Victory Motorcycles 2005 Kingpin Owner'S Manual Download Page 155

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152

WARRANTIES

II. Limitations

This Emission Control System warranty shall not cover any of the following:

A. Repair or replacement required as a result of:

(1) accident

(2) misuse

(3) repairs improperly performed or replacements improperly installed

(4) use of replacement parts or accessories not conforming to VICTORY specifications which adversely affect performance and/or

(5) use in competitive racing or related events.

B. Inspections, replacement of parts, and other services and adjustments necessary for required maintenance

C. Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined.

Summary of Contents for 2005 Kingpin

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Page 3: ...This product contains or emits chemicals known to the state of California to cause cancer and birth defects or other reproductive harm California Proposition 65 Warning...

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Page 5: ...40 9800 Tele 763 417 8650 Fax 763 542 0599 CopyrightE 2004 Polaris Sales Inc All rights reserved POLARIS POLARIS THE WAY OUT and VICTORY MOTORCYCLES are registered trademarks of Polaris Industries Inc...

Page 6: ...rcycle when it s sold If you have questions about the operation or maintenance of the motorcycle after you ve read this manual please contact an authorized VICTORY dealer To locate the nearest authori...

Page 7: ...ORTING SAFETY DEFECTS 30 COMPONENT IDENTIFICATION 32 INSTRUMENTS FEATURES AND CONTROLS 40 PRE OPERATION CHECK 53 OPERATION 67 MAINTENANCE 81 MAINTENANCE RECORD 86 CLEANING 138 STORAGE 144 WARRANTIES 1...

Page 8: ...e safety section beginning on page 6 Understand and follow the procedures in your owner s manual to keep your VICTORY motorcycle in top condition on the road or in storage Bring the manual with you wh...

Page 9: ...ual The safety alert symbol indicates a potential for personal injury to you or others The safety alert warning indicates a potential hazard that could result in serious injury or death WARNING The sa...

Page 10: ...g the motorcycle S Your ability to safely operate the motorcycle depends on your judgment and your use of safe riding habits Take a rider education course from the Motorcycle Safety Foundation or anot...

Page 11: ...ng off road riding with more than one passenger or carrying weight exceeding the maximum weight rating can make handling difficult which could cause loss of control S In the first 500 miles operate th...

Page 12: ...lls and limits and ride within them S Allow only licensed experienced operators to ride your motorcycle and then only after they have become familiar with its controls and operation S Do not ride when...

Page 13: ...n the handlebars and your feet on the footrests S Obey the speed limit and adjust your speed and riding technique based on road weather and traffic conditions As you travel faster the influence of all...

Page 14: ...ractices The rear brake provides 40 of the motorcycle s stopping power at most Consider road conditions before applying the brakes When the road is wet or rough or contains loose or other slippery sub...

Page 15: ...eat strap with both hands and to keep both feet on the passenger footrests Do not carry a passenger who cannot place both feet firmly on the passenger footrests A passenger who is not holding on prope...

Page 16: ...passenger should wear bright or light colored and or reflective clothing to improve visibility to oth er motorists A motorist s failure to see or recognize a motorcycle is the leading cause of automob...

Page 17: ...owing pages VEGAS NESS SIGNATURE SERIES VEGAS VEGAS EIGHT BALL See page 15 KINGPIN NESS SIGNATURE SERIES KINGPIN See page 16 Do not exceed the motorcycle s gross vehicle weight rating Exceeding the we...

Page 18: ...1135 lbs 515 kg Item Weight VEGAS with full capacity of all fluids 666 lbs 302 kg Weight of leather saddlebags and brackets 12 lbs 5 5 kg Cargo optional saddlebags at capacity 14 lbs 6 kg Operator wi...

Page 19: ...531 kg Item Weight KINGPIN with full capacity of all fluids 685 lbs 311 kg Weight of Touring Package Hard Bags Brackets 33 lbs 15 kg Cargo saddlebags at capacity 14 lbs 6 kg Operator with recommended...

Page 20: ...rom riding Uneven weight distribution or accessories or cargo that shift suddenly while you re riding can make the motorcycle hard to handle and result in loss of control S Do not attach large or heav...

Page 21: ...any equipment or by adding equipment not approved by VICTORY may void your warranty Such modifications may make the motorcycle unsafe to ride and could result in severe injury to operator or passenge...

Page 22: ...fuel tank if the motorcycle leans to one side Gasoline is a fire hazard and it can also damage the motorcycle s finish S Do not restrain the motorcycle using the handlebars Loosen the front turn sign...

Page 23: ...or your ability to operate controls Displace you from your normal riding position Obscure lights or reflectors S Bulky or large accessories can cause instability due to the lifting or buffeting effec...

Page 24: ...are sparks or open flame Gasoline and gasoline vapors are poisonous and can cause severe injury Do not swallow gasoline inhale gasoline vapors or spill gasoline on yourself or your clothes If you swa...

Page 25: ...ance Inspect tires regularly and replace them if they re worn or damaged Use only an approved replacement tire and see the VICTORY Service Manual or your authorized VICTORY Dealer for tire replacement...

Page 26: ...e and local laws in place and in good working condition Your license plate must be clean clearly visible in all conditions and installed in a position specified by law S Each fastener used in the moto...

Page 27: ...B A C E D B A D C E 24 SAFETY Location of Safety and Vehicle Information Labels All Models See page 25 for decal type and description...

Page 28: ...tion A FUEL WARNING P N 7079205 Location B MANUFACTURING INFORMATION Information varies by model Location C NOISE EMISSION P N 7172555 Engine Identification Number Label Location E ENGINE I D on left...

Page 29: ...26 SAFETY Location of Safety and Vehicle Information Labels All Models See page 27 for decal type and description F...

Page 30: ...FETY Location of Safety and Vehicle Information Labels All Models Location F FUSE and RELAY LOCATION Under side cover on side of fuse box cover P N 7170962 FUSE BOX REMOVAL on base of fuse box P N 717...

Page 31: ...28 SAFETY Location of Safety and Vehicle Information Labels All Models See page 29 for decal type and description G H I H I G...

Page 32: ...ion Labels VEGAS NESS VEGAS VEGAS EIGHT BALL Location G TIRE SAFETY Location H EMISSION CONTROL INFORMATION Canada Models P N 7172550 49 State Models P N 7172548 Location I PATENT NOTICE LH Rear of su...

Page 33: ...open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between y...

Page 34: ...31 SAFETY NOTES...

Page 35: ...the vehicle and engine identification numbers model number and ignition key number HANDLEBAR AREA 1 Clutch Cable 2 Indicator Lamps 3 Front Brake Fluid Reservoir 4 Right Mirror 5 Throttle Control Grip...

Page 36: ...r 8 Battery under side cover 9 Rear Turn Signal 10 Taillight 11 Rear Brake Caliper 12 Rear Axle Adjuster 1 each side 13 Horn 14 Passenger s Foot Rest except VEGAS EIGHT BALL 15 Oil Filter 16 Sidestand...

Page 37: ...gh RH side cover 6 Side Cover 7 Engine Oil Fill Cap Dipstick 8 Front Turn Signal 9 Front Fork 10 Oil Cooler 11 Rear Brake Pedal 12 Operator Foot Rest 13 Engine Oil Drain Plug under engine 14 Rear Brak...

Page 38: ...the vehicle and engine identification numbers model number and ignition key number HANDLEBAR AREA KINGPIN NESS KINGPIN 1 Clutch Cable 2 Indicator Lamps 3 Front Brake Fluid Reservoir 4 Right Handlebar...

Page 39: ...Battery under side cover 10 Taillight 11 Rear Turn Signal 12 Rear Axle Adjuster 1 each side 13 Rear Brake Caliper 14 Passenger s Foot Rest 15 Evaporative Canister California Models 16 Oil Filter 17 O...

Page 40: ...cover 5 Side Cover 6 Engine Oil Fill Cap Dipstick 7 Front Brake Lever 8 Front Turn Signal 9 Horn 10 Front Fork 11 Rear Brake Pedal 12 Operator s Foot Rest 13 Rear Brake Fluid Reservoir 14 Drive Sprock...

Page 41: ...ber to title register license or insure the motorcycle or to order replacement parts SAE assigned World Manufacturing Identifier Chassis A VEGAS EIGHT BALL C KINGPIN D NESS SIGNATURE SERIES KINGPIN E...

Page 42: ...just to the right of the oil filter You may need the engine identification number to title register license or insure the motorcycle or to order replacement parts Ignition Key Number The ignition key...

Page 43: ...cal circuits are energized and the ignition key cannot be removed The headlamp taillight and instrument lights illuminate With the engine stop run switch set to the RUN position see page 47 you can st...

Page 44: ...portion of the speedometer Trip Odometer 2 A trip odometer is included on the speedometer The trip odometer shows total miles traveled since the trip odometer was reset You can use the trip odometer t...

Page 45: ...ed in revolutions per minute RPM A red line on the gauge indicates maximum safe engine RPM With tachometer installed the trip odometer reset button 2 is located on the instrument mounting plate See pa...

Page 46: ...any time 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 illuminate as long as t...

Page 47: ...ne off immediately The low oil pressure indicator also illuminates when the ignition switch is in the ON position and the engine is not running This demonstrates that the indicator is functioning prop...

Page 48: ...lever stops Headlamp High Low Beam Switch 2 The headlamp high low beam switch toggles the headlamp between high beam low beam and momentary passing beam To activate the high beam press the upper port...

Page 49: ...ill occur shortly after speed again reaches 15 mph The 15mph speed is approximate Turn Signal Switch Momentary Feature When passing a vehicle or when changing lanes the operator has the option of usin...

Page 50: ...The engine should not start or run when the switch is in the STOP position Use the engine stop run switch to turn the engine off under either normal or emergency conditions Emergency Flasher Switch 2...

Page 51: ...dures see Starting the Engine page 71 Throttle Control Grip 4 The throttle control grip controls the engine speed To increase engine speed twist the throttle control grip toward you to decrease engine...

Page 52: ...on the gear shift pedal To shift to a higher gear lift up on the gear shift pedal For proper gear shifting procedure see Shifting Gears pages 73 and 74 Rear Brake Pedal 2 The rear brake pedal is on t...

Page 53: ...wn on the toe shift pedal To shift to a higher gear lift up on the toe shift pedal For proper gear shifting procedure see Shifting Gears pages 73 and 74 Rear Brake Pedal 2 The rear brake pedal is on t...

Page 54: ...on the cap and insert key Turn clockwise while pushing down lightly to release latch and open the cap To close the fuel cap turn key clockwise and press down on the cap Turn key counterclockwise while...

Page 55: ...ber grommets are in place before reversing the above procedure to install the side covers Sidestand The sidestand is located on the left side of the motorcycle Correctly retract the sidestand before o...

Page 56: ...ional service information in the maintenance section of this manual in the VICTORY Service Manual or from an authorized VICTORY dealer During the pre operation check you might use products that are po...

Page 57: ...the transmission is in neutral the neutral indicator should remain illuminated Headlamp Check the headlamp to see that it is on Set the headlamp switch to the high beam position The headlamp brightnes...

Page 58: ...ency Flashers Slide the emergency flasher switch to the left All four turn signals and the turn signal indicator light on the panel should flash Slide the switch to the right The turn signals and turn...

Page 59: ...l cap dipstick 1 and wipe the dipstick clean Reinstall the dipstick and turn the cap clockwise until it seats 4 Remove the dipstick again and read the oil level 5 If necessary add or remove oil to bri...

Page 60: ...next fuel stop and plan accordingly to avoid running out of fuel Fuel Hose Rail and Connections Inspect the fuel hoses for cracks or damage Inspect the hose connection at the fuel tank and at the fuel...

Page 61: ...to the tire pressure table on page 121 Tire Condition Inspect the tire sidewalls road contact surface and tread base for cuts punctures and cracking Replace damaged tires immediately see the VICTORY S...

Page 62: ...er within the first 3 4 inch 19 mm of lever travel Front Brake Fluid Level 1 To check the front brake fluid level rest the motorcycle on the sidestand and on level ground Turn the handlebars until the...

Page 63: ...master cylinder should be 080 160 inch 2 4 mm Adjust pedal freeplay as necessary see page 116 Press and release the rear brake pedal It should move freely and smoothly and should return to its rest po...

Page 64: ...rear brake fluid level remove the right side cover Straddle the motorcycle and bring it to a vertical position 2 View the brake fluid through the reservoir The fluid should be clear and at a level be...

Page 65: ...friction material Replace brake pads having less than the specified amount of friction material at their thinnest point Check Throttle Control Grip and Cables 1 Rotate the throttle control grip It sho...

Page 66: ...and the lever housing 3 Adjust clutch lever freeplay if necessary see page 111 NOTE The starter interlock switch is dependent on the clutch lever free play being set correctly to ensure activation of...

Page 67: ...ld operate smoothly and quietly 3 Place the motorcycle on the sidestand and inspect the front forks Make sure there is no fork oil present on the fork tube or around the fork seal Check Steering Strad...

Page 68: ...t amount of suspension travel and ground clearance see page 99 Inadequate ground clearance could allow components to come into contact with the ground causing loss of control WARNING Check Drive Belt...

Page 69: ...tand tightly against the motorcycle Check the condition of the sidestand rubber pad and make sure it s firmly attached to the sidestand Check Fasteners Visually inspect the entire motorcycle chassis a...

Page 70: ...or best performance and longevity Important areas covered include S Engine Break in Period S Fueling and Fill Height S Starting the Engine S Shifting Gears S Accelerating S Braking S Stopping the Engi...

Page 71: ...ly Read understand and use the following rules for operating the motorcycle during the first 500 miles 800 kilometers to ensure your engine s long term performance and durability Do not put unnecessar...

Page 72: ...ters S Do not operate the motorcycle for extended periods of time at throttle positions above 3 4 throttle At 500 miles 800 kilometers S Perform initial maintenance as described in the Maintenance sec...

Page 73: ...r the surrounding area Do not fill the fuel tank above the fuel filler insert Overfilling the fuel tank may cause fuel to overflow when it expands Fuel may leak from an improperly seated fuel cap Be s...

Page 74: ...o the ignition switch and turn the switch to the ON position see page 40 3 Mount the motorcycle and bring it to an upright position Engage the front brake and place the sidestand in the stored up posi...

Page 75: ...e check engine indicator or the low oil pressure indicator does not go out after the engine starts stop the engine See either Check Engine Indicator page 43 or Low Oil Pressure Indicator page 44 7 Lea...

Page 76: ...front of the pedal with your toe To shift to a lower gear depress the pedal with your toe HEEL TOE SHIFT PEDAL Bottom Photo Shift to a higher gear by lifting the front peg of the pedal with your toe o...

Page 77: ...ee Recommended Shift Points on page 75 8 With a quick motion simultaneously close the throttle completely and disengage the clutch 9 Raise the shift pedal with your toe or depress it with your heel un...

Page 78: ...otorcycle to skid When downshifting while passing over such surfaces release the clutch lever very gradually Downshifting in a curve may cause the rear wheel to lose traction Downshift before entering...

Page 79: ...ding to the instructions in Shifting Gears page 73 The more quickly you open the throttle the more quickly the motorcycle accelerates Abrupt acceleration can cause your body to shift suddenly toward t...

Page 80: ...that either wheel stops rotating Leave sufficient distance so you can apply the brakes gradually if you need to stop Do not apply either brake so strongly that the wheel stops rotating This may cause...

Page 81: ...engine stop run switch to the STOP position turn the ignition switch to the OFF position and remove the ignition key Stopping the engine while the motorcycle is in motion and the transmission is engag...

Page 82: ...the motorcycle Take the key with you If you must park on a slope point the motorcycle toward the top of the slope Put the transmission in gear and park the motorcycle so that it is stable when it rest...

Page 83: ...e sidestand from sinking into the asphalt Caution A hot engine or hot exhaust pipes can be hazardous The engine and exhaust pipes are hot for some time after the engine is stopped Touching the engine...

Page 84: ...the entire procedure in this section of the Owner s Manual Choose a flat firm surface for servicing the motorcycle Make sure you have the time tools and expertise to complete a procedure properly Dur...

Page 85: ...mance for its entire service life Periodic Maintenance Intervals Use the following table to determine how often you should perform maintenance on various components For additional information on maint...

Page 86: ...R R R R R R Air FIlter 91 I I R I R I R I R I R I R I R I R I R I R Drive Sprocket Nut 92 I I I Drive Belt 93 I I I I I I I I I I I I R I I I I I I I I Rear Wheel Alignment 96 I I I I I I I I I I I R...

Page 87: ...I I I I I I Evaporative Emission Control System California Only 105 I I I I I I I I I I I Fuel Filter 106 R R Fast Idle Lever 107 I I L I L I L I L I L Throttle 108 I I I I L I I I L I I I L I I I L...

Page 88: ...ear Shift Pedal 120 I I L I L I L I L I L Tires 121 I I I I I I I I I I I I I I I I I I I I I Wheel Spokes 123 I I I I I I I I I I I Spark Plugs 124 I I I I I I R I I I I Engine Compression 126 I I I...

Page 89: ...86 MAINTENANCE MAINTENANCE RECORD MAINTENANCE PERFORMED MILES KM NOTES PERFORMED BY...

Page 90: ...87 MAINTENANCE MAINTENANCE RECORD MAINTENANCE PERFORMED MILES KM NOTES PERFORMED BY...

Page 91: ...flammable materials WARNING 1 Start and run the engine until it reaches normal operating temperature Stop the engine 2 Securely support the motorcycle on the sidestand 3 Place an oil drain pan under t...

Page 92: ...end the use of only VICTORY Brand Semi Synthetic 20W 40 Motor Oil or equivalent 10 Reinstall the oil fill cap and then start and run the engine until it reaches normal operating temperature After an o...

Page 93: ...turn the cap clockwise until it seats 4 Remove the dipstick again and note the oil level 5 If necessary add or remove oil to bring the level into the area on the dipstick above the ADD mark and below...

Page 94: ...er and air filter element using the universal tool provided under the left side cover see page 136 2 To remove debris from the element use low pressure air and blow from the rear forward Wear face pro...

Page 95: ...The machined surface should smooth and free from burrs or galling 6 Clean the output shaft threads and the sprocket nut threads 7 Apply a few drops of LOCTITE Thread Locker 262 or equivalent to the ou...

Page 96: ...ion This procedure involves using the belt tension gauge part no PV 43532 which is designed specifically for measuring drive belt tension Before beginning this procedure S Make sure the drive belt is...

Page 97: ...record the position of the base of the tension gauge bracket This position represents zero force 5 Push the plunger upward until the small O ring touches the tension gauge body Make sure the tension...

Page 98: ...osen the rear axle nut A 2 Insert theuniversal tool seepage 136 through theaccess holein the back of the swingarm and turn both left and right axle adjusters B an equal amount if wheel is in alignment...

Page 99: ...tion 2 Place the transmission in Neutral and lift the rear wheel off the ground with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame 3 The axle washers 1 and...

Page 100: ...clockwise to draw the axle back or OUT counterclockwise to push the axle forward 6 Recheck rear wheel alignment as outlined after each adjustment Readjust if necessary until the marks on both axle was...

Page 101: ...ignment is incorrect repeat steps 4 7 10 Pump rear brake pedal several times to reset brake pad distance 11 Carefully lower the motorcycle and safely support it on the sidestand Care should be taken t...

Page 102: ...o correctly adjust the rear shock absorber spring Have an assistant help you complete the following procedure 1 Elevate the rear of the motorcycle until the rear wheel is about 1 inch 2 5 cm off of th...

Page 103: ...measure the distance from the center of the rear axle to the bottom of the rear fender directly above the axle This measurement must be taken from the same locations recorded in step 2 8 Subtract the...

Page 104: ...wed from the top of shock absorber to DECREASE the sag measurement and counterclockwise to INCREASE the sag measurement 12 Re check sag dimension after adjustment 13 Tighten lock nut securely against...

Page 105: ...der the frame 5 Grasp the rear tire and attempt to move the rear wheel side to side NOTE If there is movement at the rear axle inspect the wheel bearings and rear axle see the VICTORY Service Manual o...

Page 106: ...ion should operate smoothly and quietly 3 Place the motorcycle on the sidestand and inspect the front forks Make sure there is no fork oil present on the fork tube 1 or around the fork seal 2 4 Clean...

Page 107: ...front to back NOTE If there is front to back movement at the steering head the steering head bearings should be inspected lubricated and adjusted see the VICTORY Service Manual or an authorized VICTO...

Page 108: ...stains from leaking Evaporative Emission Control System California models only Visually inspect all evaporative emission control system hoses and connections Make sure all connections are tight Also...

Page 109: ...To reinstall the fuel tank reverse the removal steps routing fuel supply hose to the right of breather hose 9 Torque the fuel supply hose clamp Torque 20 in lb 2 5 Nm 10 Reinstall the fuel tank mount...

Page 110: ...tment 1 If adjustment is necessary remove seat page 127 and fuel tank page 105 2 Loosen the fast idle cable adjuster jam nut B 3 Turn the cable adjuster in or out until freeplay at the lever is 1 8 1...

Page 111: ...djust Throttle Freeplay 1 Slide the rubber covers off both cable adjusters and loosen both adjuster jam nuts 2 Turn both cable adjusters into the cable as far as possible 3 Turn the cable adjuster on...

Page 112: ...lutch lever movement from the rest position to the point of cable resistance should be between 0 020 0 040 inch 5 1 0 mm Measure the gap between the clutch lever and the lever housing 3 Adjust clutch...

Page 113: ...se a 4mm hexagonal socket to remove the screw 5 Disconnect the clutch cable from the clutch lever 6 Remove any old grease and dirt from the clutch lever and lever housing 7 Lubricate the clutch lever...

Page 114: ...t until the clutch freeplay A is 020 040 inch 5 1 0 mm 5 Tighten the adjuster jam nut securely while holding cable 6 Reinstall right side cover 7 Verify that the safety switch activates so the motorcy...

Page 115: ...of the cable to be lubricated and disconnect one end of the cable 2 Lubricate the cable and the inside of the cable housing with VICTORY Cable Lube PN 2872861 or a commercially available cable lubric...

Page 116: ...ORY Service Manual or contact an authorized VICTORY dealer for service Lubricate Front Brake Lever 1 Remove right side mirror 2 Remove brake lever pivot nut 10mm wrench or socket and pin 4mm hexagonal...

Page 117: ...rake fluid if necessary Add Front Brake Fluid 1 Straddle the motorcycle and bring it to a vertical position Turn the handlebars until the reservoir is horizontal 2 Wipe the area around the reservoir c...

Page 118: ...above the sight glass 6 Reinstall the reservoir gasket and cover Check Rear Brake Pedal Freeplay and Movement Rear brake pedal freeplay the amount of brake pedal movement from the rest position to th...

Page 119: ...eck Rear Brake Fluid Level 1 To check the rear brake fluid level remove the right side cover Straddle the motorcycle and bring it to a vertical position 2 View the brake fluid through the reservoir Th...

Page 120: ...securely under the frame 2 Remove the right side cover 3 Wipe the area around the reservoir cover with a clean cloth 4 Wipe the brake fluid container with a clean cloth 5 Remove the reservoir cover a...

Page 121: ...em could cause the brakes to malfunction Use only DOT 4 brake fluid from a sealed clean container Using the wrong brake fluid or allowing contaminants into the brake fluid system can damage the system...

Page 122: ...ct the brake disc for nicks scratches cracks or other damage Inspect the thickness of each brake disc in at least four points around the disc Minimum thickness is stamped on the inner hub of the disc...

Page 123: ...Tighten the linkage rod locknuts 4 Check the gear shift pedal height Do not remove and reposition the shift arm on the shift shaft to adjust gear shift pedal height A 90_ 5_ angle between the shift ar...

Page 124: ...ressure Table VEGAS NESS VEGAS VEGAS EIGHT BALL Up to 200 lbs 91 kg load 200 465 lbs 91 211 kg load FRONT Dunlop CRUISEMAX 80 90 21 48H 36 psi 248 kpa 38 psi 262 kpa REAR Dunlop D417 180 55 B18 74V 36...

Page 125: ...VICTORY dealer Check Tread Depth Raised areas at the base of the tread known as wear bars act as easily visible tread depth indicators When the road contact surface has worn to the top of the wear bar...

Page 126: ...h spoke and try to move it side to side or up and down All spokes should be approximately equal in tension and have the same amount of flex Tighten loose spokes or replace bent broken or missing spoke...

Page 127: ...rom the other see the VICTORY Service Manual or an authorized VICTORY dealer for assistance 1 Make sure the engine is at room temperature 2 Disconnect the spark plug wire by pulling upward on the spar...

Page 128: ...f spark plugs are in good condition and are not due for replacement you can clean them with a non metallic stiff bristle brush set the gap and reinstall them Replace spark plugs NGK CPR6EA 9 or equiva...

Page 129: ...system for stains from leaking exhaust gasses Replace exhaust gaskets if necessary see the VICTORY Service Manual or an authorized VICTORY dealer Check all exhaust system fasteners 1 Tighten exhaust h...

Page 130: ...t and left side covers 2 Remove the fuse box from the bracket see page 27 3 Remove the screws located on the right and left sides of the operator s seat 4 Lift the rear of the seat and pull rearward a...

Page 131: ...s and get prompt medical attention WARNING The motorcycle uses a permanently sealed maintenance free battery Do not remove the battery cap strip for any reason Keep the battery connections clean and t...

Page 132: ...over 2 Disconnect the negative battery cables cable ends are exposed 3 Disconnect the positive cables cable ends are covered with a red boot Disconnecting the positive cable first can produce an elect...

Page 133: ...m of dielectric grease to the posts and cable connectors 2 Following the charger manufacturer s instructions use a battery charger designed for use with 12 volt batteries The charger should have a max...

Page 134: ...ositive battery cables tighten securely and install the red boot 4 Connect the negative cables tighten securely Be sure cables have adequate side cover clearance Connecting the negative cable first ca...

Page 135: ...ox 4 Reinstall the fuse box cover with the double cutout toward the front of the motorcycle The fuse box decal should be readable from the right side of the motorcycle 5 Reinstall the fuse box to the...

Page 136: ...in an upright position and sit in the operator s seat 4 Set the ignition switch to the ON position and set the headlamp to High beam Check the headlamp for correct aim 5 To adjust the headlamp vertic...

Page 137: ...against the motorcycle If the sidestand is bent it should be replaced immediately Do not try to straighten a bent sidestand The sidestand will be weakened and may not be able to support the motorcycl...

Page 138: ...ING 3 Hold the nut and remove the sidestand pivot bolt and sidestand return spring 4 Wipe any old grease and dirt from the sidestand frame and pivot bolt 5 Lubricate the sidestand the pivot bolt and t...

Page 139: ...tems Oil Drain Plug Handlebar Adjustment Belt Tension Adjusters After loosening axle nut Passenger Seat Accessory Windshield Fasteners Accessory Driver s Backrest Fasteners Indicator Bulbs Headlight B...

Page 140: ...137 MAINTENANCE NOTES...

Page 141: ...th salty or polluted air wash your motorcycle frequently Proper cleaning requires washing and drying the motorcycle and then applying wax polish and protectants to extend the service life and appearan...

Page 142: ...essure may allow water to seep in and deteriorate wheel bearings brake caliper assemblies brake master cylinders electrical connectors steering head bearings and transmission seals Electrical componen...

Page 143: ...to remove by applying gentle pressure using the warm water and mild detergent mixture you may need to use a special cleaner Choose a cleaner designed for use on the type of surface you plan to clean...

Page 144: ...wax polish or protectants After washing and drying the motorcycle to help extend the life and appearance of its components S Wax painted surfaces Avoid cleaning waxing compounds as they may contain a...

Page 145: ...ovide plenty of soapy water for washing and keep the cloth or sponge clean by rinsing it frequently S Minor scratches may be removed with a quality plastic polishing compound Follow the manufacturer s...

Page 146: ...drier climates will require more frequent conditioning To retain the beauty and character of your leather saddlebags please follow these steps 1 Vacuum or blow any loose dust or dirt from the saddleba...

Page 147: ...aration Choose a dry well ventilated storage location inside a garage or other structure if possible The location should have a firm flat surface and allow enough space for the motorcycle To best pres...

Page 148: ...that is in service settle on internal engine components during storage Settled carbon deposits can cause engine damage Caution 2 Using pressurized air blow any debris from the area around each spark p...

Page 149: ...of mild detergent and warm water 4 Store the battery in a dry location that maintains a temperature of 32_ to 90_F 0_ to 32_C 5 While in storage fully charge the battery once a month see page 130 Par...

Page 150: ...e change the engine oil and filter see page 88 beginning with step 4 During storage temperature and humidity changes can cause condensation to form in the crankcase and mix with engine oil Running the...

Page 151: ...t which conducts exhaust gases S Removal or puncturing of any part of the intake system S Lack of proper maintenance S Replacing any moving part of the vehicle or parts of the exhaust or intake system...

Page 152: ...ime listed below provided there has been no abuse neglect or improper maintenance of your motorcycle Your emission control system may include parts such as the fuel injection system the ignition syste...

Page 153: ...El Monte CA 91734 8001 VICTORY Motorcycle Division Polaris Sales Inc Limited Warranty on Emission Control System VICTORY Motorcycle Division Polaris Sales Inc hereinafter VICTORY warrants that each n...

Page 154: ...condensers and spark plugs if failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related parts may vary from model...

Page 155: ...nts improperly installed 4 use of replacement parts or accessories not conforming to VICTORY specifications which adversely affect performance and or 5 use in competitive racing or related events B In...

Page 156: ...SE THE VICTO RY MOTORCYCLE FOR ANY PURPOSE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU B NO EXPRESS EM...

Page 157: ...performance and durability may be used in the performance of any maintenance or repairs How ever VICTORY is not liable for these parts The owner is responsible for the performance of all required main...

Page 158: ...leted by your dealer and submitted to VICTORY Motorcycle Division Polaris Sales Inc within ten days Upon receipt of this registration VICTORY Motorcycle Division Polaris Sales Inc will record the regi...

Page 159: ...explosions or any other cause beyond VICTORY Motorcycle Division Polaris Sales Inc control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible wi...

Page 160: ...CTORY Motorcycle Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR...

Page 161: ...5 in 169 cm 65 6 in 167 cm Ground Clearance 5 8 in 14 8 cm 5 8 in 14 8 cm Rake Trail 33 1 5 28 in 13 4 cm 32 8 5 43 in 13 8 cm Weight Dry Weight 620 lbs 281 kg 639 lbs 290 kg Wet Weight 666 lbs 302 k...

Page 162: ...d Dual Staggered Lubrication System Wet Sump Wet Sump Spark Plug Gap NGK CPR6EA 9 032 in 0 8 mm NGK CPR6EA 9 032 in 0 8 mm Chassis Front Suspension Type Travel Telescopic Fork 5 1 in 13 cm Inverted Te...

Page 163: ...Constant Mesh 5 speed Constant Mesh Primary Drive Gear With Torque Compensator Gear With Torque Compensator Primary Reduction Ratio 1 5 1 1 5 1 Gear Shift Pattern 1 Down 4 Up 1 Down 4 Up Internal Gear...

Page 164: ...80 55 B18 74V Dunlop D417 180 55 B18 74V Electrical Alternator 38 Amp Max Output 38 Amp Max Output Battery 12 Volts 18 Amp Hour 12 Volts 18 Amp Hour Lights and Fuses Fuses Engine ECM 15 amp 15 amp Fue...

Page 165: ...ning up to 15 Methyl Tertiary Butyl Ether MTBE can be used Gasoline containing up to 10 Ethanol can be used Gasoline that has been Reformulated or Oxygenated can be used Engine Oil Specifications Pola...

Page 166: ...d see page 38 Engine Identification Number ________________________________________ Located on top of crankcase behind rear cylinder see page 39 Ignition Key Number ___________________________________...

Page 167: ...Clutch Freeplay 111 Clutch Lever 46 Clutch Lever and Cable 109 Clutch Lever Lubrication 110 COMPONENT IDENTIFICATION 38 Components Handlebar 32 35 Control Cable Lubrication 112 Crankcase Ventilation...

Page 168: ...Maintenance Interval Table 83 85 Maintenance Record 86 87 Maintenance Safety 22 Modifications 18 N Neutral Indicator 43 Noise Emission Warranty 148 Noise Regulation 148 O Odometer 41 Oil 88 90 Oil Ch...

Page 169: ...llight Brake Light 54 Test Drive 136 Throttle Throttle Control Cable 62 108 Throttle Control Grip 48 62 108 Throttle Freeplay Adjustment 108 Tire Condition 58 122 Tire Pressure 58 121 Tire Pressure Ta...

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Victory Motorcycles 2005 Kingpin, Owner'S Manual

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