cap is protruding 0.098 inches (2.5 mm)with the top
of the upper triple clamp.
TORQUE
Fork Triple Clamp Fasteners (Upper):
17 ft-lbs (24 N·m)
5. Repeat steps for remaining fork tube.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 15 of 19
6.
• CHIEF MODELS = Install turn signals:
Install turn signal fastener w and signal bracket e.
Torque fastener to specification.
TORQUE
Front Bodywork Fastener:
88 in-lbs (10 N·m)
–
TORQUE
Install the front cover and its fasteners r.
Torque fasteners to specification.
Turn Signal Fastener (Chief Front):
35 in-lbs (4 N·m)
• SUPER CHIEF / CHIEF BOBBER = Install front
body work components:
IMPORTANT
During reassembly, push the front cover upward to
close the gap to the upper triple clamps before
securing with fasteners.
–
Install the front nacelle mounts and its fasteners
u. Torque fasteners to specification.
TORQUE
Front Bodywork Fastener:
88 in-lbs (10 N·m)
–
Install the rear cover and its fasteners e. Torque
fasteners to specification.
TORQUE
Front Bodywork Fastener:
88 in-lbs (10 N·m)
–
Install the rear clamp mounts and its fasteners
y. Torque fasteners to specification.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 16 of 19
7. Install front wheel:
• Install wheel spacer to non-brake side.
TORQUE
Front Bodywork Fastener:
88 in-lbs (10 N·m)
–
Install head light bucket and its fasteners w.
Torque fasteners to specification.
• Apply brake cleaner or isopropyl alcohol to a clean
shop towel and wipe brake discs clean.
• Separate brake pads and install caliper assembly
over brake disc.
• Install caliper mounting fasteners and torque to
specification.
TORQUE
Head Light Mount Fastener:
88 in-lbs (10 N·m)
–
–
–
TORQUE
If equipped, connect harness retention feature
to the head light bucket.
Install the head light and connect the turn
signals and head light electrical connectors.
Install head light bezel and its fastener q.
Torque fastener to specification
Caliper Mounting Fasteners (front):
29 ft-lbs (40 N·m)
• Route the wheel speed sensor wire as shown.
TORQUE
Head Light Bezel Fastener:
27 in-lbs (3 N·m)
IMPORTANT
During reassembly, push the front cover upward to
close the gap to the upper triple clamps before
securing with fasteners.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 17 of 19
• Install wheel speed sensor to brake side. Secure
the speed sensor wire with p-clip. Torque p-clip
fastener e to specification.
• Install axle pinch bolts q on lower right fork leg.
• Cycle the front suspension. Tighten axle pinch
bolts to specification.
TORQUE
P-Clamp Fastener:
80 in-lbs (9 N·m)
• Install wheel and install axle w. Torque axle to
specification.
TORQUE
Axle Pinch Fasteners:
18 ft-lbs (25 N·m)Tighten each screw once after
initial torque
8. Install front fender:
CAUTION
Use care not to scratch or damage painted surfaces
during fender installation.
TORQUE
Axle (front fork):
52 ft-lbs (70 N·m)
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 18 of 19
• Stand in front of the motorcycle facing the front
fender and squeeze the sides together while
“rolling” the fender in between the fork legs.
• Install fender mount fasteners q. Torque fasteners
to specification.
TORQUE
Front Fender Fastener:
17 ft-lbs (24 N·m)
9. Inspect all bolts for proper torque. Inspect hoses and
wiring for proper routing.
10. Lower front end of motorcycle to the ground and test
front suspension / fork operation.
11. Submit a Service Bulletin Warranty Claim for Indian
Motorcycle® ISA-21-01.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the
written consent of Polaris Inc.
ISA-21-01 (R02)
© 2022 Polaris Inc.
Page 19 of 19
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TSB/Document ID: ISA-21-01
Replacement Service Bulletin Number:
MFR Communication Date: 2022-03-31
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SUSPENSION
MFR Component System:
MFR Component Subsystem:
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