Page 2: Table Of Contents
GENERAL SPECIFICATIONS..........1.5 2012-2013 CROSS ROADS CLASSIC™ / HARD-BALL™ ..... . . 1.5 ®...
Page 3 AUDIO / COM / CRUISE CONTROL BUTTONS ......1.29 AUXILIARY DRIVING LIGHT SWITCH (CROSS ROADS CLASSIC) ....1.29 RADIO / AUDIO SYSTEM .
Page 4: General Information
Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Victory hardware from an authorized Victory dealer. Working with batteries can be hazardous. Review all battery warnings and cautions.
Page 5: Safety Information
Severe Protect these surfaces whenever the brake system is being personal injury or death could occur if the motorcycle tips or falls. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 10: Vehicle Loading
•weight of all riders’ apparel and items in or on apparel •weight of any accessories and their contents •weight of any additional cargo on the motorcycle 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 11: Vehicle Information
• Vehicle Identification Number (VIN) (also stamped into frame on right side of the steering head). • Gross Vehicle Weight Rating • Gross Axle Weight Rating • Tire and Wheel Information • Date of Manufacture 1.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 12: Veci / Neci / Tire Information Labels
Saddlebag Warning Label Saddlebag Warning Label (E). Rear Shock Air Pressure Label Rear Shock Air Pressure Label (F). 1.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 13: Publications & Technical Literature
PUBLICATIONS & TECHNICAL LITERATURE PUBLICATION PART NUMBERS Some Victory publications, such as Owner’s Manuals and Parts Books are available on-line and can be downloaded from the Victory motorcycles web site (http://www.polarisindustries.com/en-us/Victory/). Click on the Riders pull down menu and select Manuals and Parts.
Page 14: Paint Color Codes
V13ZW36EV, NV, NVA, NVC Suede Titanium Metallic / Ness Graphics V13DW36NN, NNC, NNA Suede Nuclear Sunset Paint Color Codes For current information Victory Dealers can go to www.polarisdealers.com/News, Forms, and Links. Enter PAINT CODES in the search box. PAINT COLOR: PAINT CODE NOTES...
Page 15: Break In Period
Break-in Procedure 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.
Page 16: Emissions
Exhaust Emission Control Victory Motorcycles have an electronic engine management system which controls fuel delivery and ignition timing to control hydrocarbon and carbon monoxide emissions. Follow the Periodic Maintenance Interval Table on (page 2.4) and inspect the emission control system as outlined in this manual.
Page 17: Special Service Tools
Electrical Connector Test Adapter Kit PV-43526 Inductive Timing Light PV-43537 Multimeter, Fluke 73™ PV-43546 Battery / Conductance Tester MDX - 610P / PU-50296 1.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 18 Steering Bearing, Wheel Bearing Installation Set PV-43515 Steering Stem Bearing Adjustment Socket PV-43508 Steering Stem Bearing Spanner Wrench PV-43509 Shock Spring Compressor PV-43571 1.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 19 Order Special Service Tools from SPX Corporation (Phone 800-328-6657 / FAX 586-578-7375) or use the link on the Victory Dealer Web site. If you are not a Victory dealer use the phone or FAX number listed above or visit http://polaris.spx.com/ 1.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual ©...
Page 20: Transporting, Elevating, And Securing The Motorcycle
DO NOT attempt to lift the motorcycle without properly securing it with straps. (Both sides) Platform jack To swing arm (both sides) 1.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 21: Key Switch
You must push the ignition key into the switch to select the PARK position. 1.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 22: Cross Roads Speedometer / Instruments
• Trip Hours • Avg. Speed • DC Voltage • Ambient Air Temp • Diagnostic Functionality (Engine Error Codes) • Oil Pressure Warning (MY12+) 1.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 23: Cross Roads Instrument Cluster
SPECIFICATIONS / GAUGE / AUDIO Cross Roads Instrument Cluster 1.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 25: Multi Function Display - Cross Country (Mfd)
Failure Mode Number (0-9) Indicator (FMI) • Trip Hours Meter** “Err” **Press and hold the mode button to reset. Suspect Parameter Number (SPN) 1.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 26: Clock (Cross Country)
• To change from miles to kilometers see page 1.26. segment, Step 4 will save the new setting and exit the clock mode. 6. Turn the key OFF. 1.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 27: Temperature (Cross Country)
ON or PARK position. 2. When the display flashes the DISTANCE setting, tap the mode button to advance to the desired setting. 1.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 28: Left Handlebar Switches
15 mph, cancellation will occur shortly active, all turn signals flash. after speed again reaches 15 mph. * The 15mph speed is approximate. Turn 1.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 29: Turn Signal Momentary Feature
• Turn dial (2) to align a lower number with arrow (3) on lever to increase lever reach distance. 1.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 30: Audio / Com / Cruise Control Buttons
European • FM 87.5 to 108.00 MHz Auxiliary Light Switch • MW 522 to 1602 kHz • LW 144 to 288 kHz 1.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 31 Then press and release the MODE button until the desired mode menu displays. 4. Memory Preset (PRE) Button: Press PRE to cycle through stored presets (page 1.33). 1.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 32 4. Intercom system active (if equipped). 5. Stereo indicator. NOTE: The audio system will always display the last active source when turned on. 1.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 33 (skipped if not equipped) AUX source active: FM source active: U.S. / European models U.S. / European models AM source active: U.S. models only 1.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 34 Wait 5 seconds or push VOL (+) or VOL (-) to exit. To listen to a preset location, press and release the PRE button until the desired location displays. 1.33 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 35 TUNE (See page 1.34 to enter and exit mode menus). BASS +3 EXTERNAL SPKRS TUNE TUNE BASS -3 EXTERNAL SPKRS TUNE TUNE 1.34 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 36 MUTE = The audio source volume is muted when the VOX is opened. The audio source volume gradually returns to its original level once the VOX is closed. 1.35 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 37 Otherwise, music from the NAV unit will interrupt the new source, interpreting it as navigation commands, not music. AUX MODE TUNE AUX MODE TUNE NAV MP3 1.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 38 ALL CHANNELS or another category is selected. *This menu item is skipped when XM radio is not present. 1.37 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 39: Cb Radio / Icom System
CHANNEL ADJUST screen and return to the main display. Press COM on the upper left handlebar control to activate the CB-COM system. 1.38 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 40 To set the squelch level, first lower the squelch level until noise or static is audible. Gradually increase the squelch level until the noise or Receiving static is gone. 1.39 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 41 Entertainment, CB radio or ICOM is active. Static and noise levels are decreased. Press (+) or (-) on the headset control to raise or lower volume. 1.40 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 42 27.295 27.385 27.305 27.395 “VOX” will be display on the screen whenever the driver or passenger are communicating over the intercom system. 1.41 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 43: Aux / Ipod
1. Disconnect the cable from the device by carefully pushing down on the locking tab and pulling gently to separate the connector. 2. Install the protective cap(s). 1.42 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 44 To use the MP3 function of the highlighted. NAV unit (if equipped). My Top Rated TUNE Road Tunes 2 80’s Music 1.43 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 45: Xm Radio
(if applicable), the channel name or category, the artist, and song title. To exit without selecting a new song. To select the highlighted song. 1.44 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 46 XM Category menu. Press TUNE (+) or TUNE (-) button on the left control to change the category. XM CATEGORY TUNE ALL CHANNELS 1.45 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 47: Nav Mp3
Pressing TUNE + / - on the lower left control will continue to only select stations available in the Country category. 1.46 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 48 “MEDIA VOLUME” on the Garmin unit to avoid distortion. To use the MP3 function of the NAV unit (if equipped). 1.47 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 51: Fahrenheit To Celsius
Pounds force per = Kilo pascals x 6.895 square inch (psi) (kPa) = Pounds force per Kilo pascals (kPa) x.145 square inch (psi) 1.50 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 52 SUEDE FINISH CARE ..........2.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 53: Maintenance
Approximately 4.75 liters (5.0 quarts) Use Victory 20W40 Synthetic Blend 20W40 engine oil for all temperatures. If Victory oil is not available, use a high quality 20W40 motorcycle designed for use with wet clutches (such as those with a JASO MA rating).
Page 54: Special Tools
Oil Change Kit 2873551 Paint Wax and Final Finish 2872193 Semi-Synthetic 20W/40 Engine Lubricant 2872175 (Quart) 2872176 (Gallon) Vinyl and Rubber Dressing 2872194 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 55: Periodic Maintenance
I-Inspect (tighten, clean, adjust, correct or replace if necessary) R-Replace/Rebuild P-Perform L-Lubricate with proper lubricant *Replace at specified interval or annually **Replace at specified interval or every 2 years 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 56: Air Filter
The fuel line is secured to the main wiring harness by a tie strap that should not be removed. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 57 11. Place tank on suitable flat surface that will not scratch page. fuel tank. Do not place fuel tank on frame/seat area of the motorcycle. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 58 8. Connect fuel pump wire harness electrical connector. wire bolt to 10.8 Nm or 96 in-lbs Ref. “B” on above photo. 14. Install seat and side covers. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 59: Engine Oil Level
Screw new filter on until gasket contacts the filter mounting plate. Tighten filter by hand an additional 3/4 turn. (Cont.) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 60: Reverse Idler Shaft Lubrication
Approx. 4.5 qt. (4.0 - 4.25 liter) CHANGE (WITH FILTER) ENGINE OIL CAPACITY AT Approx. 4.0 qt. CHANGE (WITHOUT FILTER) (3.75 - 4.0 liter) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 61: Idle Speed / Fast Idle Speed
1.6mm (.063") REAR: 38 psi 40 psi (1/16 inch) (1/16 inch) Dunlop Elite 3 (262 kPa) (276 kPa) 180/60R16 M/C 80H 2.10 2.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 62 Cruise Control Cable information is on page 2.12. 4. Verify throttle grip moves smoothly and returns freely when released in all handlebar positions. 2.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 63: Cruise Control Cable
NOTE: The cruise control cable (if equipped) is not manually adjustable and does not require periodic adjustment. 52 in-lbs (6.0 Nm) 2.12 2.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 64: Front Brake Lever Reach
3. At handlebar end, pull outer cable casing (B) out of perch and carefully rotate inner cable out of perch and lever. Do not kink cable. VIEW FROM BOTTOM 2.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 65: Clutch Lever Free Play
4. Tighten adjuster jam nut securely to cable. 14. Inspect clutch lever free play and adjust if necessary. Be sure cable and lever operate smoothly without binding. 2.14 2.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 66: Front Brake Fluid Level
8. Reinstall diaphragm, plate, and cover. 9. Torque screws to 25 in-lbs (3 Nm). 10. Check for deterioration of hoses. 8. Check for deterioration of hoses. 2.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 67: Brake Pad Inspection
Minimum Thickness: Rear Pad: 1.5mm (.060 in.) Minimum Thickness: Front Pad: 1.5mm (.060 in.) Grooves Grooves 2.16 2.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 68: Shift Pedal
4. Check brake pads for wear as outlined on page 2.16. 102mm above the floor board surface (see chapter 9). 7. Tighten jam nuts to 96 in-lbs (11 Nm). 2.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 70 3. Remove spark plugs and inspect for: • Insulator damage • Worn electrodes • Deposits 2.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 71: Battery Charging / Storage / Inspection
4. If battery voltage is below 12.5 VDC, charge it thoroughly (refer to page 16.7). Replace battery if it will not accept a charge. 2.20 2.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 72: Battery Removal / Installation
6. Install red protective boot over positive (+) terminal. 7. Install negative cable. Torque bolt to specification. 8. Install chin fairing (page 3.20). 2.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 73: Engine Compression Test
• Piston ring stuck in the piston ring groove • Leaking valves or head gasket • Slow starter motor cranking speed • Valve timing incorrect • Faulty gauge 2.22 2.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 74: Drive Belt Wear Analysis
5,000 miles (8,000 km) of service at the time of damage or failure. Push plunger until O-ring contacts body End View 2.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 75: Drive Belt Tension - Inspection
Rotate clockwise only during this procedure belt. If deflection is less than specified, loosen the belt. Fig. 1 Refer to specification table on page 2.26. 2.24 2.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 76: Sprocket Inspection
3. Rinse thoroughly with clear water. Dry thoroughly. NOTE: Do not inspect or adjust drive belt tension when the belt is wet. Improper adjustment will result. 2.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 77: Drive Belt Adjustment / Alignment
Be sure to keep axle seated forward against axle adjusters during this procedure. Marks are for initial alignment only. Refer to procedure for final alignment. 2.26 2.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 78: Headlamp Aim Inspection
11. Pump rear brake pedal several times to reset brake part of headlamp pad distance. Floor 12. Verify wheel rotates smoothly and freely without drag when brake pedal is released. 2.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 79: Headlamp Aim Adjustment
The beam will move in the direction of the tightened screw. • Verify proper aim and install headlamp bezel. Trailing Edge Leading Edge Front of Motorcycle 2.28 2.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 80: Sidestand & Spring Removal
13. Cycle the sidestand to be sure it moves freely, and returns to the fully retracted position. 2.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 81: Rear Suspension / Swingarm Inspection
1/4 inch drift (flat) punch to complete the peening operation. 6. Apply touch up paint or primer to exposed bare metal. 2.30 2.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 82: Rear Suspension Air Pressure Adjustment
1. Remove right side cover. 2. Remove cap from air fitting (A). 60 ft-lbs (81 Nm) 3. Open the right saddlebag and locate pressure decal. 2.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 83: Front Fork / Suspension Inspection
5. Verify all fasteners are tight. Refer to Chapter 12 for front wheel and suspension torque specifications, and Chapter 15 for brake system torque specifications. 2.32 2.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 84: Fuse Replacement (Main Fuse Box)
(C). If movement is observed, inspect front axle, wheel, and bearings (Chapter 12). NOTICE Use only the recommended fuse to prevent electrical system damage. 2.33 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 85: Fuse Replacement (Remote Fuses)
Inspect all fasteners on the vehicle to be sure they are tight. Refer to the appropriate chapter as required for torque specifications. 2.34 2.34 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 86: Lock And Ignition Switch Lubrication
Do not use glass cleaners, water or soil repellents, and petroleum or alcohol based cleaners on the windshield (if equipped), as these products can damage the windshield. 2.35 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 87: Windshield Care
2. Using a clean, dry microfiber towel, wipe surface to achieve that showroom-new Suede Finish. IMPORTANT: Be sure to apply Pure Victory Polish Suede Finish Protectant after every cleaning. 2.36 2.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 88 ASSEMBLY VIEW - HEAD PIPES ......... 3.37 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 89: 9924047 - 2012-2013 Victory Cross Roads / Cross Country Service Manual
Victory may cause loss of performance, excessive consciousness and may lead to death. emissions, and make the machine unsafe for use. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 90: General Information
• A non-marring wedge is essential to lift edges of mating parts without damage. Body Panel Tool Kit PV-49955 is recommended. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 91: Removal / Installation Procedures - Front Body
3. Tighten all screws evenly to specification. 2. Carefully remove fender between the fork legs. Front wheel removal see Chapter 12 12 ft-lbs (16 Nm) 12 ft-lbs (16 Nm) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 92: Ignition Switch / Iac Cover Removal / Installation
1. Be sure clips are in place and in good condition. 2. LH cover - route front spark plug wire below top of cover. 3. Push cover evenly inward to install. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 93: Windshield (Cross Country)
Cover - Snap into place on visor. Shoulder of screws must be in windshield holes Windshield Support before tightening any. 85 in-lbs (9.6 Nm) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 94: Windshield (Cross Country Tour)
4. Torque all screws evenly to 36 in-lbs (4.1 Nm). Do not overtighten screws or windshield may be damaged. Tighten top screws first 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 95: Windshield (Cross Roads)
18 ft-lbs (24.5 Nm) Rubber Washer Both Sides Of Windshield (All screws) Windshield 85 in-lbs (9.6 Nm) (All) Metal Washer Spacer Sleeve Rubber Washer 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 96: Headlamp Bezel
Do not touch glass surface of bulb. Bulb can be cleaned with isopropyl alcohol to remove oil residue if contaminated. NOTE: Headlamp removal is on page 3.9. Euro only 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 97: Headlamp, Hid (Cross Country Tour)
1. Make sure ignition is turned OFF and wait 5 minutes before proceeding to step 2. 2. Remove headlamp bezel (page 3.9). 3.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 98: Headlamp Assembly View (Cross Country)
Top bulb socket faces left. (LOW BEAM) Bottom bulb socket faces right. (HIGH BEAM) Europe 85 in-lbs (9.6 Nm) Headlamp (Hid) Assembly View (Cross Country Tour) 3.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 99: Hid Ballast (Cross Country Tour)
Top bulb wiring harness (C) faces left. 2. Install top cover. 3. Grease threads of cover screws and install. 4. Torque to 48 in-lbs (5.4 Nm). 3.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 100: Headlamp Assembly View (Cross Roads)
(5.4 Nm) before tightening left P-Clamp 48 in-lbs (5.4 Nm ) 36 in-lbs (4.0 Nm) 28 ft-lbs 17 ft-lbs (38 Nm) (23 Nm) 3.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 101: Auxiliary Driving Lights (Cross Roads)
Do not bend or rotate the grill during removal. 3.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 102: Dash Panel
4. Install screws and torque to 36 in-lbs (4.0 Nm). 5. Install speaker grills (page 3.14), headlamp (page 3.9), headlamp bezel (page 3.9), windshield (page 3.6, if removed). 3.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 103: Fairing Mount Assembly View (Cross Country)
(4.0 Nm) 19 ft-lbs (26 Nm) 36 in-lbs (4.0 Nm) Turn Handlebars FULL LEFT before tightening right P-Clamp 19 ft-lbs (26 Nm) 3.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 104: Fairing Mount Removal
Separate any associated connectors (D) for main harnesses and any that are routed through Handlebar switch wires, etc. 4 mount bolts: 19 ft-lbs (26 Nm) 3.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 105: Instrument Cluster / Speaker / Speaker Volume
Push connector tab and pull to separate connector from cluster. Remove screws and cluster. 15 in-lbs (1.7 Nm) 36 in-lbs (4.0 Nm) 3.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 106: Fairing Trim / Front Turn Signal Assembly View
Speedometer / Speedometer Mount (Cross View Roads) 14 in-lbs (1.5 Nm) 36 in-lbs (4.0 Nm) 36 in-lbs (4.0 Nm) Visor 36 in-lbs (4.0 Nm) 3.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 107: Chin Fairing (Inner Grill)
(4.0 Nm) 3. Align holes and install screws with washers. Installation 4. Tighten screws to specified torque. 1. Reverse removal steps. 3.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 108: Highway Bars
1. Remove screws (4 per side) securing outer fairing to inner fairing. 2. Tighten all fasteners. 52 ft-lbs (70 Nm) 52 ft-lbs (70 Nm) 3.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 109 3. Once the fairing inners have been adjusted properly, not necessary to remove fuel tank to access multi- torque screws and lock nuts to 32 in-lbs (3.6 Nm). plug. 3.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 110: Instrument Bezel (Cross Country)
3. Press inner edge of bezel toward dash until it snaps into place and all tabs are engaged with the inside edge of dash panel. 4. Install dash panel. 3.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 111: Rear Body
1. To install, reverse above process. Be sure rear tab of seat is engaged in slot. 2. Tighten seat bolts to specification. 3.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 112: Saddlebag
6. Pull lightly outward on front and rear of bag to ensure pin is secured. 7. Close and lock the saddlebag lid. 3.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 113: Saddlebag Assembly View
Detail A - Seal Joint 85 in-lbs (9.6 Nm) Detail C - Inner Seal Detail B - Outer Seal Detail D - Lid Bumper To outside 3.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 114: Rear Fender / Saddlebag Mount
Rear Fender / Saddlebag Mount 10 ft-lbs (13.5 Nm) 84 in-lbs (9.5 Nm) 18 ft-lbs (24.4 Nm) 18 ft-lbs (24.4 Nm) Tie Straps 3.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 115: Trunk
7. Starting from the back, lift trunk (A) to disengage trunk locks from mounting bracket, and slide towards rear of motorcycle (B) to remove trunk assembly. 3.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 116: Trunk Assembly View / Mount
During installation, make sure LOCK lever detent has fully engaged (clicked into place). Failure to properly secure trunk to mount may result in damage. 3.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 117: Tail Light / Turn Signal Assembly View
FRAME-BODY-EXHAUST Tail Light / Turn Signal Assembly View 3.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 118: Floorboard / Foot Control Mounting
Apply soap & water solution to install 18 ft-lbs (24.5 Nm) 12 ft-lbs (16.0 Nm) 35 ft-lbs (47.5 Nm) 96 in-lbs (10.8 Nm) 3.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 119: Passenger Footrest Mounting
FRAME-BODY-EXHAUST Passenger Footrest Mounting FOOT PEGS 35 ft-lbs (47.5 Nm) 65 ft-lbs (88.0 Nm) FLOORBOARDS (ADJUSTABLE) 3.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 120: Passenger Floorboards (Adjustable)
Installation 1. Reverse procedure to install. Torque as shown. Floorboard Adjustment Bolts: 18 ft-lbs (24.4 Nm) 3.33 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 121 2. Tighten floorboard adjustment bolts to specification. Floorboard Adjustment Bolts: 18 ft-lbs (24.4 Nm) 3.34 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 122: Exhaust System
FRAME-BODY-EXHAUST EXHAUST SYSTEM Assembly View - Exhaust Complete 3.35 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 123: Assembly View - Muffler
18 ft-lbs (24.4 Nm) 40 ft-lbs (54.0 Nm ) Shield Clamp Detail 36 in-lbs (4.0 Nm) Loosen 4-5 turns then lift screw to release. 3.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 124: Assembly View - Head Pipes
9. Disconnect oxygen sensors at the connector. Do not attempt to remove the sensor wire at the sensor. 10. Remove head pipe with rear passenger footrest bracket. 3.37 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 126 OIL PUMP INSTALLATION ..........4.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 128: Oiling System Data
Oil Pressure Sensor Loctite™ 565 or pipe sealant (115 in-lbs) Oil Pump to Crankcase / Oil Tube to Crankcase (85 in-lbs) Oil Pump Sprocket (85 in-lbs) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 129: Oil Flow
Oil Sump Gravity & Splash Lubrication Crankcase Passage Lubrication Circuit Reed Valve Cooling Circuit Air Box Breather Hose Pressure Relief Circuit Breather Circuit 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 130: Oil Cooler
P-Clamp corner of plate facing Tighten last Retainer Plate away from engine 85 in-lbs (9.6 Nm) Tighten first 85 in-lbs (9.6 Nm) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 131: Oil Cooler Inspection / Cleaning
4. Install screws and torque to 85 in-lbs (9.6 Nm). 5. Install left chin fairing and upper cooler mounting nut. 6. Install left foot rest and highway bar. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 132: Oil Pressure Inspection
552 kPa (80 psi) MINIMUM pressure is Measure at Oil Pressure Sensor @ 82 C/180 276 kPa (40 PSI) Cooling Oil OIL FLOW 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 133: Oil Pump
Be sure to retrieve the used O-rings and washers and discard. Use new O-rings and washers during assembly. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 134: Oil Pressure Relief Valves
(C) has a longer hexagonal portion and screws into the pump BASE (D). 2. Visually inspect the relief valve for obstruction or unusual wear. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 135: Oil Pump Inspection
(larger gerotor set) and lubrication. gauge at point (C). Lubrication side of pump is shown below. Cooling side is measured in the same manner. 4.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 136: Oil Pump Disassembly
9. Pull shaft with inner rotor from pump body. 10. Clean all parts and inspect for wear. 11. Dry with compressed air. 4.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 137: Oil Pump Assembly
2. Press long dowel pins into cooling side of pump body using same method as above. 3. Secure pump body in a soft jaw vise. Apply Victory engine oil to threads of lubrication pressure relief valve and install into pump body. The lubrication relief valve has a shorter hexagonal portion than the cooling relief valve.
Page 138 Victory engine oil and assemble screen to oil pump body, aligning groove (D) in screen to tab on pump. 12. Secure pump base in a soft jaw vise. Apply Victory engine oil to threads of cooling pressure relief valve and install into pump base. The cooling relief valve has a longer hexagonal portion than the lubrication relief valve.
Page 139: Oil Pump Installation
45 ft-lbs (62 Nm) 85 in-lbs (10 Nm) Tapered O-ring seat 85 in-lbs (10 Nm) faces oil pipe Fig. 2 4.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 140 14. Refer to Chapter 10 for crankcase assembly. 15. Verify proper lubrication oil pressure after assembly. Refer to page 4.7. 4.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 142 SENSOR TESTS ............5.42 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 143 TROUBLESHOOTING ..........5.58 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 144: Safety Precautions
DO NOT TAMPER WITH DO NOT TAMPER WITH THROTTLE BODY FLOW IDLE STOP SCREW SCREW DO NOT TAMPER 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 145: Specifications
Relay Jumper (to run fuel pump) PU-49466 Fuel Tank Fitting Plug Tool (9.5mm) PV-50251 IDLE SPEED NOT ADJUSTABLE! Fuel Tank Fitting Plug Tool (11.8mm) PV-50567 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 146: Service Precautions
“SNAP” Do not drop or strike F.I. components Wire terminals must be corrosion free and fully seated. Connectors should snap together and lock. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 147: Fuel System Assembly Views
18 ft-lbs (24.5 Nm) Vent Line (Front Fitting) See detail view next page. 20 in-lbs (2.3 Nm) Water Drain Line (Rear Fitting) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 148: Fuel Tank Assembly View
Right side of tank Clearance between line and throttle linkage Orient lines as shown and Fuel Pump in contact with outside wall of tank tunnel 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 149: Fuel Tank Vent Water Drain Line Routing - 49 State
Vent Line (to front fitting on tank) Water Drain (to rear fitting on tank) “T” Fitting Dart strap To atmosphere Left Side Routing Dart strap 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 150: Fuel Tank Evaporative Emissions System - California Models
Filter Atmospheric vent Plug Activated Charcoal Canister Dart Straps Secure to bracket with straps Water Drain Line To “Tank” fitting on canister 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 151: Fuel Pump / Level Sensor Reference Data
Pickup filter must be located between baffle plates in rear of tank to prevent fuel starvation at low fuel levels. See Fuel Pump Installation procedure. 5.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 152: Fuel Pump Assembly Views
Wires inside bend of fuel hose Be sure edge of pickup filter is inside baffle plate when pump is installed. See Pump Installation procedure. 5.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 153: Air Intake / Box Frame Assembly View
Air Intake / Box Frame Assembly View 36 in-lbs (4.0 Nm) 36 in-lbs* (4.0 Nm*) * Captive screws. Loosen to remove filter. Do not remove screws from filter. 5.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 154: Idle Air Control Assembly View
To Throttle Body (Front) Restricted side of “T” must be on purge valve View From Left Side side (California) or plugged side on 49 State 5.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 155: Fuel System Service
1. Disconnect vent hose (A) under seat. 2. Be sure hose is unobstructed to tank fitting and to drain line (B) to atmosphere. 5.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 156: Fuel Tank Vent Inspection - California
5. Pivot rear of tank up to gain access to fuel line/fuel fitting. Support rear of tank. Don’t Remove Tie Strap 1. Remove side covers and seat (Chapter 3). 5.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 157: Fuel Tank Installation
3. Assemble vent and drain lines to tank (if removed). 20 in-lbs (2.3 Nm) Rotate lines against side of tank Don’t Remove Tie Strap 5.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 158 14. Install seat and side covers. 10. Install rear isolators (flange side to tank) and flange bushings. 11. Lower rear of tank and install bolts. 5.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 159: Fuel Pump Removal
6. Remove vent line and drain line. 11. Inspect wires and hoses for damage. 7. Lift FRONT EDGE of pump upward until resistance is felt. 5.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 160: Fuel Filter Replacement
2. Install a new push-nut from the filter kit onto the alignment post, making sure it is firmly seated against the connector plate against the filter plate. 5.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 161: Fuel Level Sensor Removal
4. Push sensor off mounting bracket and remove it from the tank. 3. Install fuel pump (page 5.21). 5.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 162: Fuel Pump Installation
4. Install pickup end of pump first, guiding filter between baffle plates located at the back of the tank. 6. Connect fuel level sensor harness (C). 5.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 163 10. Push level sensor wires into tank and clear of hose. 14. Add fuel. Check for leaks at flange area before installing fuel tank (page 5.16). 5.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 164: Fuel Pump Circuit Diagram
FUEL SYSTEM / FUEL INJECTION Fuel Pump Circuit Diagram 5.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 165: Fuel Pump Pressure Inspection
*Fuel pump malfunction (Pump should run for about 2 seconds the instant that the key switch and Engine Stop switch are turned ON) 5.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 166: Fuel Level Sensor Resistance Test
+/- 3 Sensor Resistance Fuel sensor disconnected / ERROR Fuel Level (Room Temperature) EMPTY (Sensor Arm Down) shorted   +/- 5 5.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 167: Fuel Pump Electrical Diagnostics
(Violet/Yellow) should be close to battery voltage for 2- Pin 28 (Gray wire), keeping the pump powered. 3 seconds after turning key ON. 5.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 168 (after a CPS signal is present). Ground the Gray wire to bypass the ECM ground for testing (Key and stop switch ON). 5.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 169: Fuel Pump Current Draw Test
3. Set meter to DC Amps. Be sure red meter lead is in the 10A jack, and black meter lead is in common (-) jack. 5.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 170: Idle Air Control Removal
NOTE: The front HTL is routed behind the ignition switch cover, not above it upon assembly. 6. Remove (4) bracket screws with a 5mm ball drive hexagonal socket. 5.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 171: Throttle Body Removal
11. Disconnect throttle cables from throttle reel and move out of the way. 12. Slide IAC pipes off of front and rear of throttle body. 5.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 172: Throttle Body Installation
3. Install throttle body bolts (4) and torque to 9 Nm (85 in-lbs.) 5.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 173: Efi System Components
Engine Temperature Sensor (CHT) Diagnostic Connector Front cylinder head, left side Under left side cover Throttle Position Sensor (TPS) Left side of throttle body 5.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 174: Fuel Rail / Fuel Injector Removal
11. Clean area around injectors with compressed air to prevent foreign material from entering engine. Pull injectors out of cylinder heads; keep in order (front and rear) for assembly. 5.33 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 175: Fuel Injection System Testing And Diagnostics
Digital Wrench should always be connected to a The locations of sensors and other EFI system related vehicle for more accurate problem diagnosis. components is shown on page 5.32. 5.34 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 176: Ecm Connector Map
FUEL SYSTEM / FUEL INJECTION ECM Connector Map Refer to page 5.39 to remove connector from ECM. 5.35 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 177: Viewing And Clearing Trouble Codes
OR a default value set by the EM in the event of a fault in the sensor or wiring, it is important to verify the condition of the sensor. 5.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 178 Gear Position Sensor Signal - voltage too high P1217 Engine Temperature Sensor - engine overheat shutdown. (2009 only) TABLE CONTINUED ON FOLLOWING PAGE 5.37 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 179 “Err” displays in the clock area. 2. Record the three code numbers displayed in the gear position, temperature, and odometer displays. 5.38 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 180: Sensor Tests
1. Remove left side cover. 2. Remove the ECM connector (procedure above). 3. Pull outward at each corner of ECM to release darts. 5.39 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 181 LOCATION: Integrated with MAP sensor. BN/RD MANIFOLD ABSOLUTE PRESSURE (MAP) LOCATION: Rear cylinder inlet port; RH side. OG/BN GY/RD OXYGEN SENSOR GY/DB LOCATION: Exhaust head pipe. 5.40 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 182 BN / DB LOCATION: Left side of throttle body. OG / YE BK / WH DIAGNOSTIC CONNECTOR LOCATION: Under left side cover. 5.41 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 183: Throttle Position Sensor (Tps) Diagnostics
TPS is to look for a smooth, uninterrupted sweep between closed and open throttle. Sweep can also be checked using Digital Wrench diagnostic software. 5.42 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 184: Tmap Diagnostics
3 (5 V ref) to pin 4 ground. (sigrtrn). Does code go out? If yes, replace MAP Sensor. If no, check wiring. 5.43 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 185: Air Temperature Sensor (Ats) Diagnostics
AIR TEMPERATURE SENSOR OHMS Pin #46 to #38 2.5 K Ohms +/- 5% at 20 C (68 return (BN/DB) to OG /DG 5.44 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 186: Cylinder Head Temperature Sensor (Cht) Diagnostics
COMPONENT SETTING CONNECTIONS (±10%) CYLINDER HEAD OHMS Pin #46 to #39 30.5 K Ohms +/- 13% @ 25 C (77 TEMPERATURE SENSOR 5.45 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 187: Idle Air Control (Iac)
ON. Check for battery voltage at pin 2 and pin 5 PK). DMM “-” lead of IAC motor harness connector. to ground. 5.46 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 188: Vehicle Speed Sensor Test
(near the speed sensor). Tipover Sensor Refer to Chapter 19 and Digital Wrench for tipover sensor information. 5.47 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 189: Crankshaft Position Sensor Diagnostics
Wire side is shown - perform tests on other side Slide Latch Connect Pin 11 to ground Battery Voltage (BOOT AND WIRE COVER REMOVED) FRONT 5.48 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 190: Digital Wrench
ECM. TPS Calibration is not a menu option in Digital Wrench for 2008 - current models. 5.49 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 191 Digital Wrench Updates link in the Service and Warranty saved for future reference. Some examples are shown on drop down menu. the following pages. 5.50 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 193 FUEL SYSTEM / FUEL INJECTION ® Digital Wrench Screen Examples Cold engine at idle during warm up. Throttle partially open. TPS voltage value has increased. 5.52 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 194 RPM has stabilized Change the position of various data items in the table with these buttons. Save data grid. Meter Grid Display items 5.53 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 195: Reprogramming Process
If “Key ON” voltage is marginal, it may help to remove the headlamp relay in the fuse box. 5.54 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 196 8. You can select Vehicle Information from the Special Tests menu to view the part number of the software (map) installed when reprogramming is completed. 5.55 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 197 Authorization Key (obtained on the web) goes here in Step 7. 5. Select Engine Controller Reprogramming. Copy the Request Code required for the web site 5.56 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 198 State...), and click the Authorize button to proceed to the next screen. Authorize Button Enter the Request Code and select the SAME file you selected previously 5.57 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 199: Troubleshooting
Loose, corroded, or wet ECM and wiring harness Unplug connections - inspect connector(s) Valve train problems Valve springs, valve, head Inspect cylinder head & valves 5.58 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 200 Restricted air intake or Intake tract / Throttle body Clean air inlet tract and/or throttle throttle body body / throttle plates. 5.59 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 201 TMAP sensor Test / Replace Plugged vent hose Charge Battery / Replace Low battery voltage ECM Test batt./Charging system Test / Replace 5.60 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 202 Charge Battery When Re-Flash Is Completed Attempting Re-Flash Enter Authorization Code Sent Without Proper VIN, With Accessory Kit Calibration I.D. number, or calibration authorization code 5.61 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 204 ENGINE ATTACHMENTS & NOTES ........6.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 205: Overview - Engine Removal
Specifications ENGINE WEIGHT and OIL CAPACITY Item Specifications Engine Dry Weight Approximately 120 Kilograms (265 lbs) Oil Capacity Approximately 4.75 Liters (5.0 Quarts) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 206: Special Tools
Motorcycle table lift with wheel vise Commercially Available Engine platform jack or platform lift Commercially Available Overhead hoist or shop crane Commercially Available Engine stand. Commercially Available 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 207: Torque Values
45 ft-lbs (61 Nm) 82 ft-lbs (111 Nm) M10 x 1.5 x 90mm M12 x 1.75 x 90mm Alignment pin location 35 ft-lbs (47.5 Nm) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 208: Engine Removal
• Battery (page 2.20). • Fuel tank and fuel line (page 5.15). • Left footrest with shift linkage (page 3.31). • Engine crankcase breather hose. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 209 14. Remove front head pipe flange nuts and remove head pipe assembly. 9. Disconnect rear oxygen sensor wire at harness connector (do not attempt to disconnect wire from sensor). 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 210 17. Remove ignition switch bracket with coil and switch attached. Lift tab (U) to disconnect coil. Push tab (V) to disconnect ignition switch. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 211 25. Lift black tab to separate CPS harness. 26. Remove ground wire screw (D) near clutch cable bracket. 31. Remove upper rear engine mount bolts and plates. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 212 37. Remove lower shock bolt and lower strut bolt (G). 34. After PV-48737 plate fasteners are tightened, remove front upper engine mount bolts and plates. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 213 43. With engine lowered, cut tie straps (I) that secure the front and rear injector wire harness to the fuel rail. 6.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 214: Injector Removal
(aligned) to ensure proper spray pattern. See Chapter 5 for injector installation. 6.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 215: Engine Installation
9. Apply a rubber lubricant (sparingly) or a light film of oil to the throttle body adaptor and air box seal. 6.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 216 Adjust engine height and angle continuously as required while drawing up the bolts. 6.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 217 21. Lower and remove the rear frame crane or hoist. 22. Install front upper engine mount plates. 82 ft-lbs (111 Nm) 28. Remove platform jack or platform lift. 6.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 218: Engine Attachments & Notes
Torque screw to 85 in-lbs (9.6 Nm). 43. Attach removed wires to circuit breaker terminal and torque nut to 25 in-lbs (2.8 Nm). 6.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 219 12 ft-lbs (47.5 Nm) 35 ft-lbs (16.3 Nm) (47.5 Nm) 96 in-lbs (47.5 Nm) 12 ft-lbs (16.3 Nm) 31 ft-lbs (42.0 Nm) 6.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 223: General Information
• Mark and store all mating parts for correct engine assembly. • Use Moly Assembly Paste P/N 2871460 or Victory Semi-Synthetic 20W/40 Engine Oil P/N 2872176 to lubricate parts where indicated. • Handle and store all parts in such a way that they will not be damaged or contaminated.
Page 224: Data - Cylinder Head
Exhaust Valve Maximum Lift 10.0 mm ( .393" ) Spring Installed Height 34.20 - 36.20 mm (See illustration on page 7.19) (1.346 - 1.425") 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 225: Torque Values And Assembly Views
17 ft-lbs (23 Nm) Clean with isopropyl alcohol Align slot with tab on cover Apply firm pressure (40-60 psi) for 30 seconds Allow 24 hour cure 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 226: Camshaft Carrier / Rocker Arm
Tighten all head nuts slowly and evenly to allow lifters to bleed off pressure  Tighten only enough to seat carrier. Follow cylinder head  torque procedure on page 7.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 227: Cylinder Head
15 ft-lbs (20 Nm) Studs 10/11 mm 25 ft-lbs (34 Nm) Apply Loctite 598 to crankcase parting line below base gasket. Assemble immediately. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 228: Camshaft Timing Quick Reference
Key way aligned with front cylinder then time front camshaft crankshaft/camshaft centerline as shown above Rear cylinder TDC hole Front cylinder TDC hole Ill. 1 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 229: Cylinder Head Service
5. Insert 8mm (5/16) pin at front or rear cylinder TDC to prevent engine rotation. See page 7.7 Front tensioner only CAUTION Do not rotate engine with cam chain tensioner(s) removed. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 230: Cam Chain Tensioner Inspection
4. Replace tensioner assembly or damper if worn or damaged. 3. Install tensioner body with a new sealing washer. 4. Torque tensioner body to 55 ft-lbs (75 Nm). 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 231: Camshaft Chain & Sprocket Removal
(B). 5. Remove front cam chain tensioner (page 7.8). 6. Remove lower cam chain guide (below drive sprocket). 7.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 232: Camshaft Carrier Removal
3. Note markings “F” or “R” on drive end of camshafts. Front and Rear cylinder heads use different camshafts. 11. Replace parts worn beyond service limits. 7.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 233: Camshaft Inspection
4. Remove cylinder head (B) head gasket (C) and alignment pins (D). 2. Measure O.D. of each camshaft journal. 3. Inspect height of each cam lobe. 7.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 234: Cylinder Head Disassembly
Use a pencil magnet to remove valve keepers. 3. Remove and discard valve guide seals (D). 4. Clean carbon deposits from combustion chamber. 5. Clean gasket surfaces. 7.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 235: Cylinder Head Inspection
3. Inspect cylinder head for distortion with a straight edge and feeler gauge. Check in different directions and locations on the cylinder head as shown. Compare to specification on page 7.3. 7.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 236 8. Installation of new valve guides and/or new valves requires valve seat reconditioning. This work should be performed by an experienced technician properly equipped to perform cylinder head reconditioning. 7.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 237: Valve Inspection
Contact area too narrow Use 45 stone Contact area free of pitting Correct None and damage, centered in seat, proper width. 7.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 238: Valve Guide Removal / Installation
Always rotate the reamer in a clockwise direction. 7. Clean cylinder head thoroughly with clean solvent. 8. Inspect and recondition valve seats. 7.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 239: Valve Seat Inspection
Do not rotate valve. 6. Remove valve and measure contact area (valve seat width). 7. If valve seat is incorrect, recondition as needed. 7.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 240: Cylinder Head Assembly
(Measure with Seal Installed) Valve Guide Installed Height (From Head Surface, Seal Removed) INSTALLED HEIGHT MEASUREMENT REFER TO PAGE 7.3 FOR SPECIFICATIONS 7.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 241 3. Apply Victory engine oil to valve guide seal and install seal on valve, rotating the seal as you install it. 4. Press seal firmly in place on top of guide. Be careful not to dislodge spring from seal.
Page 242: Cylinder Head / Camshaft Installation
11. Set camshaft carrier on cylinder head. head in place on cylinder. 12. Apply engine oil to 10mm studs, nut threads, nut bases and washers. 7.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 243 Step 8 Repeat Steps 1-7 for other cylinder head. FRONT CYLINDER HEAD Front of Engine REAR CYLINDER HEAD Fig. 2 7.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 244: Camshaft Timing - Rear Cylinder
9. Install tensioner with a new sealing washer. Torque to 55 ft-lbs(75 Nm ). 10. Torque top sprocket bolt to 120 in-lbs (13.5 Nm). 100 in-lbs (11.3 Nm) 7.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 245: Camshaft Timing - Front Cylinder
17. Install front cam chain over crankshaft sprocket. 18. Install front tensioner blade (C). 14. Rear camshaft double marks are now at the top. Install cam sprocket finger tight. 7.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 246 29. Install sprocket bolt. Torque to 120 in-lbs (13.5 Nm). NOTE: Be sure all camshaft sprocket bolts have been installed and properly tightened. 7.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 247 37. Install ignition timing wheel and torque bolt to  specification. Allow adequate cure time for Loctite as directed on container. 17 ft-lbs (23 Nm) 38. Install cam drive cover. 7.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 248: Troubleshooting, Cylinder Head And Valve Train
10-15 minutes of high idle operation. If air will not bleed, replace lifter. Poor Seating of Valve(s) Repair or Replace (Continued on next page) 7.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 249 Refer to Chapter 10 Transmission Area Bearings Refer to Chapter 10 Misplaced Circlips Refer to Chapter 10 Incorrect Side Clearance Refer to Chapter 10 7.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 250 Oil Past Rings Worn or Damaged Piston, Rings, Replace Cylinder Oil Past Valve Guides Worn Valve Guides Replace Worn Valve Guide Seals Replace 7.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 252 TROUBLESHOOTING, CYLINDER & PISTON ....... 8.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 253: Cylinder & Piston
Oil Control location Arrow points to FRONT of engine Piston Ring Profile Top ring gap Oil control ring bottom rail gap 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 254: Specifications
Cylinder bore gauge: PV-3017 Straightedge, feeler gauge, precision measuring instruments: Refer to Chapter 1 or Commercially available Protective sleeves for pistons / studs: Commercially available 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 255: Cylinder Removal
Careless handling of cylinder, pistons or rings may cause irreparable damage. Do not damage gasket surfaces Bottom during cleaning. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 256: Piston To Cylinder Clearance Worksheet
If excessive surface damage, taper or out-of-round exists, the cylinder must be replaced. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 258: Piston Pin / Pin Bore Inspection
Piston Pin O.D. = Connecting Rod to Piston Pin Clearance 6. Compare measurements to specifications listed on page 8.3 and replace any worn parts. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 259: Cylinder Stud Replacement
Second ring gap Oil control ring expander gap location Arrow points to FRONT of engine Top ring gap Oil ring bottom rail gap 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 260: Piston Installation
4. Install piston over connecting rod with arrow on piston crown facing FRONT of engine. (View from RH side) Gap At Top (12:00 Position) Notch faces front of engine 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 261: Cylinder Installation
12. Slide cylinder down over piston until seated to base gasket and crankcase surface. 13. Repeat for other cylinder. 14. Install cylinder head(s). (Chapter 7). 8.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 262: Troubleshooting, Cylinder & Piston
Worn cylinder, Pistons and/ Replace parts that do not or Rings meet specification Ignition Problem Refer to Chapter 17 Fuel Problem Refer to Chapter 5 8.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 263 Replace parts that are worn clearance (to piston or beyond the service limit connecting rod) Exhaust Leak Inspect seal of exhaust system at cylinder head 8.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 264 TROUBLESHOOTING........... 9.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual...
Page 265: General
• Internal transmission or internal shifting mechanism service requires engine removal and crankcase separation. • Oil additives of any kind are not recommended by Victory. Using oil additives or oil of the wrong viscosity can have a detrimental affect on clutch performance, operation, and service life.
Page 266: Assembly Views & Torque Values
1.8 in-lbs (0.2 Nm) Torque second 53 in-lbs (6.0 Nm) 80 in-lbs (9.0 Nm) 48 in-lbs (5.4 Nm) 48 in-lbs (5.4 Nm) 87 in-lbs (9.8 Nm) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 267: Shift Linkage / Footrest - Fastener Torque
2. Rotate linkage rod until pedal height is within specified range. 3. Tighten lock nuts to 96 in-lbs (11 Nm). 96 in-lbs (11 Nm) 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 268: Primary Cover
17. Screw, (2) 5x8 8. O-Ring CAUTION The rotor contains powerful magnets. Use caution when installing primary cover to avoid personal injury. Refer to page 9.12. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 269: Shift Mechanism
2. Roller Arm, Detent 8. Retaining Ring 3. Screw, Flanged 9. Adapter, Shift Shaft 4. Shift Star 10. Washer (Install new) 5. Screw, 6x20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 270: Service Procedures
1. Apply engine oil to the bearings. 2. Temporarily install pinion shaft into primary cover. 3. Turn shaft by hand. Replace bearings that feel rough, notched, or loose. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 271: Clutch Pinion Shaft Seal Removal & Installation
4. Install dog-point screw (C) to 40 in-lbs (4.5 Nm). 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 272: Primary Cover Removal
7. Drain engine oil into suitable container. NOTE: Primary cover can be removed without draining engine oil by safely leaning and supporting motorcycle at an angle to the right. 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 273: Shift Ratchet Removal & Inspection
14. Inspect spring (I) for proper tension. 15. Remove detent roller arm and spring. 6. Inspect shift shaft for wear or damage. 85 in-lbs (9.6 Nm) 9.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 274: Shift Ratchet Installation
7. Release ratchet fork to engage ratchet with shift star. 8. Install clutch (page 9.20). 9.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 275: Primary Cover Installation
TDC location hole. 6. Torque screws in two steps to 115 in-lbs (13 Nm). Repeat torque on all screws. 9.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 276: Clutch Service
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH SERVICE Clutch Assembly View & Torque 9.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 277: Clutch Removal
Special tool: Engine lock tool PV-43502-A CAUTION Use caution when removing nut and keep hands and body clear in case tool slips off gears. 9.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 278: Clutch Disassembly
3. Compress clutch spring and remove snap ring. 10. The outermost plate can be identified by the wider pads on the friction material. 9.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 279 3. Inspect inside surfaces (B) of basket for cracks or wear (grooves) from clutch plates. 4. Replace parts that fail inspection 9.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 280 12. Inspect pressure plate for cracks, scoring, or wear on friction surface. 13. Inspect lifter retaining ring groove (H) for cracks or 9.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 281: Clutch Assembly
Rotate bearing inner race with your finger and check for smooth movement and no play. 18. Replace clutch rack assembly if necessary. 9.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 282 12. Remove spring compressor tool. Inspect retaining ring to be sure it is fully expanded and seated. 9.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 283: Clutch Installation
Be sure retaining ring is seated in groove. 6. Install primary cover (page 9.12). 7. Check engine oil and fill to proper level. 9.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 284: Primary Drive Assembly View & Torque
15. Idler Gear, Starter (See 15*NOTE above) 16. Compensator Drive Gear 17. Crankshaft Gear 18. Compensator Spring, Belleville (4) 19. Screw, 30ft-lbs (41 Nm) Single use fasteners (6) 9.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 285: Torque Compensator Removal
6. Remove outer ramp. Surface Plate Specification: Compensator Spring Stack Height Standard: 17.68-18.08mm (.696 - .712 inch) 9.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 286: Torque Compensator Inspection (Late Build)
1. Assemble the torque compensator sleeve (A), washer (B) and gear (C) as shown. 4. Grease the peaks and valleys gear, sliding ramp, and splines of sleeve. 9.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 287: Rotor (Flywheel) Removal
9. Clean balance shaft threads thoroughly to remove all old locking agent, oil, or grease. 9.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 288: Rotor (Flywheel) Installation
7. Temporarily install rotor to rotate engine until key is pointing up, and timing marks on split gear are aligned with mark on crankshaft gear. 9.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 289: Split Gear Inspection
Replace the gear assembly if wear is evident. 2. After assembly, outer gear must rotate and return freely without binding on inner gear. 9.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 290: Starter Drive
5. Replace gear if wear or damage is evident. 3. Place a shop towel in the crankcase cavity. 9.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 291: Starter Clutch Removal / Inspection
NOTE: Stepped side of washer faces out (toward gear) and flat side of washer is against limiter clutch (inset). 10. Remove torque limit clutch. 9.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 292: Starter Torque Limit Clutch Inspection
30 ft-lbs (41 Nm). Repeat final torque on all screws. 3. Place idler gear in crankcase but do not install shaft. 9.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 293: Starter Gear / Starter Clutch Installation
4. Install retaining ring (D). 5. Install rotor (page 9.25). 6. Install primary cover (page 9.12). 7. Check engine oil and fill to proper level. 9.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 294: Troubleshooting
Pressure Plate Replace distorted Clutch plate(s) worn, warped or Driven plates and/or drive Replace distorted plates Weak clutch spring Clutch springs Replace all 9.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 295 Clutch plates bind or drag when Clutch plates / hubs Adjust / repair / replace clutch is disengaged Gear/bearing wear/damage Transmission components Inspect / replace 9.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 297 Gear Ratio: 3rd Gear 1.50: 1 Gear Ratio: 4th Gear 1.20: 1 Gear Ratio: 5th Gear 1.00: 1 Gear Ratio: 6th Gear (Overdrive) 0.87: 1 10.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 298 (.4704 - .4713") (.4693") Shift Fork Rail Runout .025 mm (.001") Shift Drum Shift Drum Groove Replace drum if any wear is evident 10.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 299 Replace bearing retainer plate screws if removed! Press bearings by outer race only! Oil Jet Orientation Section AA Pressed in with flat surface LH Case facing DOWN 10.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 300 Orient guide as shown below bolt torque - END Dot faces Crankcase bolt torque - START P clamp RH Case Flat edge faces case 10.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 301: Service Procedures
• Starter idler gear and shaft • Balance Shaft: Page 10.24 • Shift Drum / Transmission: Page 10.13 8. Remove starter motor. 10.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 303 TRANSMISSION & CRANKSHAFT Assembly View - Mainshaft / Clutch Shaft MAINSHAFT / CLUTCH SHAFT 10.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 305: Power Delivery (Typical 6-Speed)
Indicates movement of sliding gear for engagement 1st Gear & Neutral 2nd Gear 1st Gear Neutral 3rd Gear 4th Gear 6th Gear (O/D) 5th Gear 10.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 306: Nsa (Neutral Selection Assist) Transmission Information
2. Remove 4th, 3rd & 2nd gear along with all applicable retaining rings, thrust washers and needle bearings from the mainshaft. 10.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 307 If the ball bearings and cause incorrect operation of the NSA system. mainshaft pockets do not line up, incorrect operation of the NSA system will result. 10.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 308: Transmission Removal
PV-45028 to prevent shaft rotation. 5. Remove shift forks, shift drum, mainshaft and countershaft from crankcase. 6. Carefully lift crankshaft out of left case. 10.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 309: Clutch Shaft Inspection / Removal
Replace should support the shaft firmly with little or no bearing if clutch shaft is removed. detectable lateral movement. 10.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 310 6. Measure shift fork rail O.D. for wear in 3 or 4 places along the length. The rail O.D. should be consistent over the entire length. 10.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 311: Connecting Rod Side Clearance Inspection
Be careful not to cause damage to these parts when servicing items within the crankcase. 2. Remove connecting rod bolts and connecting rod bearing caps. 10.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 312: Connecting Rod Inspection (Big End)
Be sure mating surfaces (A) of rod and cap are clean. must face toward the left for the left connecting rod and 3. Apply Victory engine oil to threads of rod bolts and must face toward the right for the right connecting rod nuts.
Page 313: Connecting Rod Bearing Inspection
5. If service limits are exceeded, install new rod bearings and recheck oil clearance. 6. If service limits are still exceeded, determine if crankshaft or connecting rods need to be replaced. 10.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 314: Connecting Rod Bearing Selection
Orange ( - 159 ) RED Connecting Rod with WHITE Crankshaft (or not stamped) Blue ( - 027 ) 1.417- 1.423 mm 10.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 315: Crankshaft Inspection
10.3 for the proper color (or non-marked) connecting rod or crankshaft. Measure O.D. of crankshaft rod journal in four places and compare to specifications. 10.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 318: Right Crankcase Assembly
2. If main bearings are replaced, they must be line-honed with the left side crankcase to proper finished size. Press operation and fitting must be performed by a qualified machinist. 10.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 319: Transmission Installation
4. Rotate balance shaft until counterweights are clear of 8. Move shift fork pins into drum grooves and seat rails. crankshaft. Grasp balance shaft and remove it from case. 10.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 320: Balance Shaft Installation
(A) to lock balance shaft. 6. Install oil pump sprocket bolt and torque to specification. Oil Pump Sprocket Bolt: 85 in-lbs (9.6 Nm) 10.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 321: Crankcase
Be sure all areas are covered. DO NOT ALLOW SEALANT TO DRY. CONTINUE ASSEMBLY UNTIL CASES ARE SEALED AND ALL BOLTS ARE TIGHT. 10.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 322 Repeat the final torque. Crankcase Bolts: (STEP 1) 15 / 22 ft-lbs (20 / 30 Nm) (STEP 2) 22 ft-lbs (30 Nm) torque 10.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 323 20. Tighten the lock plate screws to specified torque. 21. Install CPS timing wheel. 17 ft-lbs (23 Nm) 10.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 324: Stake Nut Installation
Be sure staking lip does not tear/crack in staking area. Stake nut with round side of punch. Properly Staked Nut Do Not Stake Here 10.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 325: Troubleshooting
Starter Clutch, Starter Motor Oil Pump Oil Pump, Oil Pump Drive Refer to chapter 4 Cam Drive Cam Chain, Cam Sprocket Refer to chapter 7 10.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 326 Bent or Distorted Shift Fork Shift Fork Rails Replace shift fork rails Rails Worn Engagement Dogs on Transmission Gears Replace necessary parts Transmission Gears 10.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 329: Drive Line / Reverse System
All surfaces and fasteners must be clean, dry, and oil free before assembly. See Chapter 13 for Rear Wheel Removal / Installation. 70 ft-lbs (95 Nm) Install New Bolts Forward 11.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 330: Drive Sprocket Fastener Torques
Adhesive bead toward cover 85 in-lbs (9.5 Nm) Place transmission in 5th gear. Apply Victory All 5/16 or 8mm Purpose grease 11.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 331: Belt Specifications / Belt Guard
DRIVE LINE / REVERSE SYSTEM Belt Specifications / Belt Guard Drive Belt (Install so VICTORY can be read from RIGHT side of motorcycle) Screws M6 X 12 96 in-lbs (10.8 Nm) Seal O-ring Seal Sleeve Sprocket Nut 180 ft-lbs (244 Nm)
Page 332: Drive Belt
8. Pull head pipes outward to gain access to front sprocket cover bolts and provide clearance for cover removal. 9. Remove drive belt. 11.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 333: Drive Sprocket Inspection
3. Install seal sleeve (H) with the chamfer on inside diameter of sleeve facing in, toward O-ring. 2. Inspect splines (B) for a tight fit on output shaft splines. 11.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 334 Drive Sprocket Removal in this chapter. 8. Torque nut to specification. Drive Sprocket Nut: 180 ft-lbs (244 Nm) 11.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 335: Rear Sprocket
Refer to the Periodic Maintenance Table in chapter 2 for drive system replacement interval. 70 ft-lbs (95 Nm) Install New Bolts 11.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 336: Reverse System
Linkage Rod End In Forward - continuity through switch 90 in-lbs (10 Nm) Connected to reverse harness grounds Pin C of module 11.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 337: Reverse Gear Case Assembly View
DRIVE LINE / REVERSE SYSTEM Reverse Gear Case Assembly View 11.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 338: Reverse Linkage Adjustment
Step 3). If ball joint is loose, hold lever and tighten ball joint to lever shaft. 90 in-lbs (10 Nm) 11.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 339: Reverse System Test
7. If reverse system does not operate properly as described above, see Reverse System Diagnostics beginning on page 19.26. Reverse System: 25A Fuse 11.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 340: Reverse Coupler Shaft Key Replacement
Continue to adjust linkage rod until motor mount tabs mate squarely with the mounting boss on the frame. NOTE: Be sure motor is flush with frame before tightening mount bolts! 11.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 341: Troubleshooting
See Chapter 19 Reverse Motor Turns But Vehicle Remove drive motor with shaft and Reverse drive key(s) sheared. Does Not Move replace key(s). 11.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 343: Front Suspension / Controls
• Refer to Chapter 14 for TIRE REMOVAL, REPAIR, & BALANCING • Refer to Chapter 15 for BRAKE SYSTEM service and repairs and HYDRAULIC CLUTCH SYSTEM BLEEDING. 12.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 344: Fork Specifications
(16.27 fl.oz. ( .10 fl.oz.) Steering Bearing Adjustment Refer to page 12.12 or See “Triple Clamp Installation” on page 12.43. 12.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 345: Assembly Views & Torque
Audio Switch Detail 18 in-lbs (2.0 Nm) (Cross Country) Cruise Switch Detail (If equipped) 18 in-lbs (2.0 Nm) 18 in-lbs (2.0 Nm) 12.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 346 Short end of stud to riser 22 ft-lbs (30 Nm) Riser Tighten front screw first Isolator Sleeve Isolator Washer 40 ft-lbs (54 Nm) 12.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 347 22 ft-lbs (30 Nm) Tighten front screw first 22 ft-lbs (30 Nm) Tighten front screw first Riser Stud Isolator Sleeve Isolator 40 ft-lbs (54 Nm) 12.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 348 2. Tighten set screw until it stop against riser bolt. 3. Tighten set screw an additional 1/4 turn. Sleeve Isolator Washer 40 ft-lbs (54 Nm) 12.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 349: Clutch Cable / Lever Perch
Include clutch and throttle 48 in-lbs cables. Do not pull strap tight. (5.4 Nm) Cables must move freely in strap. 87 in-lbs (8.5 Nm) 12.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 350: Front Fork Attachments
Clip on inner fork tube and slide against axle housing Reflector: Clean fork with denatured alcohol. 40mm Apply 20 lbs pressure for 5-10 seconds. 12.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 351: Front Axle Assembly View
Hold front brake. Move suspension through Tighten pinch bolts. full travel range 4-5 times. 18 ft-lbs (24 Nm) Repeat pinch bolt torque. 12.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 352: Fork Tube Installation Steps
3 17.0 ft-lbs (23.0 Nm) 17.0 ft-lbs (23.0 Nm) 1 284.0 - 285.0 mm TUBE HEIGHT: Equal both sides +/- 1.0mm (.040 in.) Fig. 1 12.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 353: Steering Head Adjustment / Top Triple Clamp
29.0 ft-lbs (39.3 Nm) installed, loosen fork tube pinch bolts and slide both fork tubes down out of top clamp before removing top clamp. 12.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 354: Fork Tube Assembly View
Cartridge Assembly Spring Bottom Spacer Bottom Lower Bushing Spring Washer Oil Seal Retainer Dust Seal 15-19 ft-lbs (20-26 Nm) 12.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 355: Assembly View, Cast Front Wheel
(30 Nm) Replace screws if loosened or removed. 45 in-lbs (5.0 Nm) O-Ring Slot Metal Valve Stem With Slot. See Chapter 14. 12.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 356: Assembly View, Billet Front Wheel
Hub, RH Hub, RH Bearing Seal Seal FORWARD 45 in-lbs (5.0 Nm) O-Ring Slot Metal Valve Stem With Slot See Chapter 14. 12.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 357: Assembly View, Spoked Front Wheel
Seal ABS Pulse Ring Spacer Retaining Ring 22 ft-lbs Tire (30 Nm) Replace screws if loosened or removed. Inner Tube Protective Strip 12.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 358: Heated Grips
Brown (across from HIGH button) BU/PK SWITCH CONTACTS Wire Color LtBU DB Light Blue (POWER) HIGH Dark Blue (across from LOW button) 12.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 359: Service Procedures
4. Cover fuel tank to protect it from damage. Secure all cables, switches and controls out of the way as they are removed. 5. Disconnect front brake switch wires. 12.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 361 ALLOW SOLVENT CONTACT COSMETIC SURFACES! 14. If handlebars will be reinstalled, remove any residual adhesive from bar with solvent. 12.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 362: Handlebar Adjustment - Hard-Ball
NOTE: Handlebar index marks indicate high and low handlebar positions. Index marks should be aligned with parting in handlebar clamp. Gap should be same on both sides 12.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 363: Handlebar Installation
12.7. 9. Rotate front brake lever into desired position and, starting with the rear bolt, tighten to 80 in-lbs (9 Nm) 12.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 364: Clutch Cable
12.8. 7. Adjust clutch cable free play (page 2.14). Clutch Cable Free Play .5 - 1.5mm (.020-.060) 12.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 365: Throttle Cable
Remove longest screw (H) from front corner of switch and separate the switch halves. 12.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 366 4. Feed the inner cables up through the switch cube. Cables should lie flat against the switch (switch shown removed for clarity). 11. Remove cables. 12.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 367: Front Wheel Removal
• Be sure the throttle opens and closes smoothly in all steering positions, and returns to the fully 5. Apply a thin film of Victory Multi-purpose grease to the closed position when throttle grip is released. barrel ends of the cables and carefully attach them to the twist grip.
Page 368: Front Axle Inspection
2. Set up a dial indicator to measure radial runout (up and down) (A) and compare to specifications on page 12.3. 12.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 369: Brake Disc Installation
(or remove it) by hand. Replace the wheel if outer race of a new bearing does not fit tightly in the bore. 12.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 370: Front Wheel Bearing Removal
Flat side of 50-51 mm Collar LEFT RIGHT Flat side of 50-51 mm Collar Step 9 - Install retaining ring Wheel Bearing Installation 12.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 371: Front Fork Removal
Secure caliper in such a way to avoid hose damage. 6. Remove front wheel (page 12.26). 7. Remove front fender. 12.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 372: Front Fork Tube Installation
10. Loosen lower triple clamp pinch bolts (D) evenly, 1/4 turn at a time until loose. 11. Slide fork legs down and out of triple clamps. 12.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 373: Front Fork Disassembly
Slide outer tube down to expose spacer. Keep fork upright. 8. Hold jam nut with open end wrench and remove cap. 12.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 374 15. Proceed to Fork Seal Removal / Tube Disassembly. To change fork oil only, proceed to Fork Oil Filling / Level Setting (page 12.38). 12.33 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 375: Fork Seal Removal / Tube Disassembly
3. Protect surface of outer tube. Carefully pry seal from outer tube. Do not scratch seal bore. Remove seal Retaining backing washer from outer tube. Ring Dust Seal Inner Tube 12.34 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 376: Front Fork Inspection
Do not attempt to straighten bent fork tubes. Doing so will weaken the structural integrity of the forks and make the motorcycle unsafe to operate. 4. Remove cartridge from inner tube. 12.35 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 377: Front Fork Tube Assembly
6. Inspect cartridge by moving shaft through travel range. If binding is evident, replace the assembly. 2. Torque cartridge screw. 14.8 - 19.0 ft-lbs (20-26 Nm). 12.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 378 (by hand) until fully seated in outer tube. 8. Lubricate lower bushing with fork oil. Assemble the outer tube to the inner tube. 12.37 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 379: Fork Oil Filling / Level Setting
NOTE: The quantity slightly exceeds fork capacity. Final fork oil level must be adjusted correctly as outlined later. 12.38 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 380 • Springs and spacers removed • Tube upright and level • Cartridge rod at bottom of travel SPECIFICATION: 106mm (4.17") +/- 1mm (.040") PV-59000-A 106mm 12.39 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 381 Bottom cap on damper rod. 8. Hold damper rod up and remove cartridge shaft tool. 12.40 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 382: Triple Clamp Removal
1. Remove windshield (Cross Roads) or front fairing assembly (Cross Country). 2. Remove speedometer from top triple clamp (Cross Roads). 3. Cut tie straps (A) on handlebars. 12.41 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 383 16. Remove brake line from front master cylinder. Cover end of line and master cylinder with a clean, lint-free cloth to capture any spilled brake fluid. 12.42 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 384: Steering Head Bearing Inspection
14. Tighten (4) LOWER triple clamp pinch bolts evenly, enough to hold tubes in place. 6. Torque stem nut to 29 ft-lbs (39 Nm) using Victory 15. Fully tighten crown nut to72 ft-lbs (97 Nm) using spanner socket PV-43508.
Page 385 Throttle cables route between handlebar and brake line, crossing over the top of the brake line at the bottom of handlebars as shown below. 12.44 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 386: Steering Head Bearing Replacement
Lower Race Installation: 1. Clean the bore in the steering head thoroughly. 2. Wipe a light film of Victory all purpose grease on the outer surface of the new bearing race and on the surface of the bearing bore in the steering head.
Page 387 3. Place stem through triple clamp. 9. Remove old bearing from stem and discard. 12.46 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 388: Steering Head Bearing Adjustment
See “Steering Head Adjustment / Top Triple Clamp: Cross Roads / Cross Country” on page 12.12. Or refer to the triple clamp installation procedure on page 12.43. 12.47 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 389: Troubleshooting
Set Correctly Fork Spring Free Length Different Replace Between Right & Left Wheel Assembly Out-of-Balance Balance Low Tire Pressure Inflate to specification 12.48 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 390 Replace Brake Dragging Repair as Necessary (Hydraulic or Mechanical Problem) Brake Dragging (Bent Disc) Replace Improper Assembly After Repairs Correct as Necessary 12.49 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 393: Rear Wheel & Suspension
• Refer to Chapter 15 for brake system service. • Refer to Chapter 14 for tire removal, repair, & balancing. 13.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 394: Specifications
Shock Mount Bolt (Upper) 54 ft-lbs (73.2 Nm) Shock Pushrod Bolt (Lower) 60 ft-lbs (81.4 Nm) Shock Pushrod Bolt (Upper) 54 ft-lbs (73.2 Nm) 13.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 395: Assembly Views & Torque
Assembly View - Rear Axle & Adjusters Apply Victory All Purpose grease Retainer Adjuster 65 ft-lbs (88 Nm) Forward 8 ft-lbs (10.8 Nm) 13.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 396: Assembly View - Swingarm & Suspension
Spherical Bearing Use PV-49060 to install. 65 ft-lbs Spacer (88 Nm) Swing Arm Nut 24 in-lbs (2.7 Nm) Apply Loctite 262 Forward 13.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 397: Assembly View, Cast Rear Wheel
0 - 1mm (0 - .040) Seal Seal Disc Side Sprocket Side Snap Ring Bearing seated Bearing seated in hub against spacer Cutaway View From Rear 13.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 398: Assembly View, Billet Rear Wheel
Ness Billet: 65 ft-lbs (88 Nm) Do not disassemble wheel to No Loctite on hub replace bearings. See wheel mating surfaces. bearing replacement procedure. Hub Torque Pattern 13.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 399: Assembly View, Spoked Rear Wheel
Apply Victory All Purpose Grease RH (Sprocket) Bearing Seal Spacer Seal LH (Disc) Bearing Snap Ring Cutaway View From Rear Sprocket Side Disc Side 13.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 400: Rear Wheel Service
NOTE: Axle adjuster nuts do not have to be loosened or removed, however, belt tension and alignment must be inspected after assembly. 13.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 401: Rear Axle Inspection
NOTE: Do not apply rear brake pedal once the brake caliper has been removed. 3. Replace wheel if it fails visual or measured inspection. 13.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 402: Rear Wheel Bearing Inspection
The inner race should be firm with minimal side to side movement and no detectable up and down movement. 2. Remove sprocket (page 13.15). 13.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 403 5. Install bearing remover element into bearing. Tighten 8. Extract or drive the opposite side bearing. bearing remover until firm. Do not over-tighten or tool may be damaged. 13.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 404: Wheel Bearing Installation (Typical)
4. Install tool bearing (C), washer (D), and nut (E) on threaded shaft. 13.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 405 17. Install rear sprocket (page 13.16). 11. Pull bearing in to right side of wheel until seated against spacer. 13.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 406: Brake Disc Removal
5. Replace screws with new screws which have pre- applied locking agent. 6. Evenly torque brake disc retaining bolts specification. Brake Disc Mounting Bolts 22 ft-lbs (30 Nm) 13.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 407: Rear Sprocket Installation
3. Verify that the rear sprocket is aligned into the belt guard and install the drive belt. Verify the teeth are engaged completely on both the front and rear sprockets. 13.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 408 10. Tighten axle nut until seated and back off one full turn. Tap axle forward on each side to be sure adjuster nuts are seated against swingarm. 13.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 409 18. Inspect wheel speed sensor air gap and adjust if necessary. 19. Lower the motorcycle and test drive to ensure proper operation. 13.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 410: Rear Shock
REAR SHOCK Rear Shock Service Data The rear shock is not serviceable. Use dry compressed air or Victory Air Pump and Gauge (2876654 or PV-48909) to pressurize the shock. Set ride height by performing air pressure adjustment (see Chapter 2).
Page 411: Rear Shock Removal
4. Remove lower shock and push-rod bolts (A) from 7. Remove jam nut (G) securing air valve to subpanel and swingarm. cut tie strap (H). Withdraw air valve from subpanel. 13.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 412 11. Remove rocker shaft and lower the shock assembly through the hole in swingarm far enough to access upper shock bolt. 13.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 413: Rear Shock And Rocker Inspection
7. Inspect shock spring for cracks or coil distortion. Measure free length and compare to specification. 13.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 414: Shock Absorber Installation
3. Attach shock to rocker arm and torque bolt to specification. INCORRECT Rear bolt could contact shaft when installed. FRONT Shaft not seated. 54 ft-lbs (73 Nm) 13.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 415 Cutaway View 60 ft-lbs (81.4 Nm) 7. Secure air line and vent hose in clips (A) of inner rear fender (debris flap). 13.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 416: Swingarm Service
84 in-lbs (9.5 Nm). 14. Install seat, side covers and saddlebags. (Chapter 3) 15. Bounce test suspension to check for proper operation before test ride. 13.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 417 13. Remove swingarm pivot shaft nut and washer (F). 10. Remove right passenger footrest bracket fasteners (E). 14. Push swingarm shaft out from right to left. 15. Remove swingarm. 13.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 418: Swing Arm Bushings / Bearing Replacement
12. Grease right side bearing sleeve (A) and install with a twisting motion until centered in the seals and bearing. 13.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 419: Swing Arm Installation
(2.7 Nm). 8. Torque LEFT side nut to 24 in-lbs (2.7 Nm). 9. Torque RIGHT side nut to 65 ft-lbs (88.7 Nm). 13.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 420: Troubleshooting
Tire contact with object or chassis Determine point of contact and correct Bent rear axle Replace Damaged wheel bearings Replace Brake problem Refer to chapter 15 13.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 423: General / Safety
- Bubbles, separation or any unusual damage to the inner liner of the tire. - Chemical sealants or balance additives added to the tire. WARNING All repairs must be made from inside the tire. Victory recommends the use of “head-type” plugs such as: Tech Tire Repair Uni-Seals. Complete Tech Tire Repair kits are commonly available at most automotive parts outlets.
Page 424: Tire Data
Refer to Chapter 12 (Front Wheel and Suspension) or Chapter 13 (Rear Wheel and Suspension) for wheel specifications. SPECIAL TOOLS Special Tools Rim Protectors: PV-43536 Tire Irons (for manual tire changing): Commercially available 14.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 425: Tire Inspection
• Binding or improperly assembled front forks can also contribute to excessive tire cupping. If the front forks do not react as they should the tire acts as the sole suspension component and tread deflection increases. 14.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 426: Tire Changing
The seal between the tire and rim is one of the most critical factors that contribute to the safe operation of the wheel/ tire assembly. Victory permits and recommends all three of the general methods, but realizes that careless or improper work habits can damage both the tire and rim no matter which method is used.
Page 428: Wheel Inspection
Continue to work around the tire until the tire is of air pressure can cause a loss of control and an completely dismounted. accident, resulting in serious injury or death. 14.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 429: Tire Repair Precautions
6. Pull the valve (A) until fully seated and remove tool. Fig. 8 TYPE 2 (NO HOLDING SLOT) 12 in-lbs (1.35 Nm) Fig. 9 Fig. 10 14.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 430: Tire Installation
When the tire is mounted correctly the scrubbing forces of acceleration (rear) or braking (front) press the lap joints together rather than try to separate the joint. 14.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 432: Tire Balancing
(lightest) part of the wheel. Inspect and adjust tire inflation pressure after tire cools down for at least three hours following “run-in”. 14.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 433 7. When correct amount of weight has been added to wheel, it will no longer stop in the same location and the wheel assembly is balanced. 14.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 434: Spoked Wheel Offset Measurement And Adjustment
TIRES / WHEELS SPOKED WHEEL OFFSET MEASUREMENT AND ADJUSTMENT EXAMPLE CALCULATION EXAMPLE CALCULATION 14.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 435: Spoked Wheel Offset Adjustment
Wheel Truing 1. Inspect wheel offset as outlined on page 4.12 before truing the wheel 2. Measure axial and radial runout. 14.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 436: Final Tightening
2. Organize 20 inside spokes and nipples on a clean work surface. Lubricate spoke threads and rim nipple-holes with a light oil. 14.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 438: Spoke Maintenance
8. Place wheel assembly onto a truing stand for rim offset adjustment, final spoke tightening and wheel truing of wheel. 14.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 439: Troubleshooting
Fill to specification Fork spring free length different Replace spring that does not meet between right & left specification Wheel assembly out-of-balance Balance wheel 14.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 441: Brake System Safety
BRAKE SYSTEM SAFETY General Use only genuine VICTORY replacement parts when servicing the brake system. Clean all system components prior to disassembly, including the fluid reservoir cover(s) to reduce the chance of debris entering the system during repair or maintenance work. Start with a clean work area away from dust, water or other contamination. Cleanliness is very important for proper brake system maintenance and repair.
Page 442: Specifications
ABS Tone Ring to Brake Disc 30 N-m 22 ft-lbs ABS Module Bracket to Chassis 10.8 N-m 8 ft-lbs ABS Module to Bracket 10.8 N-m 8 ft-lbs 15.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 443: Special Tools
6 mph (10 kph), the system is not surface during a hard braking event. functioning. Connect Digital Wrench and perform an ABS System inspection to determine the cause. 15.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 444: Abs System Components
Disconnect negative (-) battery cable from battery before mounted to wheel with 3 disc bolts) servicing ABS brake lines or system components. • ABS Module Assembly 15.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 445: Anti-Lock Brake System Overview
BRAKES ANTI-LOCK BRAKE SYSTEM OVERVIEW Front Brake (ABS) 15.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 451: Front Brake Calipers
Caliper Body Bolt (009-Z00-111) (009-Z00-111) 20 ft-lbs (27 Nm) Pad Retaining Pin Loctite 242 (Blue) 120 in-lbs (13.5 Nm) E12 Reverse TORX 15.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 452: Rear Brake Caliper
(included with parts kit) Pad Backing Plate Must not protrude past edge of pad Boot and Pin Brake Pad Guide Plate Pad Insulator (009-Z00-115) 15.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 454: Abs System Service
No more than 3 shims (per Wheel Speed Sensor) should be used at one time. 15.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 455: Abs Module Service
3. Attach Digital Wrench and check for ABS trouble codes. 6. Reinstall Wheel Speed Sensor and torque to specification. Wheel Speed Sensor: 8 ft-lbs (10.8 Nm) 15.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 456: Abs Brake System Bleeding
Apply cavitation. special lubricant where indicated (included in service kits). 15.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 457: Abs Brake Vacuum Bleeder
Do not allow reservoir level to fall below the LOW level or complete system bleeding will be required. 15.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 458: Abs Front Brake System Bleeding
5. Hold lever to handlebar or hold firm pressure on lever, then open bleed screw about 1/4 turn. 15.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 459: Brake Lever Reserve Inspection
15. Fill fluid reservoir and install diaphragm and cover. Torque screws to 13 in-lbs (1.5 Nm). 16. Perform Brake Lever Reserve Inspection page 15.20. 15.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 460: Brake System Service
(as described in Brake Bleeding on page 15.19) and open the bleed screw while pushing the pads and pistons back. 15.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 461 (D) while sliding pin over the top of center arm. 8. Apply a small amount of Silicone Grease (009-Z00- 111) to O-ring on the end of the pad retaining pin. 15.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 462: Rear Brake Pad Replacement
If brake drag is evident, do not operate the motorcycle. Inspect vehicle to determine cause and then repair as necessary. 15.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 463 13. Pump brake pedal slowly several times to set new pads against disc, until lever is firm and pressure can be felt. 14. Bleed brake system if necessary (page 15.18). 15.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 464: Brake Disc Inspection (Front & Rear)
(each caliper on dual front disc models) by slowly pumping brake lever. 2. Remove mirror (A). Measure thickness at 4 points around disc and 2 spots at each point. 15.25 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 465 7. Remove reservoir cover and diaphragm. 8. Pull dust boot off piston and out of cylinder bore. 9. Remove snap ring. 15.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 466 17. Apply a light film of special lubricant from piston kit to each piston seal cup. Master Cylinder Piston Diameter Service Limit: 15.72mm (.6189 in.) 15.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 467: Front Master Cylinder Installation
(1.0 Nm). Hold screw and torque nut to 52 in-lbs (6 Nm). 7. Install mirror, adjust to proper angle, hold in position and tighten nut securely. Brake 15.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 468: Front Caliper Service
4. Cover the brake hose connection on the caliper and clean the outer surfaces of caliper assembly with Victory brake cleaner or isopropyl alcohol. Dry with compressed air. 15.29 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 469: Front Caliper Service (Cont)
13. Inspect each piston bore for corrosion, scratches, scoring, or pitting. Replace caliper if any of these conditions are evident. 15.30 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 470: Front Caliper Installation
Inspect vehicle to determine cause and 17. Apply special assembly oil (included in kit) to outer then repair as necessary surface of all pistons. 15.31 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 471: Rear Master Cylinder Service
(C) and remove master cylinder. Internal stop washer 7. Pull boot back from fluid supply fitting and remove retaining ring. 15.32 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 472 16. Rotate clevis counterclockwise to remove it from the 12. Clean all parts with clean Victory DOT 4 brake fluid or pushrod with the adjuster nut inside. isopropyl alcohol. 17. Remove lock nut from pushrod and remove old boot.
Page 473 12.5 ft-lbs (17 Nm). to cups (included with parts kit) 21. Apply Victory DOT 4 brake fluid to the O-ring (K) for the supply fitting and install it in the master cylinder. 25. Apply special lubricants from service kit to the seal cups, pushrod and backing washer.
Page 474: Rear Master Cylinder Installation
BRAKES Rear Master Cylinder Installation 9. Fill reservoir with Victory DOT 4 brake fluid and bleed the system as outlined on page 15.17. Also refer to the appropriate Assembly View at the beginning of this chapter. WARNING 1. Install master cylinder on footrest support, engaging After pad installation or any brake system repair, safely clevis with brake pedal.
Page 475 12. Install piston seals and dust seals in caliper body. 13. Install pistons in their respective bore. 15.36 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 476: Rear Caliper Installation
Verify wheel turns freely without drag. If brake drag is evident, do not operate the motorcycle. Inspect vehicle to determine the cause and then repair as necessary. 15.37 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 477: Abs Trouble Codes
ABS Tire Size Mismatch C1041 ABS Module Fault C1042 ABS Incomplete Evacuation and Fill C1045 Trip Sudden Deceleration - Open / Short 15.38 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 478: Troubleshooting
Inspect / Replace Cover, Cap, Diaphragm or Reservoir as Required Fluid level too high (new brake pads installed without Correct fluid level removing added fluid) 15.39 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 479 Repair as Necessary. Inspect Pad Installation Aftermarket (not genuine Victory) Parts Install Genuine Victory Parts Worn or Damaged Wheel Bearing(s) Replace Worn Pads / Disc Replace 15.40 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 480: Abs System Troubleshooting
Bring motorcycle to a safe stop. Cycle ignition key OFF / ON to reset system. Light should go off when vehicle speed exceeds 6 mph / 10 kph. 15.41 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 483: Battery Charging System
Regulator/Rectifier to Bracket 10 Nm (85 in-lbs) Regulator/Rectifier Bracket to 10 Nm (85 in-lbs) Crankcase Stator Mounting Screws 11 Nm (100 in-lbs) Loctite™ 242 16.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 484: Battery Box And Attachments
40 in-lbs (4.5 Nm) 85 in-lbs (9.6 Nm) 19 ft-lbs (25.7 Nm) 16.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 485 3 Pin Connector (To Stator Phase Wires) 40 in-lbs (4.5 Nm) BK/RD 85 in-lbs (9.6 Nm) Circuit Breaker LOADS 25 in-lbs (2.8 Nm) 16.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 487 Do not increase the value of the fuse to correct the problem. Do not use wire, tin foil or other substitutes for fuses. 16.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 488: Battery
Inspect voltage monthly and charge according to above instructions if necessary. 16.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 489: Diagnostics
Inspect Stator (Page 16.13 - 16.14) Faulty Wiring or Connectors; Stator OK Damaged Flywheel Magnet Test Regulator/Rectifier Unit Replace Regulator/Rectifier Unit (Page 16.16) Regulator / Rectifier Faulty 16.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 490: Battery Load Test
1. Turn key OFF and wait at least 30 seconds for all powered circuits to disconnect before performing the key-off current draw test. 16.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 491: Regulated Voltage / Amperage Output Inspection
13. Install center chin fairing. 4. Connect DMM red (+) lead to battery (+) terminal and DMM black (-) lead to battery (-) terminal. 16.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 492: Stator No-Load Ac Voltage Output Inspection
NOTE: The test results obtained in step 11 can read more than specified VAC, but it is important that they are all approximately equal. 16.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 493: Stator Resistance Inspection
= 0.4 ohms (true stator winding resistance 5. Repeat resistance test on all remaining combinations of the three pins A, B, and C (three measurements total). 16.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 494: Voltage Drop: Rectifier / Regulator To Battery(+)
Visual inspections or continued voltage drop inspections are necessary to determine the cause. 16.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 495: Diode Leakage Test
/ rectifier, and the red (+) meter lead to the circuit breaker terminal. 5. Compare leakage to specification below. DIODE LEAKAGE: Less than 1.0 mA 16.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 496: Regulator / Rectifier Test
Battery + Lead (Ring terminal of Red wire) 365mV to 515mV AC Phase 3 (Pin C of 3-pin) Battery + Lead (Ring terminal of Red wire) 365mV to 515mV 16.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 497: Rectifier / Regulator Replacement
4. Lift tab (A) and push forward to separate the 3-pin connector. 5. Remove regulator / rectifier mounting screws (B). FRONT 85 in-lbs (9.6 Nm) 6. Remove wires from wire guides. 16.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 498 5. Pull wires to remove any slack or loop at point (D). Wires must not protrude into flywheel rotor area. 6. Install primary cover (page 9.12). PULL Flywheel Removal Refer to page 9.24. 16.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 501: Ignition System Specifications
280 Ohms ± 10% (No short to ground) * Spark plug end caps are not removable ** See page 17.8 for test procedure 17.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 502: Troubleshooting
Extremely high voltage is present in the ignition system. Do not touch the ignition coil, wires or spark plugs during test procedures. 17.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 503: Ignition Circuit Diagram
IGNITION Ignition Circuit Diagram WH / BK WH / DG VT/YE RD / BK VT / BK 17.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 504: Test Lead Adapter Kit
VERIFY TERMINAL PINS ARE NOT LOOSE IN CONNECTOR AND WIRE CONNECTION TO TERMINAL PIN IS SECURE. NOTE: CONNECTOR IS MARKED WITH NUMBERS 1, 30, 31, and 60 ONLY. 17.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 505: Ignition System Test Flowchart
Ground Circuit Correct clean and dry if moisture is found Replace ECM Note: ECMs rarely fail. Verify all troubleshooting steps again before replacing ECM 17.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 506: Battery Voltage Inspection - Test 1
(Test 3). NOTE: The plug caps or coil ends are NOT removable. Wire must be replaced as an assembly. 17.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 507: Coil High Tension Leads - Test 3
8. With transmission in Neutral, crank the engine. Front: 4360 - 5780  Battery voltage should again be present on the Rear: 4080 - 5050  terminal. 17.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 508: Ignition Coil Resistance - Test 5
• If both signals are present and there was battery secondary windings). voltage on the VIO/Y wire (center terminal) but still no spark, test ignition coil windings. (Test 5). (Cont.) 17.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 509: Crankshaft Position Sensor (Cps) Resistance Inspection - Test
DMM SECONDARY COIL RESISTANCE USE DIODE CHECK FUNCTION ON DMM 2.0-2.5 Vdc Open or “OL” with leads reversed 17.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 510: Crank Position Sensor Circuit And Signal Test 6A
Any fluctuating AC signal is correct for this test. Meter on AC Volts Scale 17.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 511: Ignition Coil Removal
2 screws (D). 5. Press tab (E) to remove primary connector. 84 in-lbs (9 Nm) FRONT TOP VIEW 6. Remove ignition coil. 17.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 513: General
Rotor Bolt (Flywheel) 102 Nm 75 ft-lbs Starter Motor to Crankcase Bolts 30 Nm 22 ft-lbs Starter Motor Case Screws 10 Nm (85 in-lb) 18.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 514: Diagnostics
Starter motor turns at normal speed, Ignition Problem Chapter 17 but engine does not start. Engine Problem Chapter 7-10 Fuel Delivery Problem Chapter 5 18.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 515: Starter Circuit Diagram
Starter Circuit Diagram Reverse equipped see Chapter 19 Located at rear of engine near speed sensor harness YE/BK RD/BK YE/WH YE/WH DB/YE DB/YE 18.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 516 Ensure that motorcycle is secure and transmission is in neutral for all tests. CAUTION Inspect fuses and make sure battery is fully charged before inspecting starter system. 18.5 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 517 The starter motor can Starter torque limit clutch slipping. Refer To Procedure Chapter 9. be heard spinning. Starter gears damage. Refer To Procedure Chapter 9. 18.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 518: Battery Inspection & Charging Procedures
18.8). 5. If starter motor does not turn, inspect button by performing STARTER RELAY POSITIVE CIRCUIT TEST on 18.11. 18.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 519: Neutral Switch Bypass Test
Any Gear - Other Than Black/Pink Crankcase (ground) Neutral (switch side of connector) * Be sure to subtract meter probe resistance from resistance reading 18.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 520: Clutch Switch / Circuit Test
11. If switch fails test, inspect mounting of switch. 12. If switch is mounted correctly and physically operates but does not open and close electrically, replace switch. 18.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 521: Clutch Switch Removal
Wear a face shield and approved Test. safety glasses while doing the following test. 1. Place the transmission in neutral. 18.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 522: Starter Relay Positive Circuit Test
6. If the starter motor does not operate, inspect cables by for good continuity from switch to starter relay performing tests on following pages. connector on the Y/W wire. 18.11 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 523: Starter Relay To Starter Motor Positive Cable Bypass Test
2 pin connector Starter Relay 2. Connect one clamp of a heavy-duty, automotive remote starter switch to positive terminal lug at starter motor. 18.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 524: Positive Side Voltage Drop Test
DMM leads placed as indicated. (Cont.) 5. Set DMM to DC Volts. 6. Place one lead of DMM to positive battery post. 18.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 525 18. Inspect battery post, battery cable lug and relay lug for (Cont.) corrosion or looseness. NOTE: Corrosion has resistance that limits or stops the flow of current to the starter motor. 18.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 527: Negative Side Voltage Drop Test
(Cont.) 2 pin connector Starter Relay 2. Set DMM to DC Volts. 3. Place one lead of DMM to negative battery post. 18.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 528 17. Place one lead of DMM to battery cable mount at engine. Reset the DMM to read DC Volts if necessary. 18.17 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 529: Starter Current Draw Test
2. Place transmission in neutral. 3. Position an inductive ammeter clamp on battery positive cable. Starter < 130 amps 18.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 530: Starter Motor Removal
7. Connect negative battery cable. 5. Remove 2 starter motor mounting bolts and remove starter. Starter Clutch Removal 1. Refer to Chapter 9. 18.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 533: Headlamp
Turn Handlebars FULL RIGHT before tightening left P-Clamp 48 in-lbs (5.4 Nm) 36 in-lbs (4.0 Nm) 28 ft-lbs 17 ft-lbs (38 Nm) (23 Nm) 19.2 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 534: Headlamp Assembly View - Cross Country
Top bulb socket faces left. (LOW BEAM) Battery voltage should be present Europe on Yellow/Pink wire with key ON. (EXCEPT HID) 85 in-lbs (9.6 Nm) 19.3 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 535: Headlamp (Hid) - Cross Country Tour
WIRING / LIGHTING SYSTEMS Headlamp (Hid) - Cross Country Tour Headlamp Aim Procedure See Chapter 2 19.4 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 537: Tail Lamp / Brake Lamp System Wiring Diagram
WIRING / LIGHTING SYSTEMS Tail Lamp / Brake Lamp System Wiring Diagram Lamps are internally regulated and can be powered directly to test. 19.6 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 538: Turn Signal / Hazard System
Turn signal units are internally regulated powered. Turn ignition key ON and Engine Stop and can be powered directly to test. switch to RUN. 19.7 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 539: Turn Signal Flasher Module - Input / Output
Module sends power to left turn signals on this wire when it receives a LH turn Left Turn Signal Output DARK BLUE signal input (ground) on module Pin 3 (BK/BU) (from ECM Pin 14) 19.8 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 540: Turn Signal System Overview And Diagnostics
2. Separate connector. Connect ohmmeter to Pin 4 and Pin 5 (RH turn) or Pin 4 and Pin 6 (LH turn) on switch side of connector. Hold switch to left or right and verify good continuity in each position. 19.9 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 541: Speedometer / Tachometer Signals
9. If no speed signal is present, inspect all connections and the related wires in the connectors. 10. Test speed sensor using Speedometer Signal Tester PV-43544 and adaptor harness PV-47303. 19.10 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 542: Tachometer Signal Test
Speedometer Gear Position Indicator For model years 2011-2013, ALL Victory Motorcycles with a gear indicator display will show dashes (---) if the clutch lever is pulled in (clutch disengaged). The gear indicator system uses multiple inputs to show the gear number 1 through 6.
Page 543: Switch Testing
SPECIFICATION: Continuity When Brake Applied Rear brake Front brake hydraulic micro switch pressure located on front switch brake lever perch located above oil filter 19.12 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 544: Neutral Indicator Switch Inspection
43 in-lbs (4.9 Nm) and P-clamp screws to 87 in-lbs (9.8 Nm). Clutch Switch Testing 1. Refer to page 18.9 to test the clutch switch and circuit. 19.13 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 545: Tipover Sensor (Angle Sensor)
5. Connect Digital Wrench for further diagnosis of the tipover sensor circuit. 19.14 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 546: Side Stand Switch Information (Eu Models Only)
5. Check pins 1-3 on the side stand switch connector for shorts/grounds. If found, replace switch. 19.15 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 547: Horn Relay Circuits
Battery voltage with key on and horn button pressed. Power directly to test horn. Ground horn with a jumper to test ground connection and circuit. 19.16 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 549: Heaters
Turn key OFF. Check for a good ground (less than 1 Ohm) on BK wire (on main harness side of 2-Pin). SWITCH CONTACT Wire Color LB/PK HIGH 19.18 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 550: Heated Grips
Wire Color Brown (across from HIGH button) BU/PK SWITCH CONTACTS Wire Color Light Blue (POWER) HIGH Dark Blue (across from LOW button) 19.19 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 551 Harness Connector(15)  Cruise Switch Connector (16)  Handlebar Switch Connectors (17)  Fairing Harness Connector (18)  LCD Display Connector (19) 19.20 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 552: Ground Locations
Chassis harness grounds are located under the right side cover, behind the inner panel. The ECM ground is located on the frame behind the ECM. 19.21 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 553: Cruise Control
To cancel the cruise control and erase the set speed from 4. Push the OFF button to turn the cruise control system memory, press OFF. off and erase the memory set speed. 19.22 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 554: Cruise Control Diagnostics
(Pin 4 of module should not be powered when throttle is released). 19.23 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 555: Cruise Module Input / Output
DG / WH FROM PIN 22 of ECM) WH / BN IDICATOR LAMP OUTPUT VEHICLE SPEED INPUT (FROM PIN DG / DB 21 ECM) 19.24 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 556 DG/WH Reverse Harness DB/YE GY/RD Chassis Harness RD/BK IC = Instrument Cluster Under seat / left side inner saddlebag Under seat / left side cover Wire Color Note: BU/Y = DB/YE GN = DG Under electrical cover R = RD (front of engine) W = WH Y = YE...
Page 557: Reverse System Diagnostics
Power out of module to reverse drive motor when starter button is pressed (and Reverse Output GY/RD reverse lever is in Reverse). Not Used Pin K not used 19.26 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 558 6. If switch opens and closes out of the range above, adjust linkage rod (Chapter 11). Replace switch if always grounded or open. 19.27 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.
Page 559: Reverse System Safety
(N) displays before stopping the engine. NOTE: The engine will stop if you shift into forward gear before disengaging the reverse lever. 19.28 9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual © Copyright 2012 Polaris Sales Inc.

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Victory Cross Roads Classic Service Manual

Chapter 1 1 Specifications / Gauge / Audio

Maintenance Chapter 2 Maintenance 2

Frame-Body-Exhaust Chapter 3 Frame-Body-Exhaust

Lubrication & Cooling Chapter 4 Lubrication & Cooling

Chapter 5 Fuel System / Fuel Injection

Engine Removal & Installation Chapter 6 Engine Removal & Installation

Cylinder Head & Valve Train Chapter 7 Cylinder Head & Valve Train

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Victory Cross Roads Classic