Victory Motorcycles Classic Cruiser 2002 Service Manual Download Page 3

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General

Frame/ Body/ Exhaust

Maintenance

Lubrication & Cooling

Fuel System / Fuel Injection

Engine Removal & Installation

Cylinder Head & Valves

Cylinder & Piston

Clutch, Primary, & Shift Linkage

Transmission & Crankshaft

Drive Line

Front Wheel & Suspension

Rear Wheel & Suspension

Tires

Brakes

Charging System

Ignition System & Battery

Electric Starter

Lighting & Instrumentation

Summary of Contents for Classic Cruiser 2002

Page 1: ......

Page 2: ...ons for Victory Classic Cruiser and Touring Cruiser motorcycles Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55...

Page 3: ...njection Engine Removal Installation Cylinder Head Valves Cylinder Piston Clutch Primary Shift Linkage Transmission Crankshaft Drive Line Front Wheel Suspension Rear Wheel Suspension Tires Brakes Char...

Page 4: ...IDENTIFICATION NUMBERS 1 5 MODEL IDENTIFICATION NUMBER 1 5 ENGINE NUMBER DECAL 1 5 BREAK IN PROCEDURES 1 6 PUBLICATION PART NUMBERS 1 6 EMISSION CONTROL SYSTEMS 1 7 EMISSION SOURCES 1 7 EXHAUST EMISSI...

Page 5: ...you get gasoline in your eyes or if you swallow gasoline see your doctor immediately Never try to syphon gasoline using mouth suction S If you spill gasoline on your skin or clothing immediately wash...

Page 6: ...ut 1 4 turn before removing them to prevent distortion of that component If the condition of any gasket or o ring is in question replace it with a new one Be sure the mating surfaces for the gasket ar...

Page 7: ...lashed 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 deale...

Page 8: ...uiser Black Vogue Silver V02CD16CN DN LN UN Dlx Crsr Cobalt Green Pearl White V02TD16CR DR LR UR TC Dlx Champagne Pearl white MODEL YEAR 2003 Model Number Model Description Color Model Number Model De...

Page 9: ...f 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 Loc...

Page 10: ...ne 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 0 3 4 Avoid cruising speeds above 3 4 throttle 500...

Page 11: ...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 motor...

Page 12: ...eter 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 odomet...

Page 13: ...ntensity 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...

Page 14: ...TRIP ODOMETER CLOCK SET 3 Sec SET 3 Sec DEFAULT BACK LIGHTING FLASHING HOURS DIGIT INCREASE VALUE CHANGE DIMMER VALUE CHANGE DIMMER VALUE FUEL SET SET ALTERNATOR BATTERY INCREASE VALUE INCREASE VALUE...

Page 15: ...uge Commercially Available Small Hole Gauge Set Commercially Available Straight Edge Precision PV 34673 Surface Plate Commercially Available Telescoping Gauge Set PU 45423 Torque Wrench 3 8s Drive in...

Page 16: ...rankcase Installer Crankcase Assembly PV 46299 Moly Assembly Paste PN 2871460 Order from Victory Parts Dept Mainshaft Output Shaft Seal Installation Tool PV 43505 Piston Ring Compressor 97mm PV 43570...

Page 17: ...otector 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...

Page 18: ...or Rectifier Wiring To Battery Rear Brake Line Fast Idle Cable Throttle Cable Clutch Cable Fast Idle Cable Throttle Cables Throttle Return Cable Main wire harness Crank position sensor harness Refer t...

Page 19: ...ue 9 5 Nm 7 lb ft Left View Right View Strap Includes Frame Clutch Cable Strap Includes Clutch Cable Speed Sensor Connector 1 2 1 Strap Includes Air Temp Sensor Harness Wire Harness Frame Strap Includ...

Page 20: ...nal Harness Tie Strap includes frame harness and throttle close cable only Tie Strap includes frame harness fast idle cable and throttle open cable only Included in strap Subframe Rear Harness Connect...

Page 21: ...USTMENT 2 15 SIDESTAND PIVOT SIDESTAND PAD INSPECTION 2 16 AIR FILTER INSPECTION REPLACEMENT 2 17 FUEL PRE FILTER AND FUEL LINE INSPECTION 2 18 FUEL TANK VENT CRANKCASE VENTILATION 2 19 SPARK PLUG 2 2...

Page 22: ...cm 60 8 154 cm I O Ground Clearance 5 5 in 14 cm 5 5 in 14 cm 5 in 13 cm 5 in 13 cm N S Passenger Capacity 1 1 1 1 S Maximum Load Capacity 475 lbs 215 kg 447 203 kg 451 204 5 kg 440 199 5 kg 2002 V92...

Page 23: ...in 13 cm S P Rear Type Single Shock Single Shock Single Shock Single Shock Rear Travel inches 4 in 10 cm 4 in 10 cm 4 in 10 cm 4 in 10 cm Brake Type Disc Disc Disc Disc Disc Disc Disc Disc B R A K Fro...

Page 24: ...nce 5 5 in 14 cm 5 in 13 cm I O Passenger Capacity 1 1 O N Maximum Load Capacity 444 lbs 201 kg 441 200 kg N S Gross Vehicle Weight Rating GVWR 1150 lbs 522 kg 1210 lbs 549 kg Rake Trail 30 0 Degrees...

Page 25: ...ional Telescopic Conventional Telescopic S U S Front Travel inches 5 1 in 13 cm 5 1 in 13 cm S P Rear Type Single Shock w Adjustable Preload Single Shock w Adjustable Preload Rear Travel inches 4 in 1...

Page 26: ...I I I I I I I Fast Idle Lever I I L I L I L I L I L Fasteners I I I I I I I I I I I Front Fork Oil I I I R I I R I I R I Front Forks and Front Axle I I I I I I I I I I I Front Brake Lever I I L I L I...

Page 27: ...ne 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 remain...

Page 28: ...r 3 4 Turn Past Gasket Contact Oil Pressure Sensor 50 Pipe Sealant Oil Temperature Sensor 50 Pipe Sealant Side Stand to Frame 47 35 Spark Plug 10 12 8 9 SPECIAL TOOLS Refer to page 1 11 for special to...

Page 29: ...drain plug C socket head allen screw and drain the engine oil completely into a suitable container 2 Discard drain plug sealing washer 3 Remove oil filter D by turning counter clockwise E Be sure sea...

Page 30: ...nance chart 1 Remove right side 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 Victo...

Page 31: ......

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