Victory Motorcycles Kingpin 2004 Manual Download Page 102

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100

MAINTENANCE

Fast Idle Lever and Cable

1. Move the fast idle lever. It should move smoothly from

its rest position to its completely open position and back

again. Measure fast idle lever free-play (A), which is

the amount of lever movement from the rest position to

the point of cable resistance.

Specification: 3-6mm, 1/8-1/4 in.

Fast Idle Lever Freeplay

2. If adjustment is necessary, remove seat (page 120) and

fuel tank (page 98).

3. Loosen the fast idle cable adjuster jam nut (B).
4. Turn the cable adjuster in or out until the fast idle lever

freeplay is 1/8-1/4 inch (3-6 mm).

5. Tighten the adjuster jam nut securely and reinstall the

fuel tank and operator’s seat.

6. Start the engine and let it idle with transmission in

NEUTRAL.

7. Turn the handlebars from full right to full left. If engine

RPM increases when bars are turned, re-check throttle

cable and fast idle cable adjustments, cable condition,

and routing. If problem persists contact your VICTORY

dealer.

Summary of Contents for Kingpin 2004

Page 1: ...2004 TM Kingpin...

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm...

Page 3: ...e created a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www victory us...

Page 4: ...VICTORY Motorcycle Division Polaris Industries Inc 2100 Highway 55 Medina Minnesota 55340 9800 Tele 763 417 8650 Fax 763 542 0599 CopyrightE 2003 Polaris Sales Inc All rights reserved POLARIS POLARIS...

Page 5: ...u 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 authorized VICTORY dealer call 1 8...

Page 6: ...5 SAFETY 6 COMPONENT IDENTIFICATION 30 INSTRUMENTS FEATURES AND CONTROLS 35 PRE OPERATION CHECK 47 OPERATION 60 MAINTENANCE 74 MAINTENANCE RECORD 79 CLEANING 131 STORAGE 137 WARRANTIES 141 SPECIFICATI...

Page 7: ...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 8: ...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 9: ...ting 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 a...

Page 10: ...ith 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 the motorcycle accordi...

Page 11: ...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 12: ...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 13: ...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 14: ...o cannot place both feet firmly on the passenger footrests A passenger who is not holding on properly or who cannot reach the passenger footrests can shift their body erratically which can make the mo...

Page 15: ...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 16: ...orcycle S The weight of the operator or passenger includes body weight all apparel and objects in or on apparel Examples of calculating GVWR are provided on page 15 Do not exceed the motorcycle s gros...

Page 17: ...eight 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 riding appare...

Page 18: ...from 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 hea...

Page 19: ...rating can reduce stability and handling and cause loss of control Transporting the Motorcycle If you must transport the motorcycle S Use a truck or trailer Do not tow the motorcycle with another ve...

Page 20: ...ials Park the motorcycle on a firm level surface Sloped or soft surfaces may not support the motorcycle when it s parked and it may tip over If you must park on a slope or soft surface follow the prec...

Page 21: ...l 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 effe...

Page 22: ...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 23: ...nce 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 24: ...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 25: ...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 26: ...24 SAFETY Location of Safety and Vehicle Information Labels See page 25 for decal type and description B C A D E...

Page 27: ...vary by model features and options Refer to actual decal on the vehicle Location B MANUFACTURING DATE Information varies by model Location C NOISE EMISSION Engine Identification Number Label Location...

Page 28: ...26 SAFETY Location of Safety and Vehicle Information Labels See page 27 for decal type and description F...

Page 29: ...27 SAFETY Location of Safety and Vehicle Information Labels Location F FUSE and RELAY LOCATION under side cover on top of fuse box cover FUSE BOX REMOVAL on base of fuse box...

Page 30: ...28 SAFETY Location of Safety and Vehicle Information Labels See page 29 for decal type and description G H I...

Page 31: ...f Safety and Vehicle Information Labels 49 State Models Location G TIRE SAFETY Location H EMISSION CONTROL INFORMATION California Models with catalyst Location I PATENT NOTICE LH Rear of subframe down...

Page 32: ...he vehicle and engine identification numbers model number and ignition key number Handlebar Components 1 Clutch Cable 2 Indicator Lamps 3 Front Brake Fluid Reservoir 4 Right Handlebar Switch 5 Right M...

Page 33: ...r 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 Oil Drain Plug...

Page 34: ...e 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 Sprocket under co...

Page 35: ...d the vehicle identification number to title register license or insure the motorcycle or to order replacement parts SAE assigned World Manufacturing Identifier Chassis C KINGPIN G VEGAS N ANSS T Tour...

Page 36: ...r of the crankcase 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 Numbe...

Page 37: ...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 42 you can st...

Page 38: ...ortion 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 to...

Page 39: ...r VICTORY dealer The tachometer reports current engine speed in revolutions per minute RPM A red line on the gauge indicates maximum safe engine RPM Do not operate the engine over 5600 RPM Excessive R...

Page 40: ...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 41: ...engine 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...

Page 42: ...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 43: ...switch in toward the housing when in the centered position Horn Button 4 To sound the horn press the horn button Clutch Lever 5 To disengage the clutch pull the clutch lever toward the handlebar To e...

Page 44: ...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 45: ...dures see Starting the Engine page 64 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 46: ...ft to a higher gear lift up on the toe shift pedal For proper gear shifting procedure see Shifting Gears page 66 Rear Brake Pedal 2 The rear brake pedal is on the right side of the motorcycle To engag...

Page 47: ...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 48: ...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 49: ...service information in the maintenance section of this manual in the VICTORY Service Manual P N 9918961 or from an authorized VICTORY dealer During the pre operation check you might use products that...

Page 50: ...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 51: ...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 52: ...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 53: ...our 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...

Page 54: ...tire pressure table on page 114 Tire Condition Inspect the tire sidewalls road contact surface and tread base for cuts punctures and cracking Replace damaged tires immediately see the VICTORY Service...

Page 55: ...the lever 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 un...

Page 56: ...y and should return to its rest position quickly when you release it You should feel a firm resistance in the pedal within the first 3 8 inch 8 mm of pedal travel Check Rear Brake Fluid Level 1 To che...

Page 57: ...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 58: ...d the lever housing 3 Adjust clutch lever freeplay if necessary see page 104 NOTE The starter interlock switch is dependent on the clutch lever free play being set correctly to ensure activation of th...

Page 59: ...on 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 or around the fork seal Check Steerin...

Page 60: ...t amount of suspension travel and ground clearance see page 92 Inadequate ground clearance could allow components to come into contact with the ground causing loss of control WARNING Check Drive Belt...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...sert Overfilling the fuel tank may cause fuel to overflow when it expands Fuel may leak from an improperly seated fuel cap Be sure the fuel cap properly seated and locked before starting the engine WA...

Page 66: ...ghtness 2 Insert the ignition key into the ignition switch and turn the switch to the ON position see page 35 3 Mount the motorcycle and bring it to an upright position Engage the front brake and plac...

Page 67: ...s at any one time NOTE If either the 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 38 or Low O...

Page 68: ...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 69: ...68 8 With a quick motion simultaneously close the throttle completely and disengage the clutch 9 Raise the shift pedal with your toe or if your motorcycle is equipped with a heel toe shift pedal you...

Page 70: ...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 71: ...ding to the instructions in Shifting Gears page 66 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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...R R R R Air FIlter 84 I I R I R I R I R I R I R I R I R I R I R Drive Sprocket Nut 85 I I I Drive Belt 86 I I I I I I I I I I I I R I I I I I I I I Rear Wheel Alignment 89 I I I I I I I I I I I Rear S...

Page 79: ...Control System California Only 98 I I I I I I I I I I I Fuel Filter 99 R R Fast Idle Lever 100 I I L I L I L I L I L Throttle 101 I I I I L I I I L I I I L I I I L I I I L Clutch Lever 102 I I L I L...

Page 80: ...ear Shift Pedal 113 I I L I L I L I L I L Tires 114 I I I I I I I I I I I I I I I I I I I I I Wheel Spokes 116 I I I I I I I I I I I Spark Plugs 118 I I I I I I R I I I I Engine Compression 117 I I I...

Page 81: ...79 MAINTENANCE MAINTENANCE RECORD MAINTENANCE PERFORMED MILES KM NOTES PERFORMED BY...

Page 82: ...80 MAINTENANCE MAINTENANCE RECORD MAINTENANCE PERFORMED MILES KM NOTES PERFORMED BY...

Page 83: ...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 84: ...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 85: ...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 86: ...nd air filter element using the universal tool provided under the left side cover see page 122 2 To remove debris from the element use low pressure air and blow from the rear forward Wear eye and face...

Page 87: ...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 o...

Page 88: ...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 89: ...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 90: ...osen the rear axle nut A 2 Insert theuniversal tool seepage 122 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 91: ...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 92: ...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 93: ...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 94: ...5 8 to 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...

Page 95: ...easure 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 s...

Page 96: ...om 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 adjust...

Page 97: ...of wood or steel placed securely under 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 ax...

Page 98: ...mes The front suspension 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...

Page 99: ...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 100: ...ss or 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...

Page 101: ...the fuel tank reverse the removal steps routing fuel line to the right of breather hose 8 Reinstall the fuel tank mounting screws Torque 35 ft lbs 47 5 Nm 9 Reinstall the seat Replace Fuel Filter The...

Page 102: ...ecessary remove seat page 120 and fuel tank page 98 3 Loosen the fast idle cable adjuster jam nut B 4 Turn the cable adjuster in or out until the fast idle lever freeplay is 1 8 1 4 inch 3 6 mm 5 Tigh...

Page 103: ...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 104: ...return to its rest position quickly when released 2 Clutch freeplay the amount of clutch lever movement from the rest position to the point of cable resistance should be between 0 010 0 030 inch 25 75...

Page 105: ...4 Remove clutch lever pivot nut and 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 and...

Page 106: ...adjuster 3 while holding cable 3 Turn the cable adjuster in or out until the clutch freeplay A is 010 030 inch 25 75 mm 4 Tighten the adjuster jam nut 2 securely while holding cable 1 5 Reinstall rig...

Page 107: ...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 108: ...Front Brake Lever 1 Remove right side mirtror brake lever pivot nut and pin 2 Remove any old grease and dirt from the brake lever and lever housing 3 Lubricate the brake lever and lever pivot pin wit...

Page 109: ...r above the sight glass Add brake 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 th...

Page 110: ...enough brake fluid to bring the level just above the sight glass Check Rear Brake Pedal Freeplay and Movement Rear brake pedal freeplay the amount of brake pedal movement from the rest position to th...

Page 111: ...ator rod and loosen the lock nut 3 3 Rotate the actuator rod as necessary to achieve the correct brake pedal freeplay 4 Tighten thelock nut securely and verify that therear wheel rotates freely withou...

Page 112: ...g the motorcycle to a vertical position with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame 2 Remove the right side cover 3 Wipe the area around the reservo...

Page 113: ...m seals resulting in the brakes malfunctioning WARNING 6 Carefully add enough brake fluid to bring the level between MIN and MAX 7 Reinstall the reservoir gasket and cover 8 Reinstall the side cover I...

Page 114: ...ke Disc Visually inspect 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...

Page 115: ...y 3 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 shif...

Page 116: ...g check the tire pressure before you ride Adjust tire pressure as required for the total weight of your intended load Tire Pressure Table KINGPIN Up to 200 lbs 91 kg load 200 465 lbs 91 211 kg load FR...

Page 117: ...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 118: ...grasp each spoke and try to move it side to side or up and down All spokes should be equally tight and have the same amount of flex Tighten loose spokes or replace bent broken or missing spokes see an...

Page 119: ...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 120: ...from 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 sp...

Page 121: ...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 122: ...loss of control WARNING 1 Remove the right 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 Lif...

Page 123: ...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 124: ...damage or injury Caution 4 Slide the battery out Universal Tool A The universal tool is located in a holder under the left side cover The universal tool can be used to service the following items Oil...

Page 125: ...to 16 parts water Rinse with clean water and wipe dry Apply a thin film of dielectric grease to the posts and cable connectors 2 Following the charger manufacturer s instructions use a battery charger...

Page 126: ...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 127: ...einstall 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 bracke...

Page 128: ...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 129: ...nd face when released WARNING 3 Remove the sidestand pivot bolt and remove the sidestand return spring 4 Wipe any old grease and dirt from the sidestand frame and pivot bolt 5 Lubricate the sidestand...

Page 130: ...mm see page 92 before adjusting headlight 3 Straddle the motorcycle 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...

Page 131: ...d strength immediately Road Test Before returning the motorcycle to regular use road test it in a safe environment Pay special attention to the proper fit and operation of all serviced components Make...

Page 132: ...130 MAINTENANCE NOTES...

Page 133: ...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 134: ...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 135: ...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 136: ...shing 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 abrasives that may damage the finish...

Page 137: ...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 138: ...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 139: ...rea Preparation 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 b...

Page 140: ...ervice 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 plug Wear fac...

Page 141: ...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 123 Par...

Page 142: ...e change the engine oil and filter see page 81 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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ...Gasoline containing 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 Spec...

Page 154: ...26 5 in 67 3 cm Wheelbase 65 6 in 167 cm Ground Clearance 5 8 in 14 8 cm Rake Trail 32 8 5 43 in 13 8 cm Weight Dry Weight 639 lbs 290 kg Wet Weight 685 lbs 311 kg Gross Vehicle Weight Rating GVWR 11...

Page 155: ...al Staggered Lubrication System Wet Sump Spark Plug Gap NGK CPR6EA 9 032 in 0 8 mm Chassis Front Suspension Type Travel Inverted Telescopic Fork 5 1 in 13 cm Rear Suspension Type Travel Single Monotub...

Page 156: ...Mesh Primary Drive Gear With Torque Compensator Primary Reduction Ratio 1 5 1 Gear Shift Pattern 1 Down 4 Up Internal Gear Ratios 1st 3 2 1 2nd 2 19 1 3rd 1 53 1 4th 1 24 1 5th 1 1 Final Drive Ratio...

Page 157: ...ternator 38 Amp Max Output Battery 12 Volts 18 Amp Hour Lights and Fuses Fuses Engine ECM 15 amp Fuel Pump 10 amp Headlamp Brake Lamp 15 amp Tail Lamp Flashers Indicator Lamps Horn 15 amp Ignition Gau...

Page 158: ...d see page 33 Engine Identification Number ________________________________________ Located on top of crankcase behind rear cylinder see page 34 Ignition Key Number ___________________________________...

Page 159: ...31 32 Components Handlebar 30 Control Cable Lubrication 105 Crankcase Ventilation Hose 98 D Defects 23 Drive Belt 58 86 88 Drive Belt Condition 86 Drive Belt Tension 86 88 Drive Sprocket 85 Drive Spr...

Page 160: ...trument Cluster 36 INSTRUMENTS FEATURES AND CONTROLS 35 46 INTRODUCTION 5 L Low Fuel Indicator 39 Low Oil Pressure Indicator 39 M MAINTENANCE 74 130 Maintenance 22 Maintenance Interval Table 76 78 Mai...

Page 161: ...CONTENTS 4 Tachometer Optional 37 Taillight Brake Light 48 Test Drive 129 Throttle 101 Throttle Control Cable 101 Throttle Control Cables 55 Throttle Control Grip 43 55 101 Throttle Freeplay Adjustmen...

Page 162: ...For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9919167 Printed in USA...

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