Victory Motorcycles Classic Cruiser 2002 User manual

2002 - 2004 SERVICE MANUAL
Part Number 9918960
Foreword
This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept
available for reference in the shop area. All references to left and right side of the motorcycle are from the operator’s
perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures
in order to perform the work safely and correctly. Read the text and be familiar with the service procedures before starting
the work. Certain procedures will require the use of special tools. Use only the proper tools as specified.
This manual includes procedures for maintenance, component identification and repair, along with service specifications
for Victory Classic Cruiser and Touring Cruiser motorcycles. Comments or suggestions aboutthis manual may be directed
to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina, Minnesota 55340.
2002 - 2004 Victory Standard, Deluxe, Classic, and Touring Cruiser Service Manual PN9918960.
Refer to page 1.6 for Owner’s Manual, Parts Book, and Microfiche part numbers.
E2003 Polaris Industries. All information contained in this publication is based on the latest product information available at the time of
publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and /or procedures in this publication are intended
for reference use only. No liability can be accepted for omissions or inaccuracies in this publication. Any reprinting or reuse of the depictions
and/or procedures contained in this publication is expressly prohibited. Printed in U.S.A.

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

UNDERSTANDING SAFETY LABELS & INSTRUCTIONS 1.1...............
DANGER, WARNINGS, & CAUTION SYMBOLS 1.1.......................
GENERAL SAFETY / SERVICE RULES 1.2..............................
VICTORY TOUCH UP PAINT AND REFINISHING KITS 1.3.................
VICTORY PAINT COLORS AND PAINT CODES 1.4.......................
VEHICLE IDENTIFICATION NUMBER (VIN) 1.5...........................
KEY 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 EMISSION CONTROL 1.7....................................
NOISE EMISSION CONTROL SYSTEM 1.7..............................
EVAPORATIVE EMISSION CONTROL CONTROL (CA MODELS) 1.7.......
CRANKCASE EMISSION CONTROL 1.7.................................
MULTI-FUNCTION DISPLAY (MFD) 1.8..................................
MFD FUNCTION FLOW CHART 1.10.....................................
SPECIAL SERVICE TOOLS 1.11.........................................
CABLE & HARNESS ROUTING 1.14......................................

GENERAL
1.1
TRADEMARKS
Victory acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shocks
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
UNDERSTANDING SAFETY LABELS & INSTRUCTIONS
DANGER, WARNINGS, & CAUTION SYMBOLS
This is the safety alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury. Your safety is involved!
Indicates a potential hazard which could result in severe injury or
death.
Indicates a potential hazard which may result in minor personal
injury or damage to the motorcycle.
NOTE:
The word “NOTE:” in this manual will alert you to key information
or instructions.
Indicates a situation that can result in damage to the motorcycle.
Gasoline is extremely flammable and explosive under certain
conditions.
SAlways stop the engine and refuel outdoors or in a
well ventilated area.
SDo not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
SDo not overfill the tank. Do not fill the tank neck above
the fuel tank insert. Leave air space to allow for fuel
expansion.
SIf you get gasoline in your eyes or if you swallow
gasoline, see your doctor immediately. Never try to
syphon gasoline using mouth suction.
SIf you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
SNever start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause
loss of consciousness or death in a short time.
The engine exhaust from this product
contains chemicals known to cause cancer,
birth defects or other reproductive harm.
Improper repairs or service can create
unsafe conditions that may cause severe
personal injury or death.
The engine and exhaust components on this
product become very hot during operation
and remain so for a period of time after the
engine is stopped.
Never run the engine in an enclosed area
without a properly functioning exhaust gas
evacuation system connected to the product.
Modifications to this motorcycle not approved
by Victory may cause loss of performance,
excessive emissions, and make the machine
unsafe for use.
Wear insulated protection for hands and
arms or wait until hot components have
cooled sufficiently before working on the
product.
Brake fluid is poisonous.
KEEP OUT OF REACH OF CHILDREN.
Brake fluid is poisonous. Do not ingest or
allow brake fluid to contact eyes. Always
wear eye protection when working with
brake fluid.
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing.
Brake fluid will damage plastic, painted and rubber parts. Protect
these surfaces whenever the brake system is being serviced.

GENERAL
1.2
SERVICE RULES
In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual
and familiarize themselves with the procedures before beginning. Photographs and illustrations have been
included with text as an aid. Notes, Cautions and Warnings have also been included for clarification of text and
safety concerns. Knowledge of mechanical theory, tool use and shop procedures are necessary to perform some
procedures in this manual safely and correctly.
Use only genuine Victory service parts.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act
as an abrasive and cause damage to precision parts. Clean the motorcycle before beginning service. Clean all
parts before installing.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or in the case of steering, driveline, and chassis components, can result in loss of control during
operation of the motorcycle, resulting in injury or death.
If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners in their
holes and hand tighten. Following the method and sequence indicated, tighten evenly to the specified torque value.
When removing nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn
before removing them to prevent distortion of that component.
If 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 are clean and smooth to avoid leaks and maintain specified tolerances.
Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts,
therefore, they should always be replaced with new parts. When installing new retaining rings and clips, use care
not to expand or compress them beyond what is required for installation.
Because removal damages seals, always replace with new seals during a repair.
Victory lubricants and greases have been specially formulated to provide maximum performance and
protection when applied properly. In some applications, warranty coverage may be void if improper lubricants are
used.
Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly.
Deteriorating grease loses lubricity and may contain abrasive foreign matter.
WARNING
Working with Batteries
SWhen removing or installing batteries, care should be taken to avoid the possibility of explosion
resulting in serious burns. Remove battery from the motorcycle before charging. Keep battery away
from the source of any combustion (sparks, fire, etc..) when charging.
SAlways disconnect the negative (black) cable first and reconnect it last.
SBattery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with
skin, eyes or clothing.
SIN THE EVENT OF CONTACT WITH SULFURIC ACID: External - Flush with water. Internal -Drink
large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call for
medical attention immediately.
SEyes - Flush with water for 15 minutes and call for medical attention immediately.

GENERAL
1.3
VICTORY TOUCH-UP AND REFINISHING PAINT
Service Paint products are available in three different sizes and applications. Some paint colors require up to 3
components to create a color. Prices subject to change without notice. Dealer is responsible for freight on paint
and paint products.
.6 ounce bottle: (Order Multiple of 2) For brush touch--up of small nicks.
10 ounce aerosol can: (Order Multiple of 2)
Apply light even coats for best results. Recoat time is from 30-60 minutes or after 4 days of drying to prevent lifting.
Quarts: (Sold as each)
For repaint of properly prepared plastic components or metal substrates.
Paint is a high quality acrylic urethane manufactured by U.S. Paint.
Mix as indicated on back of paint can. Paint can be recoated after paint is tack free or has ”flashed off”.
Paint finish may be wet sanded and buffed after coating has cured.
Paint is available in a variety of sizes and styles for specific painting needs:
How to order:
Place your order via the dealer web site at : www.polarisdealers.com
Phone Customer Service: 1--800--330--9407
Fax your paint order to 1--866--245--7533 using the supplied paint order form.
Prices subject to change without notice.
Please have your dealer number, telephone number, and Polaris part # to give to the Customer Service Specialist,
or include on the order form. Additional charges may apply for phoned in orders.
Note: There will be a 25% service fee charged for all returns. Polaris dealer will be responsible for return freight.
VICTORY DETAIL AND FINISH RESTORER KITS
A Detail Kit (polish, wax, and dressing) and a Restore Kit (Polish, Swirl, and Scuff remover) is available from the
Victory parts department for painted surface protection and to remove minor surface imperfections.
Detail Kit: 2872195 Restore Kit: 2872192

GENERAL
1.4
VICTORY PAINT COLORS BY MODEL
NOTE: The 8th Position in the model number is a letter that designates the country / region:
C=Canada; D=49State; L=California; U=United Kingdom
The last letter is the color designator. Refer to the chart below for model / color. Paint ordering information is
available on the dealer web site.
MODEL YEAR 2002
Model Number Model Description / Color Model Number Model Description / Color
V02CB16CC,DC,LC,UC Std. Crsr. Cruiser Black V02TB16CC, DC, LC, UC TC Cruiser Black
V02CB16CK,DK,LK,UK Std. Crsr. Solar Red / Stone White V02TB16CO, DO, LO, UO TC Solar Red / Vogue Silver
V02CB16CL,DL,LL,UL Std. Crsr. Speed Yellow / Crs Black V02TB16CP, DP, LP, UP TC Sonic Blue / Vogue Silver
V02CD16CC,DC,LC,UC Dlx. Crsr. Cruiser Black V02TD16CC, DC, LC, UC TC Dlx. Cruiser Black
V02CD16CK,DK,LK,UK Dlx. Crsr. Solar Red / Stone White V02TD16CO, DO, LO, UO TC Dlx. Solar Red / Vogue Silver
V02CD16CL,DL,LL,UL Dlx. Crsr. Speed Yellow / Crs Black V02TD16CP, DP, LP, UP TC Dlx. Sonic Blue / Vogue Silver
V02CD16CM,DM,LM,UM Dlx. Crsr. Sonic Blue / Pearl White V02TD16CQ, DQ, LQ, UQ TC Dlx. Cruiser 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 Description / Color
V03C116 / V03C216 Classic Feature / Option V03T116 / V03T216 TC Feature / Option
V03CB16CA, DA, LA, UA Classic Cruiser Black V03TB16CA, DA, LA, UA TC Cruiser Black
V03CB16CB, DB, LB, UB Classic Sonic Blue V03TB16CB, DB, LB, UB TC Sonic Blue
V03CB16CC, DC, LC, UC Classic Solar Red V03TB16CC, DC, LC, UC, TC Solar Red
V03CB16CD, DD, LD, UD Classic Flame Yellow
MODEL YEAR 2004
Model Number Model Description / Color Model Number Model Description / Color
V04T118 Touring Feature / Option V04TB16CB, DB, LB Touring Sonic Blue
V04TB16CA, DA, LA Touring Cruiser Black V04TB16CC, DC, LC Touring Solar Red
VICTORY PAINT CODES
PAINT COLORS PAINT CODE PAINT COLORS PAINT CODE
Cruiser Black (PHAT) P-266 Pearl White P-352
Indy Red P-293 Cobalt Green P-353
Steel Grey P-302 Vogue Silver P-354
Speed Yellow P-323 Champagne P-355
Sparkle Grey
(Fork Legs, Triple Clamp)
P-339
Sonic Blue P-341 Flame Yellow P-388
Solar Red P-342 Retro Turquoise P-389
Stone White P-351 Daytona Orange P-393
Flame Tank (All Years) paint codes are made up of Indy Red, Stone White, Speed Yellow, and Daytona
Orange

SAE--assigned
World Manufacturing Identifier
Chassis:
C =Kingpin
T = Touring
G = Vegas
N = ANSS
Type:
B = Standard
Engine Size:
1 = 1507 cc
Engine HP:
6 = 78--94
Series:
C = Canada
D = Domestic (49 State)
L = California
U = United Kingdom
Check Digit Model Year:
2=2002, 3 = 2003, 4=2004, etc.
Plant Code
Serial Number
*5VPCB16D032000000*
GENERAL
1.5
VEHICLE IDENTIFICATION NUMBER
MODEL NUMBER
Chassis:
C = Kingpin
T = Touring
G = Vegas
N = ANSS
Color Indicator:
See Chart on page 1.4
Engine HP:
6 = 78--94
Series:
C = Canada
D = Domestic (49 State)
L = California
U = United Kingdom
Model Year:
2 = 2002; 3 = 2003; 4 = 2004; etc.
V04TB16DC
Victory
Type:
B = Standard
D=Deluxe
IGNITION KEY IDENTIFICATION NUMBERS
The key identification number (1) is stamped on the key tag. If the
key and the identification number are lost or misplaced, the lock set
(ignition switch, seat lock (where applicable), and steering lock) must
be replaced.
Key blanks are available from service parts. Locksmiths familiar with
the motorcycle industry will be able to cut a replacement key with the
key I.D. number and a VIctory key blank.
Should the keys and key identification number become lost, the
ignition switch must be replaced.
VEHICLE IDENTIFICATION NUMBER (VIN)
The vehicle identification number (2) is stamped on the front of the
steering head.
MODEL IDENTIFICATION NUMBER
The model label (3) is located on the left side of the steering head.
ENGINE NUMBER DECAL
The engine label (4) is located on top of the crankcase behind the rear
cylinder. This label identifies the engine model and serial number. The
engine serial number is also stamped on the crankcase just to the right
of the oil filter.
1
2
3
4

GENERAL
1.6
BREAK-IN PROCEDURES
There is never a more important period in the life of a new Victory motorcycle than the period between zero and
500 miles (805 km). A Victory motorcycle is manufactured using the best possible materials and manufacturing
techniques, but the final machining process is the break-in. During break-in period, many parts in the engine wear
and polish to correct operating clearances. During this time, the operator should:
SAvoid prolonged full throttle operation.
SAvoid operation which might result in excessive heating of the engine.
The general break-in guidelines are as follows:
BREAK-IN GUIDELINES
Miles/km Throttle
Position
Notes
0-90 miles 0-1/3 Avoid prolonged operation above 1/3 throttle. Stop engine and let it cool following every hour
of operation. Vary speed of motorcycle. Do not operate machine at one set throttle position.
90-300 miles 0-1/2 Avoid prolonged operation above 1/2 throttle. Stop engine and let it cool following every hour
of operation. Vary speed of the motorcycle. Do not operate machine at one set throttle posi-
tion.
300-500 miles 0-3/4 Avoid cruising speeds above 3/4 throttle.
500 miles Replace the engine oil and engine oil filter.Have Victory dealer perform 500 mile service on the ma-
chine. See chapter 2 for more information.
500 + Avoid prolonged full-throttle operation. Vary the engine speed occasionally. Follow the pre-ride inspec-
tion outlined in the owner’s manual.
PUBLICATION PART NUMBERS
The following chart lists the part numbers for Owner’s Manuals, parts books, and parts microfiche.
OTHER VICTORY PUBLICATIONS
Year / Model Publication Part Numbers U.S. and (Canada)
Owner’s Manual Parts Book Microfiche
2002 Standard Cruiser 9917169 (Can 9917170) 9917632 9917633
2002 Deluxe Cruiser 9917169 (Can 9917170) 9917630 9917631
2002 Touring Cruiser 9917171 (Can 9917172) 9917628 9917629
2002 Deluxe Touring Cruiser 9917171 (Can 9917172) 9917634 9917635
2003 Classic Cruiser 9918229 (Can 9918230) 9918364 9918365
2003 Touring Cruiser 9918229 (Can 9918230) 9918366 9918367
2004 Touring Cruiser 9918946 (Can 9918947) 9918952 9918953

GENERAL
1.7
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to
certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, and that
motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km
(3,730 mi) after the time of sale to the ultimate purchaser, when operated and maintained according to the
instructions provided.
EMISSION SOURCES
An internal combustion engine produces carbon monoxide and hydrocarbons during operation. Hydrocarbons
must be controlled because under some conditions hydrocarbons react with sunlight to produce photochemical
smog. Carbon monoxide must be controlled because it is toxic.
EXHAUST EMISSION CONTROL
Victory Motorcycles utilizes an electronic engine management system which controls fuel delivery and ignition
timing to control hydrocarbons and carbon monoxide. No adjustments should be made to the system. If
components are replaced that affect idle speed follow the instructions in Chapter 5.
CRANKCASE EMISSION CONTROL
The crankcase emission control system is comprised of a closed system that routes crankcase emissions through
the air cleaner into the combustion chamber.
EVAPORATIVE EMISSION CONTROL CONTROL (CA MODELS)
A vacuum hose connects the purge port manifold to the charcoal canister. Evaporated fuel vapor passes from the
fuel tank, along the vent hose , and to the charcoal canister. Activated charcoal in the canister filters the regulated
elements of the vapor for storage until the engine is started and the motorcycle is driven. The canister and liquid
trap are cleaned as part of the engine’s ordinary combustion cycle. Inspect the evaporative control system clamps,
hoses, fittings, canister and other hardware for wear or damage during each maintenance period of the motorcycle.
Refer to the owner’s manual for emission system warnings and instructions.
Tank
Liquid Trap,
plugged
Canister
Ve n t t o
Atmosphere
T--Fitting and
purge lines
to throttle body
Fuel Pump
Supply
Fuel
Rail Injector
NOISE EMISSION CONTROL SYSTEM
Tampering with Noise Control Systems is Prohibited. Federal law prohibits the following acts or causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or
replacement, any device or element of design incorporated into the motorcycle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2. The use of the motorcycle after such device or element of design has been removed or rendered inoperative.
Among those acts presumed to constitute tampering are the acts listed below:
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust
gases.
2. Removal or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving part of the motorcycle or parts of the exhaust / intake system with parts other than those
specified by the manufacturer.

GENERAL
1.8
Multi--Function Display (MFD) Modes and Operation
The MFD lets the user toggle via the mode button to view the odometer, the trip odometer, the clock, the fuel
gauge, the voltmeter, the instrument cluster light dimmer, the headlamp high beam indicator light dimmer, and
the check engine indicator. The MFD operates only when the ignition switch is in the On position. To select
the desired function, press the MFD Mode button (A). To adjust a particular function, press the MFD Set
button (B).
ARH Front View B
LH Front View
ARH Front View
Set Mode
Odometer
The odometer is the default mode of the MFD after starting the engine and displays the total miles traveled.
To toggle the odometer and trip odometer reading between miles / kilometers, and the fuel gauge reading
between gallons / liters, the ignition switch must be in the On position with the MFD in odometer mode. Press
and hold the MFD Set button for 3 seconds.
To change to the next MFD function, press the MFD Mode button.
Trip Odometer
“TRIP” appears as part of the display when in trip odometer mode. The trip odometer shows total miles
traveled since the trip odometer was reset. You can use the trip odometer to calculate the miles per gallon and
estimate the number of miles traveled on a tank of fuel.
To reset the trip odometer, the ignition switch must be in the On position with the MFD in trip odometer
mode. Press and hold the MFD Set button for 3 seconds.
To change to the next MFD function, press the MFD Mode button.
Clock
A clock icon appears as part of the display when in clock mode. When the clock is operating normally, the
colon between the hour and minutes flashes.
To set the clock, the ignition switch must be in the On position with the MFD in clock mode.
1. Press and hold the MFD Set button for 3 seconds when in clock mode. The hour digits should flash.
2. Press the MFD Set button to select the desired hour.
3. Press the MFD Mode button to accept the new hour setting. The ten--minute digit should flash.
4. Press the MFD Set button to select the desired ten--minute.
5. Press the MFD Mode button to accept the new ten--minute setting. The minute digit should flash.
6. Press the MFD Set button to select the desired minute.
7. Press the MFD Mode button to accept the new minute setting. The clock should return to normal
operation, and the colon should flash.
To change to the next MFD function, press the MFD Mode button.
Notice The clock will not function if the battery voltage drops below 11.5 volts. The clock will reset to
12:00 if the battery is disconnected.

GENERAL
1.9
Multi-Function Display (MFD) Modes and Operation
Instrument Cluster Light Dimmer
“DIM” appears as part of the display when in instrument cluster light dimmer mode. To change the intensity of
the instrument cluster light, press the MFD Set button to select from six (6) intensity levels. The engine does
not need to be running to change the light intensity.
To change to the next MFD function, press the MFD Mode button.
Headlamp High Beam Indicator Light Dimmer
“HB” appears as part of the display when in headlamp high beam indicator light dimmer mode. To change the
intensity of the headlamp high beam indicator light, press the MFD Set button to select from four (4) intensity
levels. The engine does not need to be running to change the indicator intensity.
To change to the next MFD function, press the MFD Mode button.
Fuel Gauge
The fuel gauge shows the amount of fuel in the fuel tank. The fuel gauge range is from LOW (0.8 gallons/3.03
liters) to FULL (5 gallons/18.9 liters).
To change to the next MFD function, press the MFD Mode button.
Voltmeter
When the engine is not running, “BAT” and the battery voltage appear.
When the engine is running, “ALT” and the charging system voltage appear.
To return to the odometer function, press the MFD Mode button.
Check Engine Indicator
The check engine indicator will flash “CH ENG” any time the the ignition switch is in the On position and the
Engine Control Module sensors report abnormal sensor or engine operation. The check engine indicator will
continue to flash as long as the fault condition exists.

GENERAL
1.10
MFD FUNCTION FLOW CHART
FLASHING
TEN--MINUTE DIGIT
ODOMETER
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
ALTERNATOR/
BATTERY
INCREASE
VALUE
INCREASE
VALUE
SET
SET SET
FLASHING
MINUTES DIGET
SET 3 Sec
HIGH BEAM DIMMER
RH Front View LH Front View
Mode
Set
Mode Set

GENERAL
1.11
SPECIAL TOOLS
SPECIAL TOOLS -- GENERAL & PRECISION MEASUREMENT PART NUMBER
Bearing & Seal Driver Set PV-43558
Blind Bearing Remover Set Commercially Available
Bore Gauge Set PV-3017
Decal, Service Bulletin Completion 7170107
(Order from Victory Parts Dept.)
Dial Caliper (Metric, 0--150mm) PV-26900-7
Dial Caliper (Electronic. English / Metric Conversion) PV-39776
Dial Indicator (10mm travel) PV-26900-12
Dial Indicator Stand, Flexible. Magnetic Base PV-34481
Engine Ear Listening Device PV-39565
Feeler Gauge Set PV-26900-8 or PV-26900-9
Outside Micrometer (0-25 & 25-50mm) PV-3006, PV-3007
Outside Micrometer Set (0-100mm) PV-3009
PlastigaugeCommercially Available
Small Hole Gauge Set Commercially Available
Straight Edge, Precision PV-34673
Surface Plate Commercially Available
Telescoping Gauge Set PU-45423
Torque Wrench (3/8sDrive in-lb) PV-43543
Torque Wrench (3/8sDrive lb-ft) PV-43552; PV-43564
SPECIAL TOOLS -- TUNE UP & MAINTENANCE PART NUMBER
Belt Tension Gauge PV-43532
Cylinder Leakdown Tester PV-35667-A
Compression Gauge Set PV-33223
Oil Pressure Gauge Set PV-43531
Oil Filter Wrench PV-43527
Wheel Alignment Tool PV-43528
SPECIAL TOOLS -- ELECTRICAL PART NUMBER
Ammeter Inductive Clamp for Fluke 73 Multimeter PV-39617
Electrical Connector Test Adapter Kit PV-43526
Flywheel Puller PV-43533
Inductive Timing Light PV--43537
Multimeter, Fluke 73tPV-43546
Speedometer Signal Tester PV-43544
Speedometer Signal Tester Adaptor (Use with PV-43544
on 2001+ models)
PV-

GENERAL
1.12
SPECIAL TOOLS
SPECIAL TOOLS -- ENGINE / CLUTCH / TRANS PART NUMBER
Clutch Hub Holding Tool PV-43518
Clutch Shaft Holder PV-45028
Crankcase Assembly Tool (Same as Mainshaft /
Crankcase Installer)
PV-46299
Crankshaft Bearing Protector PV-43504
Crankshaft Rotation Socket (2003-current) PV-46988
Crankcase Puller (Crankcase Separation) Used on
2001 and later; and on 1999-2000 if transmission kit
has been installed)
PV-45029
Crankcase Separating Bolts & Studs (1999-2000 only) PV-43503
Cylinder Bore Gauge PV-3017
Engine Hoist or Lift Commercially Available
Engine Lock Tool PV-43502-A
Engine Stand Commercially Available
Flywheel Puller PV-43533
Mainshaft / Crankcase 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 Pliers, PV-43570 Band (3 5/8¨ to 3 7/8¨)
Split Gear Line-Up Tool Any 1/4sshaft: Example: 1/4sdrill bit shank.
Valve Spring Compressor (Adapter) PV-1253 or PV-4019, (PV-43513-A)
SPECIAL TOOLS STEERING / SUSPENSION PART NUMBER
Blind Bearing Remover Set PV-43551
Damper Rod Holder PV-43517
Fork Seal Driver PV-43516
Fork Tube Removal / Installation Tool PV-46196
Steering Bearing; Wheel Bearing; Swing Arm
Bushing Removal & Installation Set.
PV-43515
Steering Stem Bearing Adjustment Socket PV-43508
Steering Stem Bearing Spanner Wrench PV-43509
Lower Steering Stem Bearing Removal Tool PV-44683
Shock Pre-Load Adjustment Wrench PV-43507
Shock Spring Compressor PV-43571

GENERAL
1.13
SPECIAL TOOLS STEERING / SUSPENSION
(Cont.)
PART NUMBER
Gas Shock Re-Charging Kit (Includes items below) 2200421
Kit Part Charging Needle 7052069
Kit Part Air Chuck 7052068
Kit Part Gas (Low) Pressure Hose 2110003
Kit Part Re-Charging Valve 7051004
Kit Part Female / Male Fitting 7052066
Kit Part Schrader Valve 7051003
Kit Part 1/8” 3-Way Tee 7052067
Kit Part 1/8” Male Fitting 7052076
Kit Part High Pressure Regulator 2110005
Shock Shaft Seal Protector (5/8”) 2201640
Shock Rod Holding Tool (5/8”) 2872429
Shock Body Holding Tool 2871071
SPECIAL TOOLS -- WHEELS/TIRES PART NUMBER
Air Pressure Gauge Commercially Available
Bead Breaker
( May be part of the tire removal equipment being used)
Commercially Available
Tire Mounting Lubricant Commercially Available
Tire Removal Equipment Commercially Available
Rim Protector PV-43536
Valve Core Remover Commercially Available
Wheel Balancing/Truing Stand PV-43556
TOOLS -- FUEL SYSTEM / FUEL INJECTION PART NUMBER
Victory / Polaris Diagnostic Tool Kit w/ Diagnostic Software PV-46085
PV-46085 Kit Contents
(The items at right are included in main kit above and can be
ordered separately)
Diagnostic Software Disk PV-46085-3
Interface Cable PV-46085-4
Instruction Manual PV-46085-5
PV-45410 Kit Contents
(The items at right are included in main kit above and can be or-
dered separately)
Tube PV-45410-1
O2Sensor Cable PV-45410-2
Power Cable PV-45410-3
Instruction Sheet PV-45410-4
O2Sensor PV-45410-5
EGA Tool Kit With Lambda Sensor PV-45410
Fuel Pressure Gauge PV-43506
Laptop Computer (Refer to diagnostic software user manual for
minimum specifications,)
Commercially Available
* Order all tools from SPX Corporation at 1-800-328-6657 except where indicated as a Victory order number or
as “Commercially Available”. Refer to Victory Special Service Tool Catalog for ordering information.

Clutch Cable
Clutch Cable
Crank Position
Sensor Wiring
Starter Cable & Regulator/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 to following pages for tie strap location
GENERAL
1.14
CABLE & HARNESS ROUTING

To Crankshaft
Position Sensor
Strap includes frame
and harness only
Strap Includes:
Subframe and Rear Harness
Bundle in Strap
Strap Includes:
Subframe, Harness Bundle,
Rear Harness Bundle, Starter Cable,
and Charging Lead in Strap
Torque: 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 Includes:
Regulator Bracket
Regulator Wire Harness
2
Strap Includes:
Frame & Wiring Harness Only
1
Speed Sensor
Torque Harness Guide Fasteners to 9.5 Nm (7 lb. ft.)
Strap Includes:
Subframe
Main Wiring Harness
GENERAL
1.15
CABLE & HARNESS ROUTING

Included in strap:
Speedometer Bracket
LH Controls Harness
LH Turn Signal Harness
Driving Lights Harness (TC Models)
Included in strap:
Speedometer Bracket
RH Controls Harness
RH Turn Signal 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 Connector
Included in strap:
Rear Brake Light Switch Base
Rear Brake Light Switch Harness
1
1
1
2
2
2
2
3
3
Tie Strap includes frame & wire harness only
3
1
2
GENERAL
1.16
CABLE & HARNESS ROUTING