1 - Tradebit
Contents
1. after starting the engine and displays the total miles traveled To toggle the odometer and trip odometer reading between miles kilometers and the fuel gauge reading between gallons liters the ignition switch must be in the On position with the MFD in odometer mode Press and hold the MFD Set button for 3 seconds To change to the next MFD function press the MFD Mode button Trip Odometer TRIP appears as part of the display when in trip odometer mode The trip odometer shows total miles traveled since the trip odometer was reset You can use the trip odometer to calculate the miles per gallon and estimate the number of miles traveled on a tank of fuel To reset the trip odometer the ignition switch must be in the On position with the MFD in trip odometer mode Press and hold the MFD Set button for 3 seconds To change to the next MFD function press the MFD Mode button Clock A clock icon appears as part of the display when in clock mode When the clock is operating normally the colon between the hour and minutes flashes To set the clock the ignition switch must be in the On position with the MFD in clock mode 1 Press and hold the MFD Set button for 3 seconds when in clock mode The hour digits should flash Press the MFD Set button to select the desired hour Press the MFD Mode button to accept the new hour setting The ten minute digit should flash Press the MFD Mode button to accept the new ten minute setting2. 0 8 mm 244 lbs 111 Kg MAINTENANCE 6 5 Qt 6 15 Ltr 5 US Gal 19 Ltr 65 5 in 166 cm 28 3 in 72 cm 10 6 in 26 9 cm 5 1 in 13 4 in 10 cm Single Gas Shock Pre load Adjustable 720 Ibs 326 6 kg 759 16 344 3 kg 98 in 249 cm 42 in 107 cm 60 8 154 cm 5 in 13 cm 441 200 kg 1210 lbs 549 kg 30 0 Degrees 6 89 in 175 mm Touring Cruiser MCVT1507D 2003 50 V Twin 1507cc 92 cubic in Air Oil Cooling 9 2 1 180 psi 20 1241 kPa 138 97 x 102 mm Direct Drive Dual 44 mm Dual Crossover Wet Sump 2540 CR7EB 032 in 0 8 mm 244 lbs 111 Kg MAINTENANCE GENERAL SPECIFICATIONS 2003 2004 Transmission Type Manual 5 Speed Constant Mesh Manual 5 Speed Constant Mesh Clutch Type Wet Multi Disk Wet Multi Disk Diaphragm Spring Diaphragm Spring Primary Drive Reduction Wet Multi Gear Wet Multi Gear Front Wheel Cast 5 spoke 16 3 Cast 5 spoke 16 x3 Rear Wheel Cast 5 spoke 16 x3 Cast 5 spoke 16 x3 Front Tire Dunlop 491 Elite Dunlop 491 Elite II MT90B16 71H MT90B16 71H White Wall Dunlop CRUISEMAX White Wall Dunlop CRUISEMAX 130 90 16 67H 130 90 16 67H Rear Tire Dunlop D417 Dunlop D417 160 80B16 75H 160 80B16 75H White Wall Dunlop CRUISEMAX White Wall Dunlop CRUISEMAX 150 80B16 71H 150 80B16 71H Minimum Tread Depth 063 in 1 6mm 063 in 1 6mm 6mm Front Type Conventional Telescopic Conventional Telescopic Front Travel
3. on your machine or in this manual be alert to the potential A WA R N G for personal injury Your safety is involved Gasoline extremely flammable and explosive under certain conditions AWARNING Always stop the engine and refuel outdoors or in a Indicates a potential hazard which could result in severe injury or well ventilated area death Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where ACAUTION gasoline is stored m Do not overfill the tank Do notfill the tank neck above Indicates a potential hazard which may result in minor personal the fuel tank insert Leave air space to allow for fuel injury or damage to the motorcycle expansion If you get gasoline in your eyes or if you swallow CAUTION gasoline see your doctor immediately Never try to syphon gasoline using mouth suction Indicates a situation that can result in damage to the motorcycle If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing NOTE Never startthe engine or let itrun in an enclosed area The word in this manual will alert you to key information M Engine exhaust fumes are poisonous and can cause or instructions loss of consciousness or death in a short time A WARNING A WARNING A WARNING 7 st components thi The engine exhaust from this product Improper repairs or service can cr
4. POLARIS Est 1954 THE NEW AMERICAN 2002 2004 VICTORY SERVICE MANUAL P N 9918960 CLASSIC CRUISER TOURING CRUISER y OS Est 1954 PULARIS The Way Out 2002 2004 SERVICE MANUAL Part Number 9918960 Foreword This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept available for reference in the shop area All references to left and right side of the motorcycle are from the operator s perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in orderto perform the work safely and correctly Read the text and be familiar with the service procedures before starting the work Certain procedures will require the use of special tools Use only the proper tools as specified This manual includes procedures for maintenance component identification and repair along with service specifications for Victory Classic Cruiser and Touring Cruiser motorcycles Comments or suggestions aboutthis manual may be directed to Service Publications Dept 2 Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2002 2004 Victory Standard Deluxe Classic and Touring Cruiser Service Manual PN9918960 Refer to page 1 6 for Owner s Manual Parts Book and Microfiche part numbers 2003 Polaris Industries All information con
5. VO2TD16CC DC LC UC PTC Dix VO2TD16CO DO LO UO Sonic Blue Vogue Silver TC Dix Cruiser Black TC Dix Solar Red Vogue Silver VO2CD16CL DL LL UL V02CD16CM DM LM UM VO2CD16CN DN LN UN Speed Yellow Crs Black VO2TD16CP DP LP UP TCDlx Sonic Blue Vogue Silver Sonic Blue Pearl White VO2TD16CQ DQ LQ UQ TC Dix Cruiser Black Vogue Silver Cobalt Green Pearl White VO2TD16CR DR LR UR TC Dix Champagne Pearl white MODEL YEAR 2003 Model Number Model Description Color Model Description Color Model Number V03C116 V03C216 Feature Option Feature Option V03T116 VO3T216 VO3CB16CA DA LA UA Cruiser Black VO3TB16CA DA LA UA Cruiser Black V03CB16CC DC LC UC Solar Red V03TB16CC DC LC UC Solar Red V03CB16CD DD LD UD Flame Yellow Model Number Model Description Color MODEL YEAR 2004 Modei Number Model Description Color V04TB16CC DC LC Solar Red VICTORY PAINT CODES PAINT COLORS Pearl White Cobalt Green Vogue Silver Champagne Fork Legs Triple Clamp Flame Tank All Years paint codes are made up of Indy Red Stone White Speed Yellow and Daytona Orange Flame Yellow Retro Turquoise Daytona Orange 1 4 VEHICLE IDENTIFICATION NUMBER GENERAL Chassis C Kingpin Type Series T Touring B Standard C Canada G Vegas D Domestic 49 State SAE assigned N ANSS L California World Manufacturing Identifier N gi
6. 8 CONTROL LUBRICATION 2 9 BRAKE PEDAL BRAKE LEVER FREEPLAY INSPECTION 2 10 BRAKE FLUID LEVEL INSPECTION 2 11 BRAKE PAD INSPECTION eee 2 12 CLUTCH LEVER FREEPLAY TR 2 13 FAST IDLE LEVER FREEPLAY ADJUSTMENT 2 14 THROTTLE CABLE FREEPLAY ADJUSTMENT 2 15 SIDESTAND PIVOT 7 SIDESTAND PAD INSPECTION 2 16 AIR FILTER INSPECTION REPLACEMENT 2 17 FUEL PRE FILTER AND FUEL EINE INSPECTION 2 18 FUEL TANK VENT CRANKCASE VENTILATION 2 19 SPARK PLUG NS 2 20 BATTERY BATTERY STORAGE INSPECTION 2 21 BATTERY REMOVAL INSTALLATION 2 22 COMPRESSION TEST e 2 23 F SESZ F SE BOX UD eat t ERE ada 2 24 HEADLIGHT ADJUSTMENT 2 25 DRIVE BELT INSPECTION TENSION INSPECTION 2 26 DRIVE BELT TENSION ADJUSTMENT 2 27 DRIVE BELT REAR WHEEL ALIGNMENT 2 28 DRIVE SPROCKET INSPECTION 2 29 FRONT FORK INSPECTION I 2 30 SUSPENSION INSPECTION III 2 31 SHOCK SPRING PRELOAD INSPECTION 2 32 STEERING HEAD BEARING INSPECTION 2 33 TIR
7. Harness Right View Frame Strap Includes Frame Clutch Cable Strap Includes TANS 7 Subframe Main Wiring Harness Strap Includes Regulator Bracket Regulator Wire Harness 1 Strap Includes 2 Strap Includes Frame amp Wiring Harness Only Clutch Cable Speed Sensor Connector Torque Harness Guide Fasteners to 9 5 Nm 7 Ib ft 1 15 GENERAL CABLE amp HARNESS ROUTING 1 Tie Strap includes frame harness fast idle cable and throttle open cable only 2 Tie Strap includes frame harness and throttle close cable only 3 Tie Strap includes frame amp wire harness only Included in strap Included in strap Speedometer Bracket Speedometer Bracket LH Controls Harness RR RH Controls Harness RH Turn Signal Harness LH Turn Signal Harness Driving Lights Harness TC Models Included in strap Rear Brake Light Switch Base Rear Brake Light Switch Harness Included in strap Subframe Rear Harness Connector 1 16 CHAPTER 2 MAINTENANCE GENERAL SPECIFICATIONS 2002 MODELS 2 1 GENERAL SPECIFICATIONS 2003 2004 MODELS 2 3 PERIODIC MAINTENANCE INTERVAL CHART 2 5 TUNE UP SPECIFICATIONS 2 6 FASTENER TORQUE SPECIFICATIONS TUNE 2 22 2 7 MAINTENANCE PRODUCTS ee 2 7 OIL LEVEL INSPEGTION OIL AND FILTER CHANGE 2
8. U United Kingdom E Serial Number 5VPCB16D032000000 Engine Size 1 1507 cc Check Digit Model Year 6 78 94 2 2002 3 2003 4 2004 etc MODEL NUMBER Chassis C Kingpin Engine HP Series Touri 6 78 94 C Canada d D Domestic 49 State N ANSS L California U United Kingdom YQ4TB16DC 2 2002 3 2003 4 2004 etc E IGNITION KEY IDENTIFICATION NUMBERS The key identification number 1 is stamped on the key tag If the key and the identification number are lost or misplaced the lock set ignition switch seat lock where applicable and steering lock must be replaced Key blanks are available from service parts Locksmiths familiar with the motorcycle industry will be able to cut a replacement key with the key 1 0 number and a Victory key blank Should the keys and key identification number become lost the ignition switch must be replaced VEHICLE IDENTIFICATION NUMBER VIN The vehicle identification number 2 is stamped on the front of the steering head MODEL IDENTIFICATION NUMBER The model label 3 is located on the left side of the steering head ENGINE NUMBER DECAL The engine label 4 is located on top of the crankcase behind the rear cylinder This label identifies the engine model and serial number The engine serial number is also stamped on the crankcas
9. inches 5 1 in 13 cm 5 1 in 13 cm Rear Type Single Shock w Adjustable Preload Single Shock w Adjustable Preload Front Brake Single 300 x 5 mm Disc with 4 Piston Dual 300 x 5 mm Discs with 4 Piston Fixed Caliper Fixed Caliper Rear Brake Single 300 x 6 mm Disc with 2 Piston Single 300 x 6 mm Disc with 2 Piston Floating Caliper Floating Caliper Headlight 5 5 amps 5 5 amps Intl ANSI HG024XV H4 ANSI HG024XV H4 Brake Tail Light 2 1 1 6 amps 2 1 1 6 amps ANSI 198 ANSI 198 Turn Signal Light Front 2 1 amps 2 1 amps ANSI 198 ANSI 198 Turn Signal Light Rear 1 6 amps 1 6 amps ANSI 199 ANSI 199 Instrument Cluster Lights 1 3 amps 1 3 amps Backlight Dimming Feature UK Models Front Position ANSI 193 ANSI 193 Light Fuel Pump 10 amp fuse 10 amp fuse D R V E S Y S T 5 R A K E s L G H T S MAINTENANCE PERIODIC MAINTENANCE INTERVAL CHART ODOMETER READING in MILES KILOMETERS Component see operation codes below Air Auxiliary Lights Brake Fluid Battery Brake Pads Clutch Lever ontrol Cables Crankcase Ventilation System Drive Belt Drive Sprocket and Sprocket Nut Engine Oil Engine Oil Filter Engine Compression Evaporative Emission Control System CA Only Exhaust System Fast Idle Lever Fasteners Front Fork Oil Front Forks and Front Axl Front Brake Lever Fuel Filter Fuel System Gear Shift Pedal Headlamp Rear Brake Pedal Rear Shock
10. smog Carbon monoxide must be controlled because it is toxic EXHAUST EMISSION CONTROL Victory Motorcycles utilizes an electronic engine management system which controls fuel delivery and ignition timing to control hydrocarbons and carbon monoxide No adjustments should be made to the system components are replaced that affect idle speed follow the instructions in Chapter 5 CRANKCASE EMISSION CONTROL The crankcase emission control system is comprised of a closed system that routes crankcase emissions through the air cleaner into the combustion chamber EVAPORATIVE EMISSION CONTROL CONTROL CA MODELS A vacuum hose connects the purge port manifold to the charcoal canister Evaporated fuel vapor passes from the fuel tank along the vent hose and to the charcoal canister Activated charcoal in the canister filters the regulated elements of the vapor for storage until the engine is started and the motorcycle is driven The canister and liquid trap are cleaned as part of the engine s ordinary combustion cycle Inspect the evaporative control system clamps hoses fittings canister and other hardware for wear or damage during each maintenance period of the motorcycle Refer to the owner s manual for emission system warnings and instructions T Fitting and urge lines to throttle body Liquid Trap Vent to plugged Atmosphere NOISE EMISSION CONTROL SYSTEM Tampering with Noise Control Systems is Prohibited Federal law prohibits the fol
11. 5 4 ordered separately Instruction Manual PV 46085 5 PV 45410 Kit Contents Tube PV 45410 1 The items at right are included in main kit above and can be or O Sensor Cable PV 45410 2 dered separately Power Cable PV 45410 3 Instruction Sheet PV 45410 4 O Sensor PV 45410 5 EGA Tool Kit With Lambda Sensor PV 45410 Fuel Pressure Gauge 43506 Laptop Computer to diagnostic software user manual for Commercially Available minimum specifications Order all tools from SPX Corporation at 1 800 328 6657 except where indicated as a Victory order number or as Commercially Available Refer to Victory Special Service Tool Catalog for ordering information 1 13 GENERAL CABLE amp HARNESS ROUTING Refer to following pages for tie strap location Crank Position Sensor Wiring Starter Cable 8 Regulator Rectifier Wiring To Battery Clutch Cable Fast Idle Cable Throttle Cable Fast Idle Cable Throttle Return Cable Crank position sensor harness Main wire harness 1 14 GENERAL CABLE amp HARNESS ROUTING N Left View x Strap Includes Subframe and Rear Harness Bundle in Strap To Crankshaft Position Sensor P Strap Includes Subframe Harness Bundle Rear Harness Bundle Starter Cable and Charging Lead in Strap 9 5 Nm 7 lb ft Strap includes frame Beth and harness only Strap Includes Air Temp Sensor Harness Wire
12. 8 Any 1 4 shaft Example 1 4 drill bit shank PV 1253 or PV 4019 PV 43513 A Fork Tube Removal Installation Tool Steering Bearing Wheel Bearing Swing Arm Bushing Removal amp Installation Set Shock Pre Load Adjustment Wrench PV 43507 Shock Spring Compressor PV 43571 1 12 GENERAL SPECIAL TOOLS STEERING SUSPENSION PART NUMBER Cont Gas Shock Re Charging Kit Includes items below 2200421 Kit Part Charging Needle 7052069 Kit Part Air Chuck 7052068 Kit Part Gas Low Pressure Hose 2110003 Kit Part Re Charging Valve 7051004 Kit Part Female Male Fitting 7052066 Kit Part Schrader Valve 7051003 Kit Part 1 8 3 Way Tee 7052067 Kit Part 1 8 Male Fitting 7052076 Shock Shaft Seal Protector 5 8 2201640 Shock Rod Holding Tool 5 8 2872429 Shock Body Holding Tool 2871071 SPECIAL TOOLS WHEELS TIRES PART NUMBER Air Pressure Gauge Commercially Available Bead Breaker Commercially Available May be part of the tire removal equipment being used Tire Mounting Lubricant Commercially Available Tire Removal Equipment Commercially Available Rim Protector PV 43536 Valve Core Remover Commercially Available Wheel Balancing Truing Stand PV 43556 TOOLS FUEL SYSTEM FUEL INJECTION PART NUMBER Victory Polaris Diagnostic Tool Kit w Diagnostic Software PV 46085 PV 46085 Kit Contents Diagnostic Software Disk PV 46085 3 The items at right are included in main kit above and can be Interface Cable PV 4608
13. 90 Victory DOT 4 Brake Fluid 2872189 Nyogel Di Electric Grease 2871329 Victory Detail Kit 2872195 Victory Restore Kit 2872192 Loctite 262 50cc Tube 2871951 Primer N 25g Aerosol 2870585 Hand Grip Adhesive Three Bond 1501 10ml tube 2872575 Victory Fork Oil 2872184 2 7 ENGINE OIL LEVEL INSPECTION 1 Warm the engine for several minutes until operating temperature 1 reached 2 Stop engine and wait for 3 5 minutes Place the machine on a level area and hold it in an upright position Remove and clean the oil off of the dipstick Screw the dipstick in until seated Remove the dipstick and read the oil level The oil level should be up to the full line A on the dipstick Ifthe oil level is low add the recommended oil to raise the level to the full mark ENGINE OIL 8 FILTER CHANGE Oil Change Kit P N 2873551 Change engine oil and filter with the motorcycle on its side stand engine warm WARNING HOT COMPONENTS Wear insulated gloves and or allow engine and exhaust to cool before handling these parts 1 Remove the oil drain plug C socket head allen screw and drain the engine oil completely into a suitable container Discard drain plug sealing washer 3 Remove filter D by turning counter clockwise E Be sure sealing ring is removed with filter Oil Filter Wrench Strap Wrench 4 Allow oil to drain completely 5 Instal
14. Absorber All except 2004 Touring Cruiser 2004 e Cruiser Operation Codes I Inspect tighten clean adjust correct or replace if necessary R Replace Rebuild Replace at specified interval or annually L Lubricate with proper lubricant P Perform Replace at specified interval or every 2 years D Inspect sealed non rebuildable shock on 2004 Touring Cruiser in accordance with chart Replacement is recommended at 50 000 mile intervals 80 000 Kilometers 2 5 MAINTENANCE TUNE UP SPECIFICATIONS ITEM SPECIFICATION Lubrication Oil Pressure Y 3000 rpm 552 kPa 80 psi Cooling Oil Pressure 3000 rpm 414 kPa 60 psi Drive Belt Deflection All Except Touring Cruiser Models 8 mm 315 With 10 12 Ib Load 2 Center Span Touring Cruiser Models 9 mm 354 With 10 12 Ib Load Center Span 181147 181747 25 75mm 010 030 Spark Plug Gap 2002 2003 NGKCR7EB 8mm 032 2004 Touring Cruiser CPR6EA 9 8mm 032 Start the engine and warm it up for several minutes While warming up check for oil leaks If any leaks are found stop the engine immediately and determine the source of the problem before starting the engine again NOTE After the engine is started the oil indicator light should go off If the indicator light flickers or remains on immediately stop the engine and diagnose the problem before continuing TIGHTENING TORQUE Drain Plug 2002 22
15. Dunlop 491 Elite II MT90B16 71H Dunlop D417 160 80 B1675H Laced 40 Spoke 16x Laced 40 Spoke 16 x 3 5 in Dunlop 491 Elite II MT90 B16 71H use with inner tube Dunlop D417 160 80 B16 75H use with inner tube Minimum Tread Depth 063 1 6mm 063 1 6mm 063 1 6mm 063 1 6mm Conventional Conventional Conventional Conventional Telescopic Telescopic Telescopic Telescopic i Front Travel inches 5 1 in 13 cm 5 1 in 13 5 1 in 13 cm 5 1 in 13 cm i Rear Type Single Shock Single Shock Single Shock Single Shock Rear Travel inches Brake Type Disc Disc Front Brake Single 300 x 5 mm Disc with 4 Piston Fixed Caliper Rear Brake Single 300 x 6 mm Disc with 2 Piston Floating Caliper Headlight 5 5 amps Intl ANSI HGO24XV H4 4 in 10 cm Disc Disc Single 300 x 5 mm Disc with 4 Piston Fixed Caliper Single 300 x 6 mm Disc with 2 Piston Floating Caliper 5 5 amps ANSI HGO24XV Disc Disc Dual 300 x 5 mm Disc with 4 Piston Fixed Caliper Single 300 x 6 mm Disc with 2 Piston Floating Caliper 5 5 amps ANSI HGO24XV 4 in 10 cm Disc Disc Dual 300 x 5 mm Disc with 4 Piston Fixed Caliper Single 300 x 6 mm Disc with 2 Piston Floating Caliper 5 5 amps ANSI HGO24XV Brake Tail Light 2 1 1 6 amps 2 1 1 6 amps 2 1 1 6 amps 2 1 1 6 amps ANSI 198 ANSI 198 ANSI 198 ANSI 198 1 6 amps Turn Signal
16. E INSPECTION TIRE PRESSURE TABLE 2 34 oz cen 2 35 STORAGE ee P utere A pus antt d a 2 37 MAINTENANCE GENERAL SPECIFICATIONS 2002 es ee Front Wheel Travel 5 1 in 13 cm 94 in 239 cm 94 in 239 cm 98 in 249 cm 98 in 249 cm MA NA od 2002 2002 2002 2002 92 cubic in 92 cubic in 92 cubic in 92 cubic in Engine Cooling System Air Oil Cooling Air Oil Cooling Air Oil Cooling Air Oil Cooling Compression Ratio 9 2 1 9 2 1 9 2 1 9 2 1 Compression 180 psi 20 180 psi 20 180 psi 20 180 psi 20 1241 kPa 138 1241 kPa 138 1241 kPa 138 1241 kPa 138 Nnm 0OD gt UDO z oO 4 gt Wat Su 978 MAINTENANCE GENERAL SPECIFICATIONS 2002 Transmission Type Manual 5 Speed Manual 5 Speed Manual 5 Speed Manual 5 Speed Clutch Type Wet Multi Disk Wet Multi Disk Wet Multi Disk Wet Multi Disk Diaphragm Spring Diaphragm Spring Diaphragm Spring Diaphragm Spring Cast 5 spoke Primary Drive Reduction Wet Multi Gear Wet Multi Gear Wet Multi Gear Wet Multi Gear 16 x3 Front Wheel Rear Wheel Front Tire Cast 5 spoke 16 x3 Dunlop 491 Elite II MT90B16 71H Dunlop D417 160 80 B1675H Laced 40 Spoke 16 Laced 40 Spoke 16x3 5 in Dunlop 491 Elite Il MT90 B16 71H use w inner tube Dunlop D417 160 80 B16 75H use with inner tube Cast 5 spoke 16 x3 Cast 5 spoke 16 x 3
17. ERS 1 5 MODEL IDENTIFICATION NUMBER 1 5 ENGINE NUMBER DECAL 0 1 5 BREAK IN PROCEDURES 1 6 PUBLICATION PART 1 6 EMISSION CONTROL SYSTEMS 1 7 EMISSION SOURCES 1 7 EXHAUST EMISSION CONTROL 1 7 NOISE EMISSION CONTROL SYSTEM 1 7 EVAPORATIVE EMISSION CONTROL CONTROL CA MODELS 1 7 CRANKCASE EMISSION CONTROL 1 7 MULTI FUNCTION DISPLAY MFD II 1 8 MFD FUNCTION FLOW CHART 1 10 SPECIAL SERVICE I ES DE A 1 11 CABLE amp HARNESS ROUTING 1 14 GENERAL TRADEMARKS Victory acknowledges the following products mentioned in this manual FLEXLOC Registered Trademark of SPS Technologies Loctite Registered Trademark of the Loctite Corporation STA BIL Registered Trademark of Gold Eagle FOX Registered Trademark of Fox Shocks Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron UNDERSTANDING SAFETY LABELS amp INSTRUCTIONS DANGER WARNINGS amp CAUTION SYMBOLS This is the safety alert symbol When you see this symbol
18. Light Rear ANSI 199 Instrument Cluster Lights 1 3 amps Backlight Dimming Feature 1 6 amps ANSI 199 1 3 amps 1 6 amps ANSI 199 1 3 amps Turn Signal Light Front 2 1 amps 2 1 amps 2 1 amps 2 1 amps ANSI 198 ANSI 198 ANSI 198 ANSI 198 1 6 amps ANSI 199 1 3 amps UK Models Front Position ANSI 193 ANSI 193 ANSI 193 ANSI 193 uq GENERAL SPECIFICATIONS 2003 2004 Nnm 0OD gt UDO ZO 4 gt Oil Capacity Fuel Capacity Wheelbase Seat Height Footrest Height Front Wheel Travel Rear Wheel Travel Rear Suspension Type Dry Weight Wet Weight Overall Length Overall Width Overall Height Ground Clearance Passenger Capacity Maximum Load Capacity Gross Vehicle Weight Rating GVWR Trail Engine Model Number Engine Configuration Engine Displacement Engine Cooling System Compression Ratio Compression Valves Per Cylinder Bore x Stroke Starter Throttle Body Bore Size Exhaust System Type Lubrication System Engine RPM 60 mph Spark Plug Type Gap Dry Weight 6 5 Qt 6 15 Ltr 5 US Gal 19 Ltr 63 3 in 161 cm 28 3 in 72 cm 10 6 in 26 9 cm 5 1 in 13 cm 4 in 10 cm 634 16 287 6 kg 675 16 306 2 kg 94 in 239 cm 29 5 in 75 cm 44 5 113 cm 5 5 in 14 cm 444 16 201 kg 1150 Ibs 522 kg 30 0 Degrees 4 76 in 121 mm MCVT1507D 2003 50 V Twin 1507cc 92 cubic in 1241 kPa 138 NGK CR7EB 032 in
19. The minute digit should flash Press the MFD Set button to select the desired minute 2 3 4 Press the MFD Set button to select the desired ten minute 5 6 7 Press the MFD Mode button to accept the new minute setting The clock should return to normal operation and the colon should flash To change to the next MFD function press the MFD Mode button The clock will not function if the battery voltage drops below 11 5 volts The clock will reset to 12 00 if the battery is disconnected 1 8 GENERAL Multi Function Display MFD Modes and Operation Instrument Cluster Light Dimmer DIM appears as part of the display when in instrument cluster light dimmer mode To change the intensity of the instrument cluster light press the MFD Set button to select from six 6 intensity levels The engine does not need to be running to change the light intensity To change to the next MFD function press the MFD Mode button Headlamp High Beam Indicator Light Dimmer HB appears as part of the display when in headlamp high beam indicator light dimmer mode To change the intensity of the headlamp high beam indicator light press the MFD Set button to select from four 4 intensity levels The engine does not need to be running to change the indicator intensity To change to the next MFD function press the MFD Mode button Fuel Gauge The fuel gauge shows the amount of fuel in the fuel tank The fuel gauge range i
20. casionally Follow the pre ride inspec tion outlined in the owner s manual PUBLICATION PART NUMBERS The following chart lists the part numbers for Owner s Manuals parts books and parts microfiche OTHER VICTORY PUBLICATIONS Publication Part Numbers U S and Canada Owner s Manual 9917169 Can 9917170 9917633 2002 Deluxe Cruiser 9917169 Can 9917170 9917631 2002 Touring Cruiser 9917171 Can 9917172 9917629 2002 Deluxe Touring Cruiser 9917171 Can 9917172 9917635 2003 Classic Cruiser 9918229 Can 9918230 9918365 2003 Touring Cruiser 9918229 Can 9918230 9918367 2004 Touring Cruiser 9918946 Can 9918947 9918953 Year Model 2002 Standard Cruiser gt 1 6 GENERAL EMISSION CONTROL SYSTEMS The U S Environmental Protection Agency and California Air Resources Board CARB require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life and that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 6 000 km 3 730 mi after the time of sale to the ultimate purchaser when operated and maintained according to the instructions provided EMISSION SOURCES An internal combustion engine produces carbon monoxide and hydrocarbons during operation Hydrocarbons must be controlled because under some conditions hydrocarbons react with sunlight to produce photochemical
21. d with text as an aid Notes Cautions and Warnings have also been included for clarification of text and safety concerns Knowledge of mechanical theory tool use and shop procedures are necessary to perform some procedures in this manual safely and correctly Use only genuine Victory service parts Cleanliness of parts and tools as well as the work area is of primary importance Dirt and foreign matter will act as an abrasive and cause damage to precision parts Clean the motorcycle before beginning service Clean all parts before installing If difficulty is encountered in removing or installing a component look to see if a cause for the difficulty can be found If it is necessary to tap the part into place use soft face hammer and tap lightly Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or in the case of steering driveline and chassis components can result in loss of control during operation of the motorcycle resulting in injury or death If a torquing sequence indicated for nuts bolts or screws of a certain component start all fasteners in their holes and hand tighten Following the method and sequence indicated tighten evenly to the specified torque value When removing nuts bolts or screws from a component with several fasteners loosen them all about 1 4 turn before removing them to prevent distortion of that component If t
22. e justto the right of the oil filter Color Indicator See Chart on page 1 4 1 5 GENERAL BREAK IN PROCEDURES There is never a more important period in the life of a new Victory motorcycle than the period between zero and 500 miles 805 km A Victory motorcycle is manufactured using the best possible materials and manufacturing techniques but the final machining process is the break in During break in period many parts in the engine wear and polish to correct operating clearances During this time the operator should Avoid prolonged full throttle operation Avoid operation which might result in excessive heating of the engine The general break in guidelines are as follows BREAK IN GUIDELINES Miles km Throttle Position 0 90 miles 0 1 8 Avoid prolonged operation above 1 8 throttle Stop engine and let it cool following every hour of operation Vary speed of motorcycle Do not operate machine at one set throttle position 90 300 miles 0 1 2 Avoid prolonged operation above 1 2 throttle Stop engine and let it cool following every hour of operation Vary speed of the motorcycle Do not operate machine at one set throttle posi tion 300 500 miles Avoid cruising speeds above 3 4 throttle 500 miles Replace the engine oil and engine oil filter Have Victory dealer perform 500 mile service on the ma chine See chapter 2 for more information 500 Avoid prolonged full throttle operation Vary the engine speed oc
23. eate Mud sanis h Suara 5 contains chemicals known to cause cancer unsafe conditions that may cause severe 9 op he and remain so for a period of time after the birth defects or other reproductive harm personal injury or death engine is stopped A WARNING A WARNING A WARNING Never run the engine in an enclosed area Modifications to this motorcycle not approved Brake fluid is poisonous without a properly functioning exhaust gas by Victory may cause loss of performance KEEP OUT OF REACH OF CHILDREN evacuation system connected to the product excessive emissions and make the machine unsafe for use A WARNING A WARNING A WARNING Wear insulated protection for hands and Brake fluid is poisonous Do not ingest or Battery electrolyte is poisonous It contains arms or wait until hot components have allow brake fluid to contact eyes Always sulfuric acid Serious burns can result from cooled sufficiently before working on the wear eye protection when working with contact with skin eyes or clothing product brake fluid CAUTION Brake fluid will damage plastic painted and rubber parts Protect these surfaces whenever the brake system is being serviced GENERAL SERVICE RULES In order to perform service work efficiently and prevent costly errors technicians should read the text in this manual and familiarize themselves with the procedures before beginning Photographs and illustrations have been include
24. he condition of any gasket or o ring is in question replace it with a new one Be sure the mating surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances Some procedures require removal retaining rings or clips Removal can weaken and deform these parts therefore they should always be replaced with new parts When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation Because removal damages seals always replace with new seals during a repair Victory lubricants greases have been specially formulated to provide maximum performance protection when applied properly In some applications warranty coverage may be void if improper lubricants are used Parts requiring grease should be cleaned thoroughly fresh grease applied before reassembly Deteriorating grease loses lubricity and may contain abrasive foreign matter Working with Batteries e When removing or installing batteries care should be taken to avoid the possibility of explosion resulting in serious burns Remove battery from the motorcycle before charging Keep battery away from the source of any combustion sparks fire etc when charging Always disconnect the negative black cable first and reconnect it last e Battery electrolyte contains sulfuric acid and is poisonous Serious burns can result from contact with skin eyes or clot
25. he supplied paint order form Prices subject to change without notice Please have your dealer number telephone number and Polaris part to give to the Customer Service Specialist or include on the order form Additional charges may apply for phoned in orders Note There will be a 2596 service fee charged for all returns Polaris dealer will be responsible for return freight VICTORY DETAIL AND FINISH RESTORER KITS A Detail Kit polish wax and dressing and a Restore Kit Polish Swirl and Scuff remover is available from the Victory parts department for painted surface protection and to remove minor surface imperfections Detail Kit 2872195 Restore Kit 2872192 1 3 GENERAL VICTORY PAINT COLORS BY MODEL NOTE The 8th Position in the model number is a letter that designates the country region C Canada D 49State L California U United Kingdom The last letter is the color designator Refer to the chart below for model color Paint ordering information is available on the dealer web site MODEL YEAR 2002 Model Number V02CB16CC DC LC UC V02CB16CK DK LK UK VO2CB16CL DL LL UL V02CD16CC DC LC UC V02CD16CK DK LK UK Model Description Color Cruiser Black Solar Red Stone White Speed Yellow Crs Black Cruiser Black Solar Red Stone White Model Number Model Description Color VO2TB16CC DC LC UC Cruiser Black VO2TB16CO DO LO UO Solar Red Vogue Silver VO2TB16CP DP LP UP
26. hing IN THE EVENT OF CONTACT WITH SULFURIC ACID External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call for medical attention immediately e Eyes Flush with water for 15 minutes and call for medical attention immediately 1 2 GENERAL VICTORY TOUCH UP AND REFINISHING PAINT Service Paint products are available in three different sizes and applications Some paint colors require up to 3 components to create a color Prices subject to change without notice Dealer is responsible for freight on paint and paint products 6 ounce bottle Order Multiple of 2 For brush touch up of small nicks 10 ounce aerosol can Order Multiple of 2 Apply light even coats for best results Recoat time is from 30 60 minutes or after 4 days of drying to prevent lifting Quarts Sold as each For repaint of properly prepared plastic components or metal substrates Paint is a high quality acrylic urethane manufactured by U S Paint Mix as indicated on back of paint can Paint can be recoated after paint is tack free or has flashed off Paint finish may be wet sanded and buffed after coating has cured Paint is available in a variety of sizes and styles for specific painting needs How to order Place your order via the dealer web site at www polarisdealers com Phone Customer Service 1 800 330 9407 Fax your paint order to 1 866 245 7533 using t
27. l oil drain plug with new sealing washer Lubricate with engine oil and install drain plug Torque drain plug to specification Oil Drain Plug Filter 2002 38 Nm 28 Ib ft 3 4 turn after sealing ring contacts 2003 2004 27 Nm 20 Ib ft crankcase 6 Clean any residue or debris from the oil filter sealing area and threads Apply oil to new oil filter sealing ring and threads Install oil filter and tighten F 3 4 of a turn after sealing ring contacts crankcase 7 Fill crankcase to capacity with the recommended oil and reinstall dipstick 8 Start engine and run until operating temperature is reached Stop engine and wait 3 5 minutes before checking oil level 2 8 CABLE LUBRICATION The cables used on the motorcycle require periodic lubrication for smooth operation and longevity Inspect cables for smooth movement and external damage Inspect the exposed inner cable for fraying damage or rust Replace any damaged cables Disconnect one end of the cable to be lubricated Use Victory Cable Lubricant or a commercially available cable lubricant The end of the cable B should also be lubricated at this time with Victory all purpose grease Throttle cable Clutch cable Fast idle cable Seat release cable Victory All Purpose Grease 2872187 CONTROL LEVER PIVOT LUBRICATION Lubricate brake lever and clutch lever pivot points at intervals listed on periodic maintenance chart 1 Remove right side
28. lowing acts or causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement any device or element of design incorporated into the motorcycle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 Theuse of the motorcycle after such device or element of design has been removed or rendered inoperative Among those acts presumed to constitute tampering are the acts listed below 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the motorcycle or parts of the exhaust intake system with parts other than those specified by the manufacturer 1 7 GENERAL Multi Function Display MFD Modes and Operation The lets the user toggle via the mode button to view the odometer the trip odometer the clock the fuel gauge the voltmeter the instrument cluster light dimmer the headlamp high beam indicator light dimmer and the check engine indicator The MFD operates only when the ignition switch is in the On position To select the desired function press the MFD Mode button A To adjust a particular function press the MFD Set button B RH Front View LH Front View Odometer The odometer is the default mode of the
29. mirtror brake lever pivot nut and pin 2 Remove clutch and brake levers and clean old lubricant and dirt from pivot bolt lever and housing 3 Lubricate areas C with Victory All Purpose Grease on both clutch lever and brake lever 4 If removed install brake master cylinder push rod with large radius oriented toward lever and small radius toward master cylinder 5 Reinstall brake lever lever pivot pin and nut 6 Torque lever pivot pin first using a 4mm hex socket 7 Hold the pivot pin stationary and torque nut using a 10mm socket to specification below 8 Check front brake lever movement 9 Front brake lever is self adjusting Refer to page 2 10 to inspect freeplay 10 Install and adjust RH mirror 11 Reinstall the clutch lever lever pivot pin and nut 12 Torque clutch lever nut to specification above 13 Adjust clutch lever freeplay as shown on page 2 13 TORQUE Brake and Clutch Lever Pivot Pin and Nut 5 ft lbs 52 inch pounds 6 Nm MAINTENANCE Push Rod Large end toward lever gt c 2 9 SA A DOWNLOAD
30. nvaaq 1 10 GENERAL SPECIAL TOOLS SPECIAL TOOLS GENERAL amp PRECISION MEASUREMENT PART NUMBER Bearing amp Seal Driver Set PV 43558 Blind Bearing Remover Set Commercially Available Bore Gauge Set PV 3017 Decal Service Bulletin Completion 7170107 Order from Victory Parts Dept Engine Ear Listening Device PV 39565 Feeler Gauge Set PV 26900 8 or PV 26900 9 Torque Wrench 3 8 Drive in Ib PV 43543 Torque Wrench 3 8 Drive Ib ft PV 43552 PV 43564 SPECIAL TOOLS TUNE UP amp MAINTENANCE PART NUMBER SPECIAL TOOLS ELECTRICAL PART NUMBER Ammeter Inductive Clamp for Fluke 73 Multimeter PV 39617 Electrical Connector Test Adapter Kit PV 43526 Flywheel Puller PV 43533 Inductive Timing Light PV 43537 Multimeter Fluke 73 PV 43546 Speedometer Signal Tester PV 43544 Speedometer Signal Tester Adaptor Use with PV 43544 PV on 2001 models 1 11 GENERAL SPECIAL TOOLS SPECIAL TOOLS ENGINE CLUTCH TRANS PART NUMBER Clutch Hub Holding Tool PV 43518 Clutch Shaft Holder PV 45028 Crankcase Assembly Tool Same as Mainshaft PV 46299 Crankcase Installer Crankshaft Bearing Protector PV 43504 Crankshaft Rotation Socket 2003 current PV 46988 Crankcase Puller Crankcase Separation Used on PV 45029 2001 and later and on 1999 2000 if transmission kit has been installed Order from Victory Parts Dept Mainshaft Output Shaft Seal Installation Tool PV 43570 Pliers PV 43570 Band 5 8 to 3 7
31. s from LOW 0 8 gallons 3 03 liters to FULL 5 gallons 18 9 liters To change to the next MFD function press the MFD Mode button Voltmeter When the engine is not running BAT and the battery voltage appear When the engine is running ALT and the charging system voltage appear To return to the odometer function press the MFD Mode button Check Engine Indicator The check engine indicator will flash CH ENG any time the the ignition switch is in the On position and the Engine Control Module sensors report abnormal sensor or engine operation The check engine indicator will continue to flash as long as the fault condition exists 1 9 GENERAL MFD FUNCTION FLOW CHART HOLWNYALTV ANIWA ASVAYONI 138 13910 SALNNIN SNIHSV 1 195 7903 H3AWIG 39NVHO 13S H3INWIG NVI H9IH 3fYIVA ANIWA ASVAYONI ASVAYONI 145 13S 31 nNIA N3L LIDIA SHNOH SNIHSV14 SNIHSV 1 HT Set MOTA 10014 HA H3IAWIG 135 ualidWodo 1 13538 1 298 138 99 195 dlH L ti313WOGQO 11
32. tained in this publication is based on the latest product information available at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies in this publication Any reprinting or reuse of the depictions and or procedures contained in this publication is expressly prohibited Printed in U S A THE NEW AMERICAN MOTORCYCLE General Maintenance Frame Body Exhaust Lubrication amp Cooling 5 Drive Line Front Wheel amp Suspension w Rear Wheel amp Suspension Tires e un uw Charging System gnition System amp Battery Electric Starter ve Ro p un e p o mm m gt mm 1 MD CHAPTER 7 GENERAL UNDERSTANDING SAFETY LABELS amp INSTRUCTIONS 1 1 DANGER WARNINGS amp CAUTION SYMBOLS 1 1 GENERAL SAFETY SERVICE RULES 1 2 VICTORY TOUCH UP PAINT AND REFINISHING KITS 1 3 VICTORY COLORS AND CODES 1 4 VEHICLE IDENTIFICATION NUMBER VIN 1 5 KEY IDENTIFICATION NUMB
33. x1 5 38 Nm 28 ft Ibs Inspect replace O ring or sealing washer 2003 2004 12x1 5 27 Nm 20 ft Ibs Oil Filter 3 4 full turn after contacting the sealing surface OIL TYPE QUANTITY Oil Type Victory Semi Synthetic 20W40 Engine Oil Oil and Filter Change 6 15 liters 6 5 quarts Use Victory 20W40 engine oil for all temperatures If Victory oil is not available use 20W40 SG or equivalent CAUTION Do not put chemical additives in the oil Victory motorcycle oil has been specially designed for this application Additional additives are not necessary and have not been approved by Victory Engineering 2 6 MAINTENANCE FASTENER TORQUE SPECIFICATIONS TUNE UP TORQUE APPLY DESCRIPTION T Lb ft NOTES Lb in 89 m mo Persei RO Sr Lover 7 89 _ 88 88 m j Drive Sprocket Nut Retainer Plate 10 85 Screws 4 J 3 f OiPesweSemor O 60 pe OiTememueSewo presea v s j ESTA 599 j SPECIAL TOOLS Refer to page 1 11 for special tool information MAINTENANCE PRODUCTS Victory All Purpose Grease 2872187 Moly Assembly Paste 2871460 Victory Semi Synthetic 20W 40 2872176 Oil Change Kit 2873551 Victory Cable Lubricant 2872863 Carbon Clean Fuel Additive 28721
Download Pdf Manuals
Related Search