Victory Motorcycles Touring Cruiser 2003 Owner'S Manual Download Page 128

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126

MAINTENANCE

Brakes

Check Brake Pads

Look into the front brake caliper(s) from underneath, and into the

rear brake caliper from behind, you should see at least 1/16 inch (1.6

mm) of friction material on each of the brake pads. If in doubt,

measure remaining friction material. Replace brake pads having less

than the specified amount of friction material at their thinnest point.
If the brake pads require replacement, see the

Victory Service

Manual

or an authorized Victory dealer for assistance.

Check Brake Hoses and Connections

Inspect all brake hoses and connections for dampness or stains from

leaking or dried fluid. Tighten any leaking connections and replace

components as necessary.

1. Front Brake Pad

Friction Material

2. Rear Brake Pad

Friction Material

Summary of Contents for Touring Cruiser 2003

Page 1: ......

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: ...he same or similar changes to motorcycles previously built Victory Motorcycle Division Polaris Industries Inc 2100 Highway 55 Hamel Minnesota 55340 9800 Tele 763 542 0500 Fax 763 542 0599 CopyrightE 2...

Page 5: ...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 authorized Victory dealer ca...

Page 6: ...TENTS 4 INTRODUCTION 5 SAFETY 6 COMPONENT IDENTIFICATION 37 INSTRUMENTS FEATURES AND CONTROLS 45 PRE OPERATION CHECK 64 OPERATION 78 MAINTENANCE 92 CLEANING 148 STORAGE 154 WARRANTIES 158 SPECIFICATIO...

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: ...e operating 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 Foundati...

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 famil iar with its controls and operation S Do not ride whe...

Page 12: ...ur hands on 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 influe...

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: ...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 mot...

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 automo...

Page 16: ...additional cargo on the motorcycle S The weight of the operator or passenger includes body weight all apparel and objects in or on apparel Do not exceed the motorcycle s gross vehicle weight rating Ex...

Page 17: ...ting 1150 lbs 522 kg Item Weight Classic Cruiser with full capacity of all fluids 675 lbs 306 kg Weight of Touring package 33 lbs 15 kg Cargo optional saddlebags at capacity 14 lbs 6 kg Operator with...

Page 18: ...g 1210 lbs 549 kg Item Weight Touring Cruiser with full capacity of all fluids 759 lbs 344 kg Weight of Touring package 11 lbs 5 kg Cargo saddlebags at capacity 20 lbs 9 kg Operator with recommended r...

Page 19: ...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 20: ...each S Do not exceed the motorcycle s gross vehicle weight rating Exceeding the weight rating can reduce stability and handling and cause loss of control Transporting the Motorcycle If you must transp...

Page 21: ...stible materials 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 fol...

Page 22: ...sition Limit suspension or steering travel or your ability to operate controls Displace you from your normal riding position Obscure lights or reflectors S Bulky or large accessories can cause instabi...

Page 23: ...e 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 sw...

Page 24: ...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 25: ...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 26: ...24 SAFETY Location of Safety and Vehicle Information Labels Classic Cruiser B D A C Refer to page 25...

Page 27: ...ormation Labels Classic Cruiser Location A Information on this decal will vary by model features and options Refer to actual decal on the vehicle Location B Location C Location D U S Models Location D...

Page 28: ...26 SAFETY Location of Safety and Vehicle Information Labels Classic Cruiser A C D B Refer to page 27...

Page 29: ...Location D on left crankcase half Location C in fuse box cover HEADLAMP RELAY RELAIS DE PHARE PCM DIODE PCM RELAY RELAIS DE PCM FUEL PUMP RELAY RELAIS DE POMPE CARBURANT HORN BRAKE HEADLAMP KLAXON FR...

Page 30: ...28 SAFETY Location of Safety and Vehicle Information Labels Classic Cruiser Shown with options A C B Refer to page 29...

Page 31: ...29 SAFETY Location of Safety and Vehicle Information Labels Classic Cruiser Location A Location B Inside Saddlebag Location C...

Page 32: ...30 SAFETY Location of Safety and Vehicle Information Labels Touring Cruiser A B C D Refer to page 31...

Page 33: ...ormation Labels Touring Cruiser Location A Information on this decal will vary by model features and options Refer to actual decal on the vehicle Location B Location C Location D U S Models Location D...

Page 34: ...32 SAFETY Location of Safety and Vehicle Information Labels Touring Cruiser Shown with options S Deluxe Touring Cruiser only Deluxe Touring Cruiser only A B C D Refer to page 33...

Page 35: ...33 SAFETY Location of Safety and Vehicle Information Labels Touring Cruiser Location C Inside Saddlebag Location B Both Sides Location A Location D...

Page 36: ...34 SAFETY Location of Safety and Vehicle Information Labels Touring Cruiser C D B A...

Page 37: ...on D On Left Crankcase Half Location C In Fuse Box Cover HEADLAMP RELAY RELAIS DE PHARE PCM DIODE PCM RELAY RELAIS DE PCM FUEL PUMP RELAY RELAIS DE POMPE CARBURANT HORN BRAKE HEADLAMP KLAXON FREINS PH...

Page 38: ...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 39: ...icle and engine identification numbers model number and ignition key number Handlebar Components 1 Clutch Cable 2 Instrument Cluster 3 Fuel Cap 4 Front Brake Fluid Reservoir 5 Right Mirror 6 Throttle...

Page 40: ...de cover 9 Operator s Seat 10 Seat Strap 11 Passenger s Seat 12 Rear Brake Caliper 13 Rear Turn Signal 14 Taillight 15 Rear Axle Adjuster 1 each side 16 Horn 17 Passenger s Foot Rest 18 Oil Filter 19...

Page 41: ...p Dipstick 9 Headlamp 10 Steering Lock 11 Front Turn Signal Running Light 12 Front Fork 13 Oil Cooler 14 Rear Brake Pedal 15 Operator s Foot Rest 16 Engine Oil Drain Plug under engine 17 Rear Brake Fl...

Page 42: ...Steering Lock 8 Front Turn Signal Running Light 9 Front Fork 10 Oil Cooler 11 Rear Brake Pedal 12 Operator s Foot Rest 13 Engine Oil Drain Plug under engine 14 Drive Sprocket under cover 15 Rear Brake...

Page 43: ...ark Plug 2 8 Ignition Switch 9 Side Cover 10 Battery under side cover 11 Seat one piece 12 Lockable Hard Saddlebags 13 Rear Turn Signal 14 Taillight 15 Exhaust Muffler 16 Rear Brake Caliper 17 Horn 18...

Page 44: ...vehicle identification number to title register license or insure the motorcycle or to order replacement parts 5VPCB16D032000000 SAE assigned World Manufacturing Identifier Chassis C Classic T Touring...

Page 45: ...ight 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 identificatio...

Page 46: ...44 NOTES...

Page 47: ...the motorcycle The steering lock is on the right side of the steering head To lock the steering turn the handlebars fully to the left and open the lock cover Insert the key and turn it clockwise To u...

Page 48: ...position and remove the ignition key when leaving the motorcycle unattended On Position In the ON position all electrical circuits are energized and the ignition key cannot be removed The headlamp ru...

Page 49: ...ignition key into the ignition switch seat release and turn the key counterclockwise Helmet Holders Classic Cruiser The helmet holders are a secure place to store your helmet while the motorcycle is p...

Page 50: ...h Beam Indicator 4 Low Fuel Indicator 8 Multi Function Display MFD Speedometer The speedometer reports current motorcycle speed in miles per hour or kilometers per hour Tachometer The tachometer repor...

Page 51: ...gnition switch is in the ON position and the engine is not running This demonstrates that the indicator is functioning properly Low Fuel Indicator The low fuel indicator illuminates when approximately...

Page 52: ...the right turn signals are active Both turn signal indicators flash when the emergency flashers are active If a turn signal bulb has failed or if there is a short circuit in the turn signal system th...

Page 53: ...ip odometer reading between miles and kilometers and the fuel gauge reading between gallons and liters the ignition switch must be in the ON position with the MFD in odometer mode Press and hold the S...

Page 54: ...ur 3 Press the MODE button to accept the new hour setting The ten minute digit should flash 4 Press the SET button to select the desired ten minute 5 Press the MODE button to accept the new ten minute...

Page 55: ...indicator light dimmer mode To change the intensity of the headlamp high beam indicator light press the SET button to select from four 4 intensity levels The engine does not need to be running to cha...

Page 56: ...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 If the check...

Page 57: ...METER METRIC ENGLISH RESET TRIP ODOMETER 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 ALTERNAT...

Page 58: ...the switch to activate the low beam press the lower portion of the switch To activate the momentary passing beam press and hold the lower portion of the switch Turn Signal Switch The turn signal swit...

Page 59: ...ch operation pull the lever quickly and release it gradually Notice The motorcycle is equipped with a clutch interlock switch that prevents the engine from starting when the transmission is in gear an...

Page 60: ...Emergency Flasher Switch The emergency flasher switch activates and cancels the emergency flashers When the emergency flashers are active all of the turn signals flash To activate the emergency flash...

Page 61: ...e 88 Throttle Control Grip The throttle control grip controls the engine speed To increase engine speed twist the throttle control grip toward you to decrease engine speed twist the grip away from you...

Page 62: ...a higher gear press down on the rear or lift up on the front of the gear shift pedal For proper gear shifting procedure see Shifting Gears on page 84 Rear Brake Pedal The rear brake pedal is on the r...

Page 63: ...cap clockwise to align the Victory logo if desired For fueling procedure see Fueling and Fill Height page 81 Auxiliary Light Switch Touring Cruiser A toggle switch located under the left side of the...

Page 64: ...ard Touring Cruiser models are equipped with lockable hard saddlebags Use the ignition key to lock or unlock the saddlebag Each saddlebag has a net for small cargo The load carrying capacity for locka...

Page 65: ...ing grommets then remove cover from the motorcycle Reverse this procedure to install the side cover Sidestand The sidestand is located on the left side of the motorcycle Correctly retract the sidestan...

Page 66: ...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 67: ...e If the transmission is in neutral the neutral indicator should remain illuminated Pressing the MFD MODE button should advance the MFD through the various functions see page 51 Headlamp Check the hea...

Page 68: ...procedure for the right turn signals Emergency Flashers Slide the emergency flasher switch to the left All four turn signals and both turn signal indicators in the instrument cluster should flash Slid...

Page 69: ...e oil fill cap 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 bring...

Page 70: ...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 rail...

Page 71: ...r to the tire pressure table on page 128 Tire Condition Inspect the tire sidewalls road contact surface and tread base for cuts punctures and cracking Replace damaged tires immediately see the Victory...

Page 72: ...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 73: ...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 4 inch 19 mm of pedal travel Check Rear Brake Fluid Level 1 To che...

Page 74: ...rake pads If in doubt measure the remaining friction material Replace brake pads having less than the specified amount of friction material at their thinnest point Check Throttle Control Grip and Cabl...

Page 75: ...h 5 1 0 mm Measure the thickness of the gap between the clutch lever and the lever housing 3 Adjust clutch lever freeplay if necessary see page 118 Check Fast Idle Lever 1 Move the fast idle lever It...

Page 76: ...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 77: ...cycle has the correct amount of suspension travel and ground clearance see page 107 Inadequate ground clearance could allow components to come into contact with the ground causing loss of control WARN...

Page 78: ...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 79: ...77 NOTES...

Page 80: ...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 81: ...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 82: ...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 83: ...ller insert Overfilling the fuel tank may cause fuel to overflow when it expands Fuel may leak from an improperly seated or tightened fuel cap Tighten the fuel cap until you hear one or more distinct...

Page 84: ...o restraints for tightness 3 Insert the ignition key into the ignition switch and turn the switch to the ON position see page 46 4 Mount the motorcycle and bring it to an upright position Engage the f...

Page 85: ...t 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 on page 54 or Low O...

Page 86: ...in the illustration to the right The motorcycle has a heel toe shift pedal which allows you to shift to a higher gear by depressing the rear of the pedal with your heel or by lifting the front of the...

Page 87: ...see Recommended Shift Points on page 86 With a quick motion simultaneously close the throttle completely and disengage the clutch Raise the shift pedal with your toe or depress it with your heel until...

Page 88: ...torcycle 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 you enter...

Page 89: ...ng to the instructions in Shifting Gears on page 84 The more quickly you open the throttle the more quickly the motorcycle accelerates Abrupt acceleration can cause your body to shift suddenly toward...

Page 90: ...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 91: ...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 92: ...perating the motorcycle with the forks locked severely restricts steering and can cause loss of control WARNING If you must park on a slope point the motorcycle toward the top of the slope Put the tra...

Page 93: ...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 94: ...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 95: ...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 96: ...ir FIlter page 100 I I R I R I R I R I R I R I R I R I R I R Drive Sprocket and Sprocket Nut page 101 I I I Drive Belt page 102 I I I I I I I I I I I I R I I I I I I I I Rear Wheel Alignment page 105...

Page 97: ...ssion Con trol System Calif Only page 112 I I I I I I I I I I I Fuel Filter page 113 R R Fast Idle Lever page 114 I I L I L I L I L I L Throttle page 115 I I I I L I I I L I I I L I I I L I I I L Clut...

Page 98: ...8 I I I I I I I I I I I I I I I I I I I I I Wheel Spokes page 130 I I I I I I I I I I I Spark Plugs page 131 I I I I I I R I I I I Engine Compression page 133 I I I I I I Exhaust System page 133 I I I...

Page 99: ...eal and reinstall the drain plug Torque 20 ft lbs 27 Nm 7 Clean any residue or debris from the oil filter mounting plate and threads 8 Make sure the new oil filter gasket is properly seated in the oil...

Page 100: ...ut Revving the engine while the low oil pressure indicator is illuminated can damage the engine Caution 11 Stop the engine and make sure there are no leaks around the drain plug and oil filter Check t...

Page 101: ...s 2 Remove the dipstick again and note the oil level 3 If necessary add or remove oil to bring the level into the area on the dipstick above the ADD mark and below the FULL mark see page 67 Repeat ste...

Page 102: ...1 Remove the air filter access cover and the air filter element 2 To remove debris from the element use low pressure air and blow from the rear forward Wear face protection when using pressurized air...

Page 103: ...th a new sprocket nut if necessary 5 Clean the output shaft threads and the sprocket nut threads 6 Apply a few drops of Loctite Thread Locker 262 or equivalent to the output shaft threads 7 Apply the...

Page 104: ...sing 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 dry and at room temperature S...

Page 105: ...nd 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 tensio...

Page 106: ...l amount until the drive belt tension is correct see Check Drive Belt Tension page 102 making sure the adjusters are firmly seated against the axle spacers 3 Tighten the adjuster jam nuts Torque 12 ft...

Page 107: ...l placed securely under the frame 2 Remove the swing arm pivot caps and install the rear wheel alignment tool on the right side of the motorcycle 3 Measure and record the distance from the tip of the...

Page 108: ...the rear wheel forward to keep the axle spacers seated against the axle adjusters 8 Reinstall the swing arm pivot caps 9 Check and adjust drive belt tension see page 102 10 Hold the axle adjusters in...

Page 109: ...g procedure 1 Elevate the rear of the motorcycle until the rear wheel is about 1 inch 2 5 cm off of the ground Use an appropriate motorcycle lift or a block of wood or steel placed securely under the...

Page 110: ...sure the suspension moves freely without binding 7 Without moving the motorcycle have your assistant measure the distance from the center of the rear axle to the bottom of the rear fender directly ab...

Page 111: ...aced 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 axle see the Victory...

Page 112: ...thly 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 Replace Front Fork Oil Front fork o...

Page 113: ...steering head bearings should be inspected lubricated and adjusted see the Victory Service Manual or an authorized Victory dealer Notice The steering head bearings require periodic lubrication even i...

Page 114: ...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 Al...

Page 115: ...the removal steps routing fuel line under breather hose 8 Reinstall the fuel tank mounting screws Torque 20 ft lbs 27 Nm 9 Reinstall the seat Replace Fuel Filter The fuel filter is attached to the el...

Page 116: ...nt from the rest position to the point of cable resistance should be 1 8 1 4 inch 3 6 mm 3 Adjust fast idle lever freeplay if necessary Adjust Fast Idle Lever Freeplay 1 Remove the operator s seat 2 R...

Page 117: ...inch 3 6 mm 3 Adjust throttle freeplay if necessary Adjust Throttle Freeplay 1 Slide the rubber covers off both cable adjusters and loosen both adjuster jam nuts 2 Turn both cable adjusters into the...

Page 118: ...d 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 02 0 04 inch 5 1 m...

Page 119: ...le adjuster and loosen the adjuster jam nut 5 Turn the cable adjuster all the way in 6 Remove clutch lever pivot nut and screw 7 Disconnect the clutch cable from the clutch lever 8 Remove any old grea...

Page 120: ...cover off the cable adjuster and loosen the adjuster jam nut 5 Turn the cable adjuster in or out until the clutch freeplay is 0 02 0 04 inch 5 1 0 mm 6 Tighten the adjuster jam nut and reinstall the r...

Page 121: ...Lever Cable S Seat Release Cable Classic Cruiser 1 Loosen the adjuster 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...

Page 122: ...If the brake lever travels too far before beginning to engage the brake see the Victory Service Manual or contact an authorized Victory dealer for service Lubricate Front Brake Lever 1 Remove brake l...

Page 123: ...el in or 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...

Page 124: ...ight 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 the point of c...

Page 125: ...the brake pedal freeplay Check 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 flu...

Page 126: ...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 127: ...ould 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 sea...

Page 128: ...brake pads having less than the specified amount of friction material at their thinnest point If the brake pads require replacement see the Victory Service Manual or an authorized Victory dealer for...

Page 129: ...sary 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 s...

Page 130: ...Dunlop 491 Elite II MT90 B16 71H 34 psi 235 kpa 40 psi 275 kpa REAR Dunlop D417 160 80 B16 75H 36 psi 250 kpa 41 psi 280 kpa Touring Cruiser Up to 200 lbs 91 kg load 200 449 lbs 91 204 kg load FRONT D...

Page 131: ...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 132: ...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 authorized...

Page 133: ...arkedly different 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...

Page 134: ...If 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 CR7EB or equivale...

Page 135: ...or 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 header fl...

Page 136: ...eck all exhaust system fasteners 1 Tighten exhaust header flange nuts Torque 12 ft lbs 16 Nm 2 Tighten muffler clamps Torque 45 ft lbs 61 Nm 3 Tighten muffler mounting screws Torque 18 ft lbs 24 Nm 4...

Page 137: ...seat mounting screws are located at the front of the seat Removing the passenger seat is unnecessary for regular maintenance 4 To reinstall the operator s seat slide the tongue of the seat into the pa...

Page 138: ...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 139: ...sconnect the positive cables cable ends are covered with a red boot Disconnecting the positive cable first can produce an electric shock that could result in damage or injury Caution 4 Slide the batte...

Page 140: ...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 charge...

Page 141: ...ten 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 can produce an electric shock...

Page 142: ...ed fuse from the fuse box and seat the new fuse firmly in its place 4 Reinstall the fuse box cover with the double cutout toward the front of the motorcycle The fuse box decal should be readable from...

Page 143: ...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 remove...

Page 144: ...cle in an upright position and sit in the operator s seat 3 Set the ignition switch to the ON position and turn the auxiliary lights on Check the auxiliary lights for correct aim 4 To adjust the light...

Page 145: ...gs 1 Remove the screws washers and spacers from inside the saddlebag and remove the saddlebag from the motorcycle 2 To reinstall the saddlebag return all spacers and fasteners to their original locati...

Page 146: ...arness connector 3 Disconnect the wiring harness connector 4 Disengage bracket on bottom of bag from muffler bracket and remove bag 5 To reinstall the saddlebag engage bottom of bag into bracket on mu...

Page 147: ...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 148: ...pring Wear face protection The sidestand return spring is under tension and can injure your eyes and face when released WARNING 3 Remove the sidestand pivot bolt 4 Remove any old grease and dirt from...

Page 149: ...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 150: ...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 151: ...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 152: ...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 153: ...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 abras...

Page 154: ...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 155: ...er 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 saddlebag 2...

Page 156: ...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 157: ...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 158: ...rgent 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 Charge Battery page 138 P...

Page 159: ...oil and filter see page 97 beginning with step 2 During storage temperature and humidity changes can cause condensation to form in the crankcase and mix with engine oil Running the engine with oil th...

Page 160: ...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 161: ...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 162: ...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 163: ...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 164: ...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 165: ...SE THE VICTORY MOTOR CYCLE 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 166: ...erformance 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 maint...

Page 167: ...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 168: ...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 169: ...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 170: ...63 3 in 161 cm 65 5 in 166 cm Ground Clearance 5 5 in 14 cm 5 5 in 14 cm Rake Trail 30 0 4 76 in 12 1 cm 30 0 6 89 in 17 5 cm Weight Dry Weight 634 lbs 288 kg 720 lbs 326 6 kg Wet Weight 675 lbs 306 2...

Page 171: ...cu in 1507 cc Cooling System Air Oil Air Oil Compression Ratio 9 2 1 9 2 1 Valve Train 4 Valves Per Cylinder With Hydraulic Lifters 4 Valves Per Cylinder With Hydraulic Lifters Bore and Stroke 97 x 10...

Page 172: ...1 1 1 Final Drive Ratio 2 13 1 2 13 1 Clutch Type Wet Multi Plate Diaphragm Spring Wet Multi Plate Diaphragm Spring Chassis Front Suspension Type Travel Telescopic Fork 5 1 in 13 cm Telescopic Fork 5...

Page 173: ...pe Size Dunlop D417 160 80B 16 75H Dunlop D417 160 80 B16 75H 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 Ignitio...

Page 174: ...G METHANOL Using gasoline methanol blends can result in poor starting and driveability and may damage critical fuel system components Gasoline containing up to 15 Methyl Tertiary Butyl Ether MTBE can...

Page 175: ...Specifications Polaris recommends the use of Victory Brand Semi Synthetic 20W 40 Motor Oil or equivalent Service Manual Available You can purchase a genuine 2003 Victory Service Manual through your de...

Page 176: ...d see page 42 Engine Identification Number ________________________________________ Located on top of crankcase behind rear cylinder see page 43 Ignition Key Number ___________________________________...

Page 177: ...er Lubrication 117 Components Classic Cruiser 38 39 Components Touring Cruiser 40 41 Control Cable Lubrication 119 Crankcase Ventilation Hose 112 D Defects 36 Drain Plug 97 Drive Belt 75 102 104 Drive...

Page 178: ...lders 47 Horn 66 Horn Button 57 Hoses and Connections 72 I Ignition Key 45 Ignition Key Number 43 Ignition Switch 46 47 Indicator Lights 49 50 Initial Maintenance 93 Instrument Cluster 48 65 Instrumen...

Page 179: ...45 Spark Plugs 131 132 Speedometer 48 Starter Button 58 Starting the Engine 82 83 Steering 74 110 111 Steering Lock 45 Stop Run Switch 58 66 Stopping the Engine 89 Suspension Front 74 110 111 Suspensi...

Page 180: ......

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Victory Motorcycles Touring Cruiser 2003, Owner'S Manual

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