Victory Vision Street 2008 Service Manual

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SPECIFICATIONS / GAUGE / AUDIO

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

TRADEMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SERVICE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

2008 - 2009 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

2010 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

VIN NUMBER / MANUFACTURER LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

VECI / NECI / TIRE INFORMATION LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

KEY IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

PUBLICATIONS & TECHNICAL LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

MATERIAL SAFETY DATA SHEET (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

VICTORY TOUCH-UP & REFINISHING PAINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

VICTORY DETAIL & FINISH RESTORER KITS AND PRODUCTS . . . . . . . . . . . . . . . 1.13

PAINTING TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

PAINT COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16

BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17

EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18

SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19

TRANSPORTING, ELEVATING, AND SECURING THE MOTORCYCLE . . . . . . . . . . . 1.22

INSTRUMENTATION / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23

CLOCK, GEAR POSITION, TRIP ODOMETER, TEMPERATURE, ODOMETER . . . . . 1.25

CHANGING INFORMATION DISPLAY UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

CONSOLE MOUNTED SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

HAND GRIP HEATER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

HAZARD SWITCH (EMERGENCY FLASHERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

DRIVING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27

SEAT HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28

LEFT HANDLEBAR SWITCH, MODE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28

HEADLAMP HIGH / LOW BEAM SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28

WINDSHIELD ADJUSTMENT SWITCH (MOTORIZED) . . . . . . . . . . . . . . . . . . . . . . . . 1.28

MANUAL WINDSHIELD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29

TURN SIGNAL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29

CLUTCH LEVER & STARTER INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29

RIGHT HANDLEBAR CONTROLS, ENGINE STOP SWITCH, STARTER BUTTON . . 1.30

AUDIO / COM / CRUISE CONTROL BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30

MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30

LINKED BRAKE SYSTEM / ABS BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30

FRONT BRAKE LEVER REACH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31

FOOT CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31

FUEL DOOR, FUEL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32

GLOVE / STORAGE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32

SADDLEBAGS, TRUNK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33

SPECIFICATIONS / GAUGE / AUDIO

CHAPTER 1

1.1

Chapters

Table of Contents

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Summary of Contents for Victory Vision Street 2008

Page 1: Table Of Contents
REFINISHING ............1.13 VICTORY TOUCH-UP & REFINISHING PAINT....... 1.13 VICTORY DETAIL &...
Page 2 SPECIFICATIONS / GAUGE / AUDIO RADIO / AUDIO SYSTEM ..........1.34 RADIO / AUDIO SYSTEMS OPERATION .
Page 3: 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 4: Safety Information
Modifications to this motorcycle not approved Brake fluid is poisonous. without a properly functioning exhaust gas by Victory may cause loss of performance, KEEP OUT OF REACH OF CHILDREN. evacuation system connected to the product. excessive emissions, and make the machine unsafe for use.
Page 5: General Specifications
SPECIFICATIONS / GAUGE / AUDIO GENERAL SPECIFICATIONS 2008 - 2009 Vision Street / Vision Tour / 10th Anniversary Vision / NSS Vision Specifications 2008-2009 VICTORY VISION Models Oil Capacity 5.0 Qt. (4.75 ltr) (Approximately 4.5 qts. or 4.25 ltr at oil & filter change) Fuel Capacity 6.0 US Gal (22.7 ltr) (1.0 U.S.
Page 6 SPECIFICATIONS / GAUGE / AUDIO 2008-2009 Vision Street / Vision Tour / 10th Anniversary / NSS Vision Specifications (cont.) 2008 - 2009 VICTORY VISION Models Transmission Type Manual, 6 Speed Overdrive, Constant Mesh Clutch Type Wet, Multi-Plate Diaphragm Spring Primary Drive Type...
Page 7 SPECIFICATIONS / GAUGE / AUDIO 2010 VICTORY VISION Tour / Tour ABS / 8-Ball / NSS Vision Specifications VICTORY VISION TOUR / TOUR ABS VICTORY VISION 8-BALL / NESS Oil Capacity 5.0 Qt. (4.75 ltr) (Approximately 4.5 qts. or 4.25 ltr at oil & filter change) Fuel Capacity 6.0 US Gal (22.7 ltr) (1.0 U.S.
Page 8 SPECIFICATIONS / GAUGE / AUDIO 2010 VICTORY VISION Tour / Tour ABS / 8-Ball / NSS Vision Specifications (cont.) 2010 VICTORY VISION Models Transmission Type 6 Speed Constant Mesh With True Overdrive Clutch Type Wet, Multi-Plate Diaphragm Spring Primary Drive Type...
Page 9: Vehicle Loading
SPECIFICATIONS / GAUGE / AUDIO VEHICLE LOADING GROSS VEHICLE WEIGHT RATING (GVWR) WARNING Exceeding the gross vehicle weight rating of your motorcycle can reduce stability and handling and could cause loss of control. NEVER exceed the gross vehicle weight rating of your motorcycle. The maximum load capacity of your motorcycle is the maximum weight you may add to your motorcycle without exceeding the GVWR.
Page 10: Vehicle Information
P = Kingpin 8-Ball (Premium package equipped as S = Victory Vision specified for model. V10SD36DAP V = Victory Vision 8-Ball T = Top Premium Model X = Jackpot (Premium package and additional upgrades as specified for model) Example: 2010 - T designates ABS...
Page 11: Vin Number / Manufacturer Label
Key blanks are available from Victory. Locksmiths familiar with the motorcycle industry will be able to cut a ENGINE NUMBER LOCATION replacement key with the I.D. number and a Victory key blank. The engine number (C) is stamped into the right crankcase boss.
Page 12: 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 13: Refinishing
Paint finish may be wet sanded and buffed after coating has cured. How to order: Authorized Victory Dealers only. Place your order via the dealer web site at: www.polarisdealers.com / News Forms & Links / Pure Polaris NOTE: There will be a 25% service fee charged for all returns. Polaris dealer will be responsible for return freight VICTORY DETAIL &...
Page 14: Paint Colors By Model
V08S236 VICTORY VISION Tour - Feature / Option V08SD36CA, CAP, CAT, DA, DAP, DAT, LA, LAP, LAT VICTORY VISION Tour, Solid Black V08SD36CC, CCP, CCT, DC, DCP, DCT, LC, LCP, LCT VICTORY VISION Tour, Midnight Cherry V08SD36CD, CDP, CDT, DD, DDP, DDT, LD, LDP, LDT VICTORY VISION Tour, Supersteel Gray ...
Page 15: Model Year
SPECIFICATIONS / GAUGE / AUDIO PAINT COLORS BY MODEL (Cont.)  VICTORY VISION TOUR MODEL YEAR 2010 V10SD36CGP, DGP, LGP VICTORY VISION Tour, Solid Pearl White V10SD36CPP, DPP, LPP VICTORY VISION Tour, Ocean Blue/Sandstone Metallic  VICTORY VISION TOUR ABS MODEL YEAR 2010...
Page 16: Paint Color Codes
SPECIFICATIONS / GAUGE / AUDIO 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: 2008 - 2010 PAINT NOTES CODE Cobalt Blue P-1278 P-574 Cobalt Blue / P-585 Tinted Black (1st Overlay) / P-500 Graphics...
Page 17: 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 18: 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 2.5 and inspect the emission control system as outlined in this manual.
Page 19: Special Service Tools
Bodywork Removal Tool Set PV-49955 Bore Gauge Set, 50-100mm PV-3017 Decal, Service Bulletin Completion 7170107 (Order from Victory Parts Dept.) Dial Caliper (Metric, 0-150mm) PV-26900-7 Dial Caliper (Electronic Conversion. English 0-6” / Metric 0-150mm) PV-39776 Dial Indicator, Adjustable (Metric. 10mm travel) PV-26900-12 Dial Indicator Stand, Flexible.
Page 20 Shock Spring Compressor PV-43571 PV-47060 Damper Rod Extension tool is for TYPE 1inverted (MARZ, Hammer / KP) forks only. PV-49453 works on ALL Victory cartridge forks including Type 1 and Type 2 (KYB) Vision forks. 1.20 © 2009 Polaris Sales Inc.
Page 21 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/ 1.21...
Page 22: Transporting, Elevating, And Securing The Motorcycle
SPECIFICATIONS / GAUGE / AUDIO TRANSPORTING, ELEVATING, AND SECURING THE MOTORCYCLE GENERAL GUIDELINES WARNING Care should be taken to be sure the motorcycle will not tip or fall while elevated. Severe personal injury or death could occur if the motorcycle tips or falls. If you must transport the motorcycle or secure it to a lift table: •...
Page 23: Instrumentation / Controls
SPECIFICATIONS / GAUGE / AUDIO INSTRUMENTATION / CONTROLS IGNITION SWITCH The ignition switch has 4 positions - OFF, ON, ACC, and IGNITION KEY LOCK. The switch is also used to open or lock the fuel door on the right side of the console, and to lock the glove The ignition key operates the ignition switch, fuel door compartment on the left side of the console.
Page 24 SPECIFICATIONS / GAUGE / AUDIO INSTRUMENT CLUSTER VOLT METER The instrument cluster includes the items listed on the (4) The volt meter displays battery voltage being supplied following pages. The MODE button (page 1.28) is used to to main electrical circuits when the key is in the ON position. toggle through various functions, change unit display (mph to kph) and to reset all functions except the odometer and The meter will display approximate battery voltage when...
Page 25 SPECIFICATIONS / GAUGE / AUDIO CLOCK GEAR POSITION (1) The clock is displayed with the key in the ON or ACC (2) The number of the current transmission gear is position. To change from 12 hour clock to 24 hour clock, displayed with the key in the ON position and the Stop/Run see page 1.26.
Page 26: Changing Information Display Units
SPECIFICATIONS / GAUGE / AUDIO CHANGING INFORMATION DISPLAY UNITS CONSOLE MOUNTED SWITCHES The console mounted switches are used to control the Standard and Metric Information Display options are following features: available as indicated in the table: 2008 Standard Metric 2010 2009 Display Display...
Page 27: Indicator Lamps
SPECIFICATIONS / GAUGE / AUDIO INDICATOR LAMPS Low Fuel High Beam RH Turn LH Turn Pressure Cruise Neutral Control Check Battery Engine Light Sensor Gear Position Port “R” displayed if in Reverse Gear (2009 -2010 equipped with Reverse Gear only) Indicator Lamp Function Indicator Lamp Function The Check Engine indicator (Malfunction...
Page 28: Seat Heater
SPECIFICATIONS / GAUGE / AUDIO SEAT HEATER HEADLAMP HIGH / LOW BEAM SWITCH The seat heater switches (if equipped) are located on the The headlamp high/low beam switch toggles the headlamp seat under the left passenger hand grip. between high and low beam. Note: To energize headlamp circuit on 2009 models, tap starter button or start engine.
Page 29: Manual Windshield Adjustment
SPECIFICATIONS / GAUGE / AUDIO MANUAL WINDSHIELD ADJUSTMENT TURN SIGNAL MOMENTARY FEATURE 1. Stop the motorcycle and turn the key OFF. When passing a vehicle or when changing lanes, you have the option of using the momentary feature built in to the turn 2.
Page 30: Right Handlebar Controls
SPECIFICATIONS / GAUGE / AUDIO RIGHT HANDLEBAR CONTROLS MIRRORS ENGINE STOP SWITCH The rear view mirrors are adjusted by applying light pressure to left, right, top, or bottom edge (A). The engine stop/run switch completes or interrupts the ignition, starter, and fuel pump circuits. Press RUN side of engine stop/run switch (RUN position).
Page 31: Front Brake Lever Reach Adjustment
The controls are in the center position as Front brake lever “reach” or distance to the hand grip is delivered from Victory. adjustable. To adjust the front brake lever reach: To move the controls to the front or rear position, do the •...
Page 32: Glove Compartment
SPECIFICATIONS / GAUGE / AUDIO FUEL DOOR GLOVE COMPARTMENT The fuel door is located on the right hand side of the To OPEN the glove compartment: console. To open the fuel door: • Turn the handlebars as required to clear the •...
Page 33: Trunk Operation
SPECIFICATIONS / GAUGE / AUDIO SADDLEBAGS Use the ignition key to lock and unlock the saddlebags. Lock the saddlebags when riding. • Refer to loading information beginning on page 1.9. TRUNK OPERATION Use the ignition key to Lock and unlock the trunk. Lock the trunk when riding.
Page 34: Radio / Audio System
SPECIFICATIONS / GAUGE / AUDIO RADIO / AUDIO SYSTEM MAIN USER INTERFACE 1. LCD screen: The LCD screen displays information RADIO / AUDIO SYSTEMS OPERATION for the active source or sources. The following pages describe the operation and function of 2.
Page 35: Left Hand Controls / Rear Passenger Control
NOTE: To prevent battery drain, do not leave the key 1. PTT (Push to Talk) - Press and hold top or bottom of in the ACC position for long periods. Victory PTT button to transmit (page 1.44). recommends using the audio system only when the 2.
Page 36: Volume Control / Audio Mute / Audio Volume / Passenger Volume
SPECIFICATIONS / GAUGE / AUDIO When powered, the screen will display the active VOLUME CONTROL source(s). The driver can set the volume level for the front and rear speakers, turn the speakers off or on, and mute the system audio. AUDIO MUTE 2008-2009 Display Press and release MUTE to drop audio system volume.
Page 37: Audio Source Selection
SPECIFICATIONS / GAUGE / AUDIO AUDIO SOURCE SELECTION NAV MP3 source active: Press and release S/E or SRC until desired source is active. 2010 Display U.S. / European models FM source active: iPod source active: 2008-2009 Display U.S. / European models 2010 Display AM source active:...
Page 38: Audio Tuning
SPECIFICATIONS / GAUGE / AUDIO MW (Medium Wave) source: MEMORY PRESETS The audio system features 12 user-defined presets that 2008-2009 2010 can be used to store favorite stations. To set a preset, select the desired source (FM, AM, WX, XM, MW, LW, or AUX-iPod). European models only Use TUNE or seek/scan to locate a radio station.
Page 39 SPECIFICATIONS / GAUGE / AUDIO BASS SETTING EXTERNAL SPEAKERS Press (+) or (-) on the console panel to adjust the level. Press (+) or (-) on the console panel to turn the speakers (See page 1.38 to enter and exit mode menus). on or off.
Page 40: Cb Headset Volume Controls / Cb Headset Ent Mode
SPECIFICATIONS / GAUGE / AUDIO CB HEADSET VOLUME CONTROLS* ICOM VOLUME* The headsets have 3 separate volume settings: Intercom (See page 1.38 to enter and exit mode menus). (ICOM) volume, CB receive volume, and entertainment Press (+) or (-) on the console panel to change settings. (ENT) volume.
Page 41: Radio Data System (Rds)
SPECIFICATIONS / GAUGE / AUDIO RADIO DATA SYSTEM (RDS) XM DISPLAY* (See page 1.38 to enter and exit mode menus). (See page 1.38 to enter and exit mode menus). 2010 models only: 2008-2009: Press (+) or (-) on the console to turn RDS on or off. ON Press (+) or (-) on the console panel to set the screen to setting will display artist, song title, etc.
Page 42: Xm Category
SPECIFICATIONS / GAUGE / AUDIO XM CATEGORY* NOAA WEATHER BAND (WB or WX) (See page 1.38 to enter and exit mode menus). Weather band channels are broadcast by the National Oceanic and Atmospheric Administration (NOAA). NOAA Press (+) or (-) on the console panel to set the music operates more than 940 transmitters covering the United selection category when tuning XM.
Page 43: Cb Radio / Icom System
CB/ICOM system prior to Display operating the motorcycle. NOTE: To prevent battery drain, do not leave the key in the ACC position for long periods. Victory 2010 Display recommends using the audio system only when the engine is running.
Page 44: Push-To-Talk (Ptt) / Squelch
SPECIFICATIONS / GAUGE / AUDIO PUSH-TO-TALK (PTT) SQUELCH Press and hold the top or bottom of the PTT button on the Squelch blocks undesired signals and noise by allowing upper LH control to transmit over CB radio. the reception of signals only over a specified level. The passenger push and hold the rear PTT button.
Page 45: Cb Radio Volume Setting (Driver / Passenger)
SPECIFICATIONS / GAUGE / AUDIO CB RADIO VOLUME SETTING (Driver)* CB LO/DX* *Setting skipped when CB radio is not present. *Setting skipped when CB radio is not present. Press and release the MODE button on the console panel Press and release the MODE button on the console panel to enter the audio system mode menus.
Page 46: Cb Frequencies
SPECIFICATIONS / GAUGE / AUDIO CB FREQUENCIES ICOM SYSTEM The FCC has designated 40 citizen band (CB) channels for Press and release ICOM on the upper LH control to consumer use. activate the intercom system. NOTE: Channel 9 is designated as an EMERGENCY channel for emergency use only.
Page 47: Icom Volume Setting (Driver / Passenger)
SPECIFICATIONS / GAUGE / AUDIO ICOM VOLUME SETTING (Passenger) Press S/E on the lower LH control to exit the VOX volume set screen and return to the main display. The passenger can control the rear speaker volume only when the CB radio, ICOM, or rear headset speakers are active.
Page 48: Aux / Ipod
AUX / iPod function. To use your iPod, connect the iPod input cable. NOTE: To prevent battery drain, do not leave the key in the ACC position for long periods. Victory AUX Input Cable recommends using the audio system only when the engine is running.
Page 49: Aux Mode (2010)
SPECIFICATIONS / GAUGE / AUDIO AUX MODE (2010) Press and release preset buttons (2) through (12) to access your iPod user-defined play-list(s). To change the mode, press the MODE button on the console repeatedly as required to toggle to the AUX 2008-2009 MODE screen.
Page 50: Xm Radio
NOTE: To prevent battery drain, do not leave the key in the ACC position for long periods. XM monthly service subscription sold separately. XM Mini- Victory recommends using the audio system only Tuner and Home Dock required (each sold separately) to when the engine is running.
Page 51: Xm Radio Reception / Xm Radio Specific Menu Options
SPECIFICATIONS / GAUGE / AUDIO XM RADIO RECEPTION XM RADIO SETTINGS If XM radio is not receiving a signal due to being indoors (2010 Models) (or any overhead obstruction) “No Sgnl” appears in the display. To access XM specific menus, turn the audio system power ON and change the active source to XM using the SRC button on the console.
Page 52: Xm Channel Selection
NAV MP3 Press TUNE (+) or TUNE (-) button on the left control to BEFORE YOU BEGIN - NAV MP3 change the channel. Here are a few helpful tips for VICTORY VISION motorcycles equipped with the Garmin ® zumo ®...
Page 53 NAV MP3 player. NOTE: To prevent battery drain, do not leave the key in the ACC position for long periods. Victory recommends using the audio system only when the engine is running. Press the power button to turn the audio system on.
Page 54: Getting Started / Changing Aux Mode To Nav Mp3
6. Carefully insert the cartridge back into the CD player. NOTE: To prevent battery drain, do not leave the key in the ACC position for long periods. Victory 7. Close and latch the CD player door. recommends using the audio system only when the engine is running.
Page 55: Sae Tap Drill Sizes
SPECIFICATIONS / GAUGE / AUDIO REFERENCE DECIMAL EQUIVALENTS SAE TAP DRILL SIZES 1/64 ....0156 1/32....0312 .
Page 56: Fahrenheit To Celsius
SPECIFICATIONS / GAUGE / AUDIO FAHRENHEIT TO CELSIUS MEASUREMENT CONVERSION CHART  C to F: 9 ( C + 40) 5 - 40 = NIT OF EASURE ULTIPLIED BY ONVERTS TO  F to C: 5 ( F + 40) 9 - 40= ft-lb x 12...
Page 57 MAINTENANCE CHAPTER 2 MAINTENANCE SERVICE SPECIFICATIONS ..........2.2 TUNE UP .
Page 58: 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 59: Fastener Torque Specifications
SPECIAL TOOLS MAINTENANCE TOOLS • Belt Tension Gauge PV-43532 (Sonic Tension Meter is optional and commercially available) • Spanner Wrench - PV-46993 • Compression Gauge Set PV-33223 • Victory Air Pump & Gauge 2876654 or PV-48909 © 2009 Polaris Sales Inc.
Page 60: Maintenance Products
MAINTENANCE MAINTENANCE PRODUCTS LUBRICANTS / CHEMICALS MAINTENANCE PRODUCT PART NUMBERS Product Part Number All Purpose Grease 2872187 Brake Cleaner 2872191 Brake Fluid, DOT 4 2872189 Carb and Throttle Body Cleaner, 13 oz. Aerosol 2872890 Dielectric Grease (Nyogel™) 2871329 Electrical Contact Cleaner 2872864 Fork Oil - Cartridge Forks - Vision TYPE 1 (MARZ) 2874828...
Page 61: Periodic Maintenance
MAINTENANCE PERIODIC MAINTENANCE Periodic Maintenance Interval Table ENGINE ODOMETER READING in MILES (KILOMETERS) Component (see operation codes below) Air Filter 2.16 Crankcase Vent System 2.23 Drive Belt Engine Compression 2.21 Engine Oil* R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R Engine Oil Filter* Evaporative Emission...
Page 62: Air Filter / Air Box Drain Hose
MAINTENANCE AIR FILTER ENGINE OIL LEVEL The standard Victory air filter element is a dry paper 1. Warm the engine for several minutes until operating design - do not apply air filter oil. temperature is reached. 1. Remove (2) screws (A).
Page 63: Engine Oil And Filter Change
Tighten filter by hand an additional 3/4 turn. 10. Add approximately 4.5 quarts (4.25 liters) of oil through dipstick hole. Use only Victory brand Semi- Synthetic 20W-40 Motor Oil or equivalent oil for use with wet clutches such as JASO MA rating.
Page 64: Idle Speed / Fast Idle Speed
“adjust” the throttle plate flow screw (A) or plate stop screw (B)! They are factory pre-set. If idle is Victory motorcycles are produced using the erratic or if idle speed is incorrect, refer to troubleshooting designated tires listed below as original equipment.
Page 65: Throttle Cable Inspection / Lubrication / Free Play
3. Turn throttle opening cable adjuster (front cable) out 3. Spray each barrel end (A) with Victory Multi Purpose until freeplay is within specified range. Lubricant 2872863. 4. Hold adjuster in place and tighten lock securely (by hand) against the adjuster.
Page 66: Cruise Control Cable
Inspect outer cable casing for damage. 2. Inspect exposed inner cable for fraying, kinks, or corrosion. Replace any damaged, frayed or corroded cables.  3. Spray each barrel end with Victory Multi Purpose 6.0 Nm (52 lb-in) 19mm (3/4 ) Max Lubricant 2872863.
Page 67: Front Brake Lever Reach / Lever Reserve
MAINTENANCE FRONT BRAKE LEVER REACH CLUTCH LEVER LUBRICATION (HYDRAULIC) Lever “reach” or distance to the hand grip is adjustable. To adjust the front brake lever reach: 1. Squeeze the clutch lever to the handlebar and release • Pull the lever away from the grip (1) and hold. it.
Page 68: Clutch Pull Rod Bushing Lubrication (Hydraulic)
MAINTENANCE 5. Tighten pivot screw first, then install and tighten nut. CLUTCH LEVER LUBRICATION (CABLE) 1. Disconnect clutch cable from lever arm at primary cover as described for Clutch Pull Rod Bushing 1.0 Nm (9 lb-in) Lubrication. 2. Clean lower cable bushing and cable. Inspect inner cable wire for damage or frayed strands.
Page 69: Clutch Lever Free Play (Cable)
MAINTENANCE CLUTCH FLUID CLUTCH LEVER FREE PLAY (CABLE) 1. With handlebars pointing straight ahead, measure the 1. Set the vehicle upright on a level surface and turn clutch lever free play (A). handlebars until top of reservoir is level. 2. View fluid level through sight glass. Maximum Level Minimum Level .5 - 1.5 mm (.020 - .060”)
Page 70: Brake Fluid Level
MAINTENANCE FRONT BRAKE FLUID LEVEL REAR BRAKE FLUID 1. Set vehicle upright on a level surface and turn handlebars until top of reservoir is level. Minimum Level 1. Set vehicle upright and view the rear brake fluid reservoir through the right leg fairing with the top of the 2.
Page 71: Brake Pad Inspection
MAINTENANCE FRONT BRAKE PAD INSPECTION REAR BRAKE PAD INSPECTION Wear indicator grooves are provided on each front brake Wear indicator grooves are provided on each rear brake pad to allow for a visual inspection without pad removal. pad to allow for a visual inspection without pad removal. Inspect pads by viewing from rear of caliper.
Page 72: Shift Pedal / Brake Pedal
Torque values are shown on page 9.6. 2. Inspect condition of breather hose (A) and hose clamps. 2. Lubricate the shift pedal pivot bushing with Victory All Purpose Grease P/N 2872187 (page 9.6). REAR BRAKE PEDAL EVAPORATIVE EMISSION CONTROL SYSTEM (California Models) 1.
Page 73: Fuel Filter / Fuel System Inspection
1. Replace components that fail inspection (described above) with genuine Victory replacement parts only. 2. Pull straight forward at the bottom of the lower fuel tank communication hose cover (C) to release clips from lower hose.
Page 74: Spark Plug Removal & Inspection
MAINTENANCE SPARK PLUG REMOVAL & INSPECTION WARNING HOT COMPONENTS Wear insulated gloves and/or allow engine and exhaust to cool before handling these parts. 1. With the engine at room temperature, grasp the spark plug boot (A) at the base to disconnect. DO NOT pull on the wire or spark plug wire may be damaged.
Page 75: Battery
MAINTENANCE BATTERY BATTERY CHARGING This motorcycle is equipped with a maintenance free Refer to “BATTERY CHARGING - GENERAL” on page battery which is located in front of the engine. DO NOT 16.5. remove cell caps or add distilled water to the battery. Refer to Chapter 16 for battery and charging system diagnostic procedures.
Page 76: Battery Removal / Installation
MAINTENANCE BATTERY REMOVAL BATTERY INSTALLATION 2.0 Nm (18 lb-in) 9.6 Nm (85 lb-in) 5.4 Nm (48 lb-in) 36 lb-in. 85 lb-in. 85 lb-in. 4.5 Nm (4 Nm) (10 Nm) (10 Nm) (40 lb-in) NOTICE FRONT Do not disconnect the positive cable before the 9.6 Nm (85 lb-in) negative cable.
Page 77: Engine Compression Test / Cylinder Leakage
MAINTENANCE CYLINDER LEAKAGE TEST ENGINE COMPRESSION TEST If compression is low, perform a cylinder leakage test to 1. Warm engine to operating temperature. determine where leakage is occurring. Follow instructions provided with test equipment. 2. Shift transmission into neutral and stop engine. 3.
Page 78: Drive Belt Wear Analysis / Condition
MAINTENANCE DRIVE BELT WEAR ANALYSIS Internal Tooth Cracks (Hairline) External Tooth Cracks Missing Teeth Chipping (Not Serious) OK to run, but monitor condition. Replace Belt OK to run, but monitor condition. Replace Belt Fuzzy Edge Cord Hook Wear Stone Damage Bevel Wear (Outer Edge Only) OK to run, but monitor condition.
Page 79: Drive Belt Tension Inspection
MAINTENANCE DRIVE BELT TENSION - INSPECTION 7. Slide O-ring on belt tension gauge to the 10 lb. mark. 8. Place tape measure or ruler next to drive belt at mid- WARNING span (Fig. 2) and align a major graduation mark on the ruler with the lower edge of the belt surface.
Page 80: Belt Deflection
MAINTENANCE DRIVE BELT ADJUSTMENT / ALIGNMENT SPECIFICATIONS: DRIVE BELT BELT DEFLECTION Rear Wheel Alignment / Belt Adjustment Model Deflection @ 10 lbs. force WARNING All 2008-2010 (Except 2010 8-Ball 32.0 mm ± .5mm A mis-aligned rear axle can cause drive line noise ...
Page 81 MAINTENANCE 4. Turn adjuster nuts (D) to achieve: 6. Rotate the wheel BACKWARD. Tighten LEFT rear axle adjuster until belt begins to track to right sprocket • Recommended belt tension flange (outboard) during backward wheel rotation. • Wheel alignment (marks equal both sides) Rear Wheel Alignment - Final 7.
Page 82: Headlamp Aim Inspection / Adjustment
MAINTENANCE HEADLAMP AIM INSPECTION HEADLAMP AIM ADJUSTMENT The headlamp high beam should shine straight ahead. The headlamp adjustment knob can be accessed through The low beam will spread more to the right (U.S. / the opening in the headlamp housing mount under the Canada).
Page 83: Sidestand Inspection / Sidestand Pad Inspection
MAINTENANCE SIDESTAND & SPRING REMOVAL SIDESTAND INSPECTION 1. Support the motorcycle in an upright position. WARNING 2. Inspect sidestand spring for damage or loss of tension. Be sure stand returns to fully retracted position. The sidestand spring is under tension. Wear eye and face protection when removing and installing 3.
Page 84: Sidestand Pad Replacement
MAINTENANCE Sidestand Pad Installation SIDESTAND PAD REPLACEMENT 1. Install new sidestand pad with open end on trailing Sidestand Pad Removal edge of stand. 1. Remove side stand from frame. 2. Install new rivets from top to bottom. 2. Place sidestand in a soft-jawed vise. 3.
Page 85: Rear Suspension / Swingarm Inspection
MAINTENANCE REAR SUSPENSION / SWINGARM 7. Remove the seat (page 3.5). INSPECTION 8. Inspect fasteners, bushings, and bearings on all suspension components, including shock absorber top WARNING mount (D), strut (E), and rocker arm (F). Care should be taken to be sure the motorcycle will not tip or fall while elevated.
Page 86: Rear Suspension Adjustment
• Victory Air Pump & Gauge 2876654 or PV-48909 is the preferred tool for checking and adjusting rear DO NOT exceed 110 PSI (758 kPa) when filling the suspension air pressure.
Page 87: Front Suspension Inspection
MAINTENANCE FRONT SUSPENSION INSPECTION STEERING HEAD / FRONT WHEEL INSPECTION WARNING WARNING Damaged, worn, or loose suspension components may cause loss of control, increasing the chance of Care should be taken to be sure the motorcycle will a crash or possible injury. Damaged, worn, or loose not tip or fall while elevated.
Page 88: Fuse Replacement
RH Fuse Box LH Fuse Box LOCK AND IGNITION SWITCH LUBRICATION 1. Insert spray nozzle of Victory Multi-Purpose Lubricant into the ignition switch and each lock cylinder and spray for 1-2 seconds. 2. Insert key and turn it to all positions to distribute the Push Center UP lubricant.
Page 89 Spray- Rinse-and-Ride Wash • Do not use abrasive cleaners. Paint wear or other This is the new way to clean a Victory motorcycle quickly cosmetic damage can occur if abrasives are used. and easily, then resume riding. Pure Victory Spray Rinse...
Page 90: Storage
Rinse windshield with water to remove loose dirt and dust. and exhaust system to normal operating temperature. Wash the windshield using one of the Pure Victory wash products described on page 2.33 (follow directions on the container for the product you choose) then rinse (if...
Page 91 FRAME-BODY-EXHAUST CHAPTER 3 FRAME-BODY-EXHAUST SAFETY ............. . . 3.2 GENERAL INFORMATION .
Page 92: Safety
Engine exhaust from this product contains poisonous Modifications to this motorcycle not approved by carbon monoxide gas that can cause loss of Victory may cause loss of performance, excessive consciousness and may lead to death. emissions, and make the machine unsafe for use.
Page 93: General Information
FRAME-BODY-EXHAUST GENERAL INFORMATION Also used on the Victory Vision are fasteners with 10mm and 13mm hex drive heads common to other Victory BODY FASTENER TYPES models. NOTICE SPECIAL TOOLS • PV-49955 Body Panel Tool Kit or commercially Review the following general information before available equivalent.
Page 94: Removal / Installation Procedures - Front Body
FRAME-BODY-EXHAUST REMOVAL / INSTALLATION PROCEDURES - FRONT BODY FRONT FENDER Installation Removal 1. Install lower fender to fork legs. Tighten (2) mounting screws finger tight until stepped flange engages the 1. Lift center of each dart (A) and remove darts. fender.
Page 95: Console Cover / Air Deflectors
FRAME-BODY-EXHAUST CONSOLE COVER AIR DEFLECTORS Removal Removal 1. Open glove compartment door and fuel door. 1. Rotate deflector fully outward to allow easier access to rear screw. 2. Lift the rear console cover straight upward at each corner to remove it. Do not tip the panel backward. 2.
Page 96: Iac Cover / Left Engine Cover
FRAME-BODY-EXHAUST IAC COVER / LEFT ENGINE COVER WINDSHIELD ACCESS PANEL With access panel removed, you can access: Removal • Fuse boxes • Windshield adjustment mechanism or motor 1. Grasp left engine or Idle Air Control (IAC) cover (right side) and pull outward to release 3 clips (A). •...
Page 97: Instrument Bezel
FRAME-BODY-EXHAUST WINDSHIELD INSTRUMENT BEZEL Removal Removal Refer to Assembly View page 3.15. 1. Use a non-marring tool such as PV-49955 Body Tool 1. Remove windshield access panel (page 3.6). Kit (shown) or an auto body windshield tool as a 2. Loosen all screws (A) about 1 turn. wedge.
Page 98: Mirrors
FRAME-BODY-EXHAUST MIRRORS Installation 1. Engage tab (C) of mirror in slot (D) of housing. Refer to Assembly View page 3.20. 2. Install screws and windshield access panel. 1. Remove windshield access panel (page 3.6). 2. Remove (A) (6mm hex). 4.0 Nm (36 lb-in) 4.0 Nm (36 lb-in) 3.
Page 99: Visor
FRAME-BODY-EXHAUST VISOR Installation Removal 1. Slide visor into place. Tip windshield to align bracket holes and install pin (manual) or bolt (motorized). Refer to Assembly View page 3.20. 2. Install pin retaining clip (manual) or torque bolt 1. Remove windshield access panel (page 3.6). (motorized) to 16-19 Nm (12-14 lb-ft).
Page 100 FRAME-BODY-EXHAUST CONSOLE SPEAKER GRILL / SPEAKER Removal Removal Refer to Assembly View page 3.17. Refer to Assembly View page 3.19. 1. Remove instrument bezel (page 3.7). 1. Remove instrument bezel (page 3.7), windshield access panel (page 3.6), and mirrors (page 3.8). 2.
Page 101: Fuel Tank Covers
FRAME-BODY-EXHAUST FUEL TANK COVERS 6. 2008-2009: Lift green tab UP with a scribe or small screw driver just far enough to disengage lock tab. Removal 2010: Push tab down to release from catch. Disconnect accessory power wire(s) from socket on Refer to Assembly View page 3.21.
Page 102 FRAME-BODY-EXHAUST LEG FAIRING 6. Remove the screws at the front and rear of each outer leg fairing. NOTE: Inner and outer leg fairings are removed as an assembly with grills attached. Refer to Assembly View page 3.22. 1. Remove air deflectors (page 3.5) and fuel tank covers (page 3.11) 2.
Page 103: Turn Signal Lens, Front
FRAME-BODY-EXHAUST TURN SIGNAL LENS, FRONT 9. Carefully lift outside end of turn signal assembly upward while pulling inside end forward slightly to Removal disengage peg (F) on headlamp housing from alignment hole (G) of turn signal lens. 1. Remove windshield access panel (page 3.6) and fuse box covers.
Page 104: Fairings (Front Outer)
FRAME-BODY-EXHAUST FAIRINGS (FRONT OUTER) INSTRUMENT DISPLAY Removal Removal 1. Remove windshield access panel (page 3.6). 1. Remove windshield access panel (page 3.6) and radio console (page 3.5). 2. Remove fuse box covers. 2. Follow steps to remove left and right fuel tank cover 3.
Page 105: Assembly Views - Front Body
FRAME-BODY-EXHAUST ASSEMBLY VIEWS - FRONT BODY WINDSHIELD / WINDSHIELD MOTOR Install ALL screws lightly past shoulder before tightening any to final torque. Tighten in order 1-6. 4.0 Nm (36 lb-in) T-Nuts Pad washers (3 each outside end) (2 in center) 9.5 Nm (84 lb-in) 17.6 Nm (13 lb-ft) Washer...
Page 106: Belly Pan
FRAME-BODY-EXHAUST BELLY PAN Windshield Access Panel Fairing Air Deflector Leg Fairing Grill Belly Pan Bottom View - Windshield Access Panel Clean with isopropyl alcohol before applying antenna pad 3.16 © 2009 Polaris Sales Inc.
Page 107: Console / Console Attachments
FRAME-BODY-EXHAUST CONSOLE / CONSOLE ATTACHMENTS Hand Grip Heater Hazard Driving Lamp Accessory (If equipped) Wire color: Wire color: PK/GN / GN/PK BU/W / BK/W Wire color: Front - BN Center - BU/PK Rear - BU 3.17 © 2009 Polaris Sales Inc.
Page 108: Console / Radio
FRAME-BODY-EXHAUST CONSOLE / RADIO Protect the console finish with a soft cloth when removing or installing wires or attachments. 3.18 © 2009 Polaris Sales Inc.
Page 109: Front Support / Speaker / Speaker Volume
FRAME-BODY-EXHAUST FRONT SUPPORT / SPEAKER / SPEAKER VOLUME 3.19 © 2009 Polaris Sales Inc.
Page 110: Visor / Front Speaker Grill
FRAME-BODY-EXHAUST VISOR / FRONT SPEAKER GRILL Pad placement 3.20 © 2009 Polaris Sales Inc.
Page 112: Leg Fairing / Leg Fairing Support
FRAME-BODY-EXHAUST LEG FAIRING T20 Torx Grill LEFT Leg Fairing T20 Torx 2.0 Nm (18 lb-in) Inner Leg Fairing RIGHT 2.0 Nm (18 lb-in) Route antenna guide tube between grill and fairing mount tabs 3.22 © 2009 Polaris Sales Inc.
Page 113 FRAME-BODY-EXHAUST LEG FAIRING SUPPORT T20 Torx T20 Torx Leg Fairing Support Assembly Order: Leg fairing support must be placed, fastened, and torqued to the main instrument panel before placing the rear bolts to the frame, or air deflectors may not align with mounts. 2.0 Nm (18 lb-in) 3.23 ©...
Page 114: Front Turn Signal Headlamp / Fairing
FRAME-BODY-EXHAUST FRONT TURN SIGNAL HEADLAMP / FAIRING Fairing This screw secures front inner edge of fairing to headlamp housing. 3.24 © 2009 Polaris Sales Inc.
Page 117: Removal / Installation Procedures - Rear Body
FRAME-BODY-EXHAUST REMOVAL / INSTALLATION PROCEDURES - REAR BODY SEAT SIDE COVER Removal Removal 1. Remove seat (1). WARNING 2. Pull center of both darts out and remove (1). Always make sure the seat is securely fastened before riding the motorcycle. A loose seat could cause a sudden shift in riding position, causing you to lose control of the motorcycle.
Page 118: Lower Access Panels (Saddlebag Lower Panel)
FRAME-BODY-EXHAUST LOWER ACCESS PANELS (SADDLEBAG 6. Pull straight outward at rear of access panel to disengage rear-most tab (A) and hold it clear of the LOWER PANEL) peg on tail trim panel. Removal 7. Press tail trim panel back down into place until secured in its original position (B).
Page 119: Street Trim Panel Removal / Installation
FRAME-BODY-EXHAUST STREET TRIM PANEL REMOVAL STREET TRIM PANEL INSTALLATION Victory Vision Street Victory Vision Street 1. Remove seat (page 3.27). 1. Lift tail light trim (“M” panel) enough to provide clearance to install street trim panel. 2. Remove license plate and plate bracket by removing two 4mm internal hex drive screws (1).
Page 120: Trunk Removal / Installation
FRAME-BODY-EXHAUST TRUNK REMOVAL 5. Remove compartment cover by squeezing between notches (3) and lift cover away. Victory Vision Tour 1. Remove seat (page 3.27). 2. Locate and disconnect trunk wire harness (1) and any accessory wiring. 6. Remove three of four trunk mount bolts (4) with a 13 mm socket, leaving front right bolt for last.
Page 121: Tail Light Trim ("M" Panel) / Rear Bumper Cover
4. Pull top corners up to disengage top tabs on each lower access panel. side. NOTE: On Victory Vision Tour models (equipped REAR BUMPER COVER with a trunk), the “M” panel must be moved rearward before front of panel can be raised high enough to...
Page 122: Tail Light / Tail Light Housing
FRAME-BODY-EXHAUST TAIL LIGHT TAIL LIGHT HOUSING Removal Removal 1. Remove “M” panel (page 3.31). 1. Remove trunk (if equipped - page 3.30) or street trim panel (page 3.29). 2. Remove rear bumper cover (page 3.31). 2. Remove tail lights (page 3.32). 3.
Page 123: Saddlebag Door / Saddlebag (Inner Bag)
FRAME-BODY-EXHAUST SADDLEBAG DOOR SADDLEBAG (INNER BAG) Removal Removal (Instructions below are for left saddlebag. Right bag 1. Open saddlebag door. removal similar). 2. Remove six screws that fasten two upper hinge plates Refer to illustration on page 3.40 for fastener location to door.
Page 124: Saddlebag Support Plate (Passenger Hand Grip And Trim)
FRAME-BODY-EXHAUST SADDLEBAG SUPPORT PLATE 6. Open both saddlebag doors. (PASSENGER HAND GRIP AND TRIM) 7. Remove two saddlebag door latch bracket screws (A) and bracket with latch and cable attached (10mm socket). Set bracket aside (remove both left and right). Removal 8.
Page 125: Assembly Views - Rear Body
FRAME-BODY-EXHAUST ASSEMBLY VIEWS - REAR BODY TAIL TRIM “M” PANEL 3.35 © 2009 Polaris Sales Inc.
Page 127 FRAME-BODY-EXHAUST LICENSE PLATE MODULE (EUROPE) 18 LB-IN. (2 Nm) 96 LB-IN (10.8 Nm) 25 LB-IN. 96 LB-IN (2.8 Nm) (10.8 Nm) 3.37 © 2009 Polaris Sales Inc.
Page 128: Trunk Base / Trunk Lid
FRAME-BODY-EXHAUST TRUNK BASE Some parts shown for reference only 3.38 © 2009 Polaris Sales Inc.
Page 131: Tail Light / Tail Light Housing
FRAME-BODY-EXHAUST TAIL LIGHT / TAIL LIGHT HOUSING 3.41 © 2009 Polaris Sales Inc.
Page 132: Floorboard / Foot Control Mounting
FRAME-BODY-EXHAUST FLOORBOARD / FOOT CONTROL MOUNTING LEFT SIDE (SHIFT) Lubricate with Multi Purpose Lubricant P/N 2872863 96 lb-in (10.8 Nm) Pedal position adjustment: 1) Remove screw 2) Move pedal assembly forward or rearward 92.5 +/- 3mm until screw hole aligns with on of the other two threaded holes.
Page 133: Passenger Floorboard Mounting
FRAME-BODY-EXHAUST PASSENGER FLOORBOARD MOUNTING LEFT SIDE RIGHT SIDE 3.43 © 2009 Polaris Sales Inc.
Page 134: Lower Access Panel / Passenger Hand Grip / Side Cover
FRAME-BODY-EXHAUST LOWER ACCESS PANEL / PASSENGER HAND GRIP / SIDE COVER 8-Ball 3.44 © 2009 Polaris Sales Inc.
Page 135: Exhaust System
FRAME-BODY-EXHAUST EXHAUST SYSTEM YSTEM ASSEMBLY VIEW - EXHAUST S 3.45 © 2009 Polaris Sales Inc.
Page 136: Assembly View - Muffler & Head Pipe Shields
FRAME-BODY-EXHAUST ASSEMBLY VIEW - MUFFLER & HEAD PIPE SHIELDS Muffler Shields Locate clamp lock on back of muffler 50mm 560mm 280mm Catalyst not removable Center on head pipe Head Pipe Shields 3.46 © 2009 Polaris Sales Inc.
Page 137: Exhaust Muffler
FRAME-BODY-EXHAUST EXHAUST MUFFLER REMOVAL 6. Loosen both the muffler clamp and the crossover pipe clamp on the left side, and the muffler clamp and head NOTICE: Allow exhaust to cool completely before you pipe bolt (near the crossover pipe) on the right side. begin work.
Page 138: Head Pipe Removal
FRAME-BODY-EXHAUST 9. Move the muffler back and forth to expand the joint and HEAD PIPE REMOVAL allow lubricant to enter. Tap muffler with a rubber NOTICE: Allow exhaust to cool completely before you hammer at the front (D) and slide it off the head pipe begin work.
Page 139 LUBRICATION & COOLING CHAPTER 4 LUBRICATION & COOLING OILING SYSTEM ............4.2 OPERATION.
Page 140: Oiling System
LUBRICATION & COOLING OILING SYSTEM TROUBLESHOOTING OPERATION LOW OIL PRESSURE HIGH OIL PRESSURE The engine must be running in order to perform some of Incorrect oil being used or Incorrect oil being used the procedures in this section. Read, understand and low oil level follow the warnings and cautions contained in this section.
Page 141: Oiling System Data
(4.5 U.S. qts) Recommended Engine Oil Victory 20W/40 for all Not Applicable If Victory 20W/40 is not available, use motorcycle oil suitable operating temperatures. for wet clutches (such as those with JASO MA rating). DO NOT use additives of any kind.
Page 142: Oil Flow
LUBRICATION & COOLING OIL FLOW DIAGRAM Valve Adjusters Camshaft Journals Rocker Arm Shafts Lower Camshaft Carrier Cylinder Cylinder Head Cam Chains / Sprockets Heads Right Side (Exhaust Valve Bridge) RH Front Cylinder Stud Crankcase Passage Passage In Passage in Head Gasket Cylinders (Left side) Stator Crankshaft...
Page 143: Oil Cooler
LUBRICATION & COOLING OIL COOLER ASSEMBLY VIEW - OIL COOLER AND LINES Apply mild soap and water Clean from this side to ease assembly Apply Victory Engine Oil To O-Rings O-Ring 9.6 Nm (85 lb-in) O-Ring O-Ring Flat Washer Flat Washer 9.6 Nm (85 lb-in)
Page 144: Oil Cooler Inspection / Cleaning
LUBRICATION & COOLING OIL COOLER INSPECTION / CLEANING OIL COOLER REMOVAL 1. Inspect cooler, lines, and all connections for leaks. Also refer to Illustration on page 4.5. 2. Inspect lines for proper routing. Replace if there is any 1. Place drain pan beneath oil cooler and lines. sign of abrasion or damage.
Page 145: Oil Cooler / Line Installation
LUBRICATION & COOLING OIL COOLER / LINE INSTALLATION Refer to Illustration on page 4.5 for detail views. Oil Lines to Engine Oil Cooler Installation 1. Installation of lines to engine is easier with lines If oil lines were removed from cooler and engine, install removed at the oil cooler end.
Page 146: Oil Pressure Inspection
LUBRICATION & COOLING OIL PRESSURE INSPECTION COOLING OIL FLOW INSPECTION Cooling oil inspection is accomplished by verifying oil flow LUBRICATION OIL PRESSURE through the cooler. The temperature of the cooler should be close to crankcase temperature. Pressure testing Use caution when working around hot engine oil. Review cannot be performed at the Cylinder Head Temperature all WARNINGS on page 4.2.
Page 147: Oil Pump
LUBRICATION & COOLING OIL PUMP LUBRICATION/COOLING OIL PUMP ASSEMBLY Replace all gaskets, washers, and O-rings Pump - Check for free rotation after installation Fitting (Nipple) Install after pump and pipe (A) 62 Nm (45 lb-ft) 9.6 Nm (85 lb-in) O-Ring(X2) 1/2-3/4 turn past gasket contact (by hand) Washer...
Page 148: Oil Pressure Relief Valves
LUBRICATION & COOLING OIL PRESSURE RELIEF VALVES proper location on the oil pump. The lubrication pressure relief valve screws into the main oil pump body, and has a The lubrication and cooling systems operate at different oil SHORTER hexagonal portion. The cooling pressure relief pressures, regulated by pressure relief valves.
Page 149: Oil Pump Inspection
LUBRICATION & COOLING OIL PUMP INSPECTION 3. Measure clearance between pump body and outer gerotor on the lubrication side. Inspect the oil pump when lubrication oil pressure is below specification. The oil pump contains 2 sets of inner and outer gerotors. Follow the inspection procedure for both sets of gerotors and both ends of the pump.
Page 150: Oil Pump Disassembly
LUBRICATION & COOLING OIL PUMP DISASSEMBLY Oil Jet Dowel 9X26 mm Torque: 13 Nm (115 lb-in.) Pressure Relief Valve Assembly - 85 PSI Cooling Gerotor (Lubrication Pump) Shorter Hex Pump Body Torque: 27 Nm (20 lb-ft.) Dowel 9X10mm Pump Base Pressure Relief Valve Assembly - 105 PSI Lubrication Gerotor (Cooling Pump) Longer Hex...
Page 151: 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 152 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 153: Oil Pump Installation
LUBRICATION & COOLING OIL PUMP INSTALLATION 6. Start the top two oil pump retaining bolts (E) and the rear pipe bolt (F) but do not tighten at this time. 1. Refer to Fig. 2. Clean oil pipes and dry with compressed air.
Page 154 LUBRICATION & COOLING 12. Remove sprocket so chain can be installed. 13. Install chain over oil pump sprocket and balance shaft sprocket. Align pump sprocket to shaft and install retaining bolt (A). Torque to 9.6 Nm (85 lb-in). NOTE: The sprocket is a floating design. A small amount of end play is normal after tightening the retaining bolt.
Page 155 FUEL SYSTEM / FUEL INJECTION CHAPTER 5 FUEL SYSTEM / FUEL INJECTION SAFETY PRECAUTIONS ..........5.3 FUEL SAFETY .
Page 156 FUEL SYSTEM / FUEL INJECTION SENSOR TESTS............5.32 THROTTLE POSITION SENSOR (TPS) DIAGNOSTICS .
Page 157: Safety Precautions
FUEL SYSTEM / FUEL INJECTION SAFETY PRECAUTIONS FUEL SAFETY Many hazards are present when working on or around the fuel injection system. Read and pay close attention to the following warnings and cautions when working on any component in this section. WARNING Gasoline is extremely flammable and explosive under certain conditions.
Page 158: Specifications
TOOL DESCRIPTION NUMBER Diagnostic Tool Kit - with Digital Wrench Software PU-47052-C (and license serial PV-46085 number), Standard Interface Cable PU- 47151, and Victory Adapter PV-46085-2) SmartLink Interface Kit* PU-47471 *Kit Includes: CAN Interface Cable (PU-47469) Serial Interface Cable (PU-47470)
Page 159: Service Precautions
FUEL SYSTEM / FUEL INJECTION SERVICE PRECAUTIONS Static electricity can damage the ECM beyond repair. The human body can easily store enough static electricity to EFI SYSTEM PRECAUTIONS damage sensitive electronic components. Before working with any components of the Fuel Injection system, ground NOTICE: While electronic fuel injection is very durable yourself to dissipate any static charge.
Page 160: Fuel System Assembly Views
FUEL SYSTEM / FUEL INJECTION FUEL SYSTEM ASSEMBLY VIEWS FUEL TANK HOSE CONNECTION - 49 STATE MODELS Over flow Drain Hose and Fuel Tank Vent Inspection - 49 State 1. Remove covers as required (Chapter 3) and disconnect hoses from fittings at right side of fuel tank. 2.
Page 161: Fuel Tank Hose Connection - California Models
FUEL SYSTEM / FUEL INJECTION FUEL TANK HOSE CONNECTION - CALIFORNIA MODELS Purge Valve (ECM controlled) Tank Vent Inspection (California Models) 1. Remove covers as required (Chapter 3). 2. Open fuel cap. 3. Disconnect line from fitting on evaporative emissions canister marked “TANK”. 4.
Page 162: Fuel Level Sensor / Fuel Pump
FUEL SYSTEM / FUEL INJECTION FUEL LEVEL SENSOR / FUEL PUMP / GAUGE TEST FUEL PRESSURE: 3.50 BAR (350 kPa) (51 psi) See page 5.20 for pressure test procedure. Fuel Level Sensor Resistance Test is on page 5.17. Fuel pump connector: Main wire harness connector pins: 2010 2008-2009...
Page 163: Fuel Pump And Fuel Tank Assembly View
FUEL SYSTEM / FUEL INJECTION FUEL PUMP AND FUEL TANK ASSEMBLY VIEW 2008-2009 CORRECT INCORRECT Contact  Follow pump installation 2010 procedure page 5.12. AIR INTAKE / BOX FRAME ASSEMBLY VIEW 9.6 Nm Air Intake Silencer - 2010 (85 lb-in) 9.6 Nm (85 lb-in) Seal...
Page 164: Idle Air Control Assembly View
FUEL SYSTEM / FUEL INJECTION IDLE AIR CONTROL ASSEMBLY VIEW Install fitting to depth of paint mark Do not insert tube too far into tee or elbow, or the IAC air delivery will be restricted. 9.6 Nm (85 lb-in) Whenever IAC is disconnected, or after ECM re-programming (re-flash), cycle the ignition key ON and OFF a few times (with kill switch in RUN position) to allow the IAC...
Page 165: Fuel System Service
FUEL SYSTEM / FUEL INJECTION FUEL SYSTEM SERVICE 7. WAIT until the ECM centers the IAC valve (the clicking sound stops) and then wait an additional 10 seconds. FUEL SYSTEM DEPRESSURIZATION or until you hear a faint single “click” from the relay. 8.
Page 166: Fuel Pump Installation
FUEL SYSTEM / FUEL INJECTION 6. Carefully remove the pump from the tank by lifting and FUEL PUMP INSTALLATION turning the assembly 180 degrees, then tilt the 1. Prepare fuel tank for assembly by thoroughly cleaning assembly forward and complete pump removal. inside the tank and all sealing surfaces, including the opening for the pump.
Page 167 FUEL SYSTEM / FUEL INJECTION 5. Compress the pump flange against the tank and o-ring. If the flange lays completely flat, re-verify the o-ring is in place and install the flange screws. Torque to specification using the torque pattern as shown. DO NOT install or torque the flange screws until the pump flange is seated completely flat on the tank.
Page 168: Fuel Tank Assembly View
FUEL SYSTEM / FUEL INJECTION FUEL TANK ASSEMBLY VIEW Cap area drain 47.5 Nm (35 lb-ft) Vent (from pump) to canister (CAL) or atmosphere (49 state) 7.7 Nm (68 lb-in) Tank Mount Detail 7.7 Nm (68 lb-in) 47.5 Nm (35 lb-ft) 5.14 ©...
Page 169: Fuel Tank Removal
FUEL SYSTEM / FUEL INJECTION FUEL TANK REMOVAL FUEL TANK INSTALLATION Refer to Fuel Tank Assembly View on page 5.14. 1. Assemble grommets and stepped spacers to LEFT tank mount holes. See Mount Detail on page 5.14. 2. Install crossover hose (G) securely on LEFT tank. You should hear an audible CLICK when hose fitting is fully WARNING seated on fitting.
Page 170: Fuel Pump Circuit Diagram
FUEL SYSTEM / FUEL INJECTION FUEL PUMP CIRCUIT DIAGRAM ECM Connector (Under Seat) RH Switch Connector (Under Console) Engine Harness Connector (Under Left Side Cover) Fuel Pump / Level Sensor Connector (Top of RH Fuel Tank) FUEL PUMP RELAY To test pump and wiring between tank and relay, perform a current draw test (page 5.19).
Page 171: Fuel Level Sensor Resistance Test
FUEL SYSTEM / FUEL INJECTION FUEL LEVEL SENSOR RESISTANCE TEST OVERVIEW OF OPERATION: The fuel level sensor is a mechanical float arm located on the fuel pump inside the fuel tank. Circuit resistance determines the reading on the fuel gauge located on the instrument panel. When the fuel level indicated on the fuel gauge is below ...
Page 172: Fuel Pump Electrical Diagnostics
FUEL SYSTEM / FUEL INJECTION FUEL PUMP ELECTRICAL DIAGNOSTICS FUEL SYSTEM Fuel Pump Pressure 3.50 BAR (350 kPa) (51 psi) Fuel Pump Volume 60-80 liters/hr @ 12VDC Fuel Pump Current Draw Less than 5 amps @ 12.0 VDC NOTE: When ignition switch is turned ON and Engine Stop switch is in the RUN position, fuel pump will run momentarily (about 2-3 seconds).
Page 173: Fuel Pump Current Draw Test
FUEL SYSTEM / FUEL INJECTION BATTERY POWER TO FUEL PUMP (Cont.) 4. Insert one meter lead in pin socket (30) and other meter lead in pin socket (87) of relay block. These terminals 6. If there is battery voltage on terminal 86, check are the farthest apart diagonally in the relay socket.
Page 174: Fuel Pump Pressure Inspection
FUEL SYSTEM / FUEL INJECTION FUEL PUMP PRESSURE INSPECTION Fuel Pressure Gauge: PU-43506-A WARNING Attach gauge to valve GASOLINE Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Open flames, sparks and cigarettes must be kept away from gasoline.
Page 175: Idle Air Control Removal
FUEL SYSTEM / FUEL INJECTION IDLE AIR CONTROL REMOVAL 7. Disconnect primary wire harness from coil. Also refer to IAC Assembly View on page 5.10. 1. Remove RH cover and IAC cover (page 3.6). 2. Remove wire dart (A). 3. Push tab (B) to disconnect IAC harness. 4.
Page 176: Efi System Components
FUEL SYSTEM / FUEL INJECTION EFI SYSTEM COMPONENTS FUEL INJECTION COMPONENT LOCATIONS Fuel Pump (with pressure regulator and filter) Idle Air Control (IAC) Located inside RH fuel tank Under IAC cover Under seat Throttle Body & Fuel Injectors Fuel Line / Fuel Rail (pulse damper on RH side of fuel rail) Tipover Sensor (2009 +) Crank Position Sensor...
Page 177: Fuel Rail / Fuel Injector Removal
FUEL SYSTEM / FUEL INJECTION FUEL RAIL / FUEL INJECTOR REMOVAL FUEL RAIL INSTALLATION 1. Remove leg fairings (page 3.12). 1. Install new O-rings on each injector and lubricate with engine oil. (Note: Service O-rings are the same color 2. Remove ignition coil with bracket (page 17.12) and and suitable for use on bottom and top of injector).
Page 178: Fuel Injection System Testing And Diagnostics
“ON” for 2-3 seconds when the ignition key and Engine Stop switch are turned on to pressurize the system for The ECM used on the Victory motorcycle stores trouble start-up. codes in memory. Trouble codes are stored by the ECM...
Page 179: Ecm Connector Map
FUEL SYSTEM / FUEL INJECTION ECM CONNECTOR MAP Refer to page 5.29 to remove connector from ECM. Slide Latch TOP VIEW - ECM CONNECTOR (WIRE SIDE SHOWN) (BOOT AND WIRE COVER REMOVED) FRONT Note: Touch pins with probes, do not force probe into connector pin. FUEL SYSTEM RELATED ECM CONNECTOR MAP (System related wire color &...
Page 180: Viewing And Clearing Trouble Codes
FUEL SYSTEM / FUEL INJECTION VIEWING AND CLEARING TROUBLE CODES SENSOR DIAGNOSTICS - IMPORTANT INFORMATION TO UNDERSTAND BEFORE Trouble codes are logged in the ECM memory when a YOU BEGIN sensor or other supported system fault occurs. To view the codes, do the following: If a sensor fails or reads outside a “normal”...
Page 181: Trouble Codes
FUEL SYSTEM / FUEL INJECTION TROUBLE CODES  Access codes by clicking on the icon on the Digital Wrench diagnostic screen.  Refer to Digital Wrench guided diagnostics for detailed P-code description and troubleshooting. See page 5.28 for description of FMI / SPN codes and where they appear. Code Access Icon P-CODE BLINK...
Page 182 FUEL SYSTEM / FUEL INJECTION P-CODE BLINK DESCRIPTION NUMBER CODE P1351 1268 Ignition Coil Primary Driver Cyl 1 (Front) - driver circuit open or grounded P1352 1269 Ignition Coil Primary Driver Cyl 1 (Front) - driver circuit short to battery + P1353 1268 Ignition Coil Primary Driver Cyl 2 (Rear) - driver circuit open or grounded...
Page 183: Ecm Harness Connector Test Precautions
FUEL SYSTEM / FUEL INJECTION ECM HARNESS CONNECTOR TEST ECM CONNECTOR REMOVAL PRECAUTIONS 1. Remove seat (page 3.27). NOTICE: Tests in this section may require reading NOTICE: The lock lever also serves as an eject / install resistance and voltages at ECM connector. Once ECM mechanism for the 60 pin connector.
Page 184: Efi Sensor Circuit Wiring Diagrams
FUEL SYSTEM / FUEL INJECTION EFI SENSOR CIRCUIT WIRING DIAGRAMS NOTE: IAC diagram is on page 5.47 FUEL INJECTORS W / BU W / BK VIO / PK FUEL PUMP OR / GN BN / BU INTAKE AIR TEMP BN / R MANIFOLD ABSOLUTE PRESSURE (MAP) OR / BN...
Page 185 FUEL SYSTEM / FUEL INJECTION EFI SENSOR CIRCUIT WIRING DIAGRAMS NOTE: IAC diagram is on page 5.47 CRANKSHAFT POSITION SENSOR Shield OR / BU CYLINDER HEAD TEMP (CHT) BN / BU BN / R THROTTLE POSITION BN / BU SENSOR (TPS) OR / Y BK / W DIAGNOSTIC CONNECTOR...
Page 186: Sensor Tests
FUEL SYSTEM / FUEL INJECTION SENSOR TESTS THROTTLE POSITION SENSOR (TPS) DIAGNOSTICS FAIL CODE: P0122 / P0123 INDICATES INSPECT LOCATION Voltage received at ECM from TPS is outside of Resistance readings at ECM connector. Left side throttle parameters. This test inspects TPS and wiring. body To view and clear trouble codes refer to page 5.26.
Page 187: Temperature & Manifold Absolute Pressure Sensor (Tmap)
FUEL SYSTEM / FUEL INJECTION TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) DIAGNOSTICS FAIL CODE: P0107 / P0108 (MAP SENSOR COMPONENT OF TMAP SENSOR) COMPONENT AFFECTED: Manifold Absolute Pressure Sensor INDICATES INSPECT LOCATED Continuity of wires from ECM connector to TMAP connector at sensor. Voltage received Check for +5 DCV at TMAP sensor BN / R wire (ECM connector attached and On rear...
Page 188: Air Temperature Sensor (Ats) Diagnostics
FUEL SYSTEM / FUEL INJECTION AIR TEMPERATURE SENSOR (ATS) DIAGNOSTICS FAIL CODE: P0112 / P0113 COMPONENT AFFECTED: Air Temperature Sensor INDICATES INSPECT LOCATED Voltage received at ECM Resistance readings at ECM connector (ECM disconnected). On rear cylinder head from ATS is outside of This test will inspect wiring, connectors, and Air Temperature intake port (in TMAP sensor).
Page 189: Cylinder Head Temperature Sensor (Cht) Diagnostics
FUEL SYSTEM / FUEL INJECTION CYLINDER HEAD TEMPERATURE SENSOR (CHT) DIAGNOSTICS FAIL CODE: P0117 / P0118 COMPONENT AFFECTED: Cylinder Head Temperature Sensor (Engine Temperature) INDICATES INSPECT Voltage received at ECM from CHT sensor is outside of Resistance readings through sensor and wiring at ECM parameters.
Page 190: Idle Air Control (Iac)
FUEL SYSTEM / FUEL INJECTION IDLE AIR CONTROL (IAC) be sure hoses are connected properly and securely when idle control problems exist. If an IAC code is present, Air leaks or air restrictions in the IAC air supply or delivery perform the following circuit tests.
Page 191: Vehicle Speed Sensor Test
FUEL SYSTEM / FUEL INJECTION VEHICLE SPEED SENSOR TEST MEMORY CHECK SUM ERROR To view and clear trouble codes refer to page 5.26. See To view and clear trouble codes refer to page 5.26. See page 5.25 for wire colors / pin number in connector. page 5.25 for wire colors / pin number in connector.
Page 192: Crankshaft Position Sensor Diagnostics
FUEL SYSTEM / FUEL INJECTION CRANKSHAFT POSITION SENSOR DIAGNOSTICS See page 17.11 for CPS test procedure. BATTERY VOLTAGE AT ECM DIAGNOSTICS FAIL CODE: P0562 / P0563 COMPONENT AFFECTED: Battery Voltage to ECM INDICATES INSPECT Voltage received at ECM is outside of parameters. Vehicle Battery Voltage To view and clear trouble codes refer to page 5.26.
Page 193: Digital Wrench
Polaris Digital Wrench™ software on a laptop computer. Once installed, select the HELP icon (?) for more information. TOOLS DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER Victory/Polaris Diagnostic Tool Kit PU-46085-A Digital Wrench Software: PU-48731 Standard Interface Cable: PU-47151 PU-46085-A (above) INCLUDES: Victory Adapter: PV-46085-2...
Page 194: Digital Wrench Features
Vehicle specific service reports can be saved for future http://polaris.diagsys.com/. reference. Victory dealers can access the Digital Wrench site by Data grids with typical or “normal” sensor values can be visiting www.polarisdealers.com and clicking on the saved for future reference. Some examples are shown on Digital Wrench Updates link in the Service and Warranty the following pages.
Page 195: Digital Wrench Feature Map
FUEL SYSTEM / FUEL INJECTION   DIGITAL WRENCH FEATURE MAP 5.41 © 2009 Polaris Sales Inc.
Page 196: Digital Wrench Screen Examples
FUEL SYSTEM / FUEL INJECTION DIGITAL WRENCH SCREEN EXAMPLES Cold engine at idle during warm up. Throttle partially open. TPS voltage value has increased. 5.42 © 2009 Polaris Sales Inc.
Page 197 FUEL SYSTEM / FUEL INJECTION DIGITAL WRENCH SCREEN EXAMPLES Warm engine at idle. RPM has stabilized Change the position of various data items in the table with these buttons. Save data grid for future reference Meter Grid Display items 5.43 ©...
Page 198: Digital Wrench Screen Examples
FUEL SYSTEM / FUEL INJECTION DIGITAL WRENCH SCREEN EXAMPLES TPS Sweep can be checked for smooth transition from zero to full throttle with engine off Special Tests menu for Service Reports Saves as a .txt file You can save a Service Report for future reference, comparison, or for diagnostic assistance.
Page 199: Process Overview
FUEL SYSTEM / FUEL INJECTION REPROGRAMMING THE ENGINE CONTROL 2. DEDICATED LAPTOP: Best results are obtained using a laptop computer that is “dedicated to Polaris/Victory MODULE (ECM) service”. A laptop that is used by a variety of people and in several applications around the dealership is...
Page 200 FUEL SYSTEM / FUEL INJECTION 4. CLOSE NON-ESSENTIAL PROGRAMS: 6. COMMUNICATION PROBLEMS: If you have had Victory recommends that you DO NOT install non- problems communicating with a vehicle while essential programs on a Service Department laptop. performing diagnostic functions, do not attempt...
Page 201: Reprogramming Process
FUEL SYSTEM / FUEL INJECTION REPROGRAMMING PROCESS 4. Select Engine Controller Reprogramming. If you are not familiar with the reprogramming process, review tips beginning on page 5.45 before you begin. Following is an overview of the reprogramming process. Follow the on-screen instructions as you progress through the steps.
Page 202 FUEL SYSTEM / FUEL INJECTION 7. Go to www.polarisdealers.com and click on “Re-Flash 10. In the empty box provided on the screen, enter the 9 Authorization” from the Service and Warranty drop- digit Calibration I.D number from the card enclosed down menu.
Page 203: Troubleshooting
FUEL SYSTEM / FUEL INJECTION TROUBLESHOOTING FUEL SYSTEM TROUBLESHOOTING PROBLEM POSSIBLE CAUSE AFFECTED PART(s) REPAIR RECOMMENDED Engine turns over with Compression too low See engine section electric starter, but won’t No spark at spark plugs See ignition system start No fuel reaching intake Out of fuel Add Fuel tract...
Page 204 FUEL SYSTEM / FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING (cont.) PROBLEM POSSIBLE CAUSE AFFECTED PART(s) REPAIR RECOMMENDED Engine Stalls Fuel Pump Problem Low battery voltage Battery/Charging system Faulty fuel pump Check fuel pressure No signal from ECM Repair Wiring Wiring problem Repair/Chk Pump Relay Excessive rich or lean TMAP Sensor...
Page 205 FUEL SYSTEM / FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING (cont.) PROBLEM POSSIBLE CAUSE AFFECTED PART(s) REPAIR RECOMMENDED Poor Running in upper Control Circuit/ Engine speed sensor Test / Replace rpm ranges Sensors not Test / Replace functioning correctly Air temperature sensor Test / Replace Manifold Absolute Test / Replace...
Page 206 Repair manifold seal Won’t Accept New Non-Current Go to Calibration Calibration File Set Dealer website (Victory Re- Flash) and download the most current Victory Calibration File Low Battery Voltage Attach Battery Charger During Re-Flash, and Re- Charge Battery When Re-Flash...
Page 207: Engine Removal And Installation
ENGINE REMOVAL & INSTALLATION CHAPTER 6 ENGINE REMOVAL & INSTALLATION OVERVIEW - ENGINE REMOVAL ......... . 6.2 GENERAL .
Page 208: Overview - Engine Removal
ENGINE REMOVAL & INSTALLATION OVERVIEW - ENGINE REMOVAL GENERAL A floor jack or commercially available motorcycle engine lift or hoist is required for engine removal. Arrange for assistance when removing and installing the engine. Once engine is removed from frame, an engine stand is recommended for engine disassembly and assembly. Engine removal and installation methods may differ slightly depending on available equipment, but always be sure the engine and chassis are securely supported and secured at all times.
Page 209: Special Tools
ENGINE REMOVAL & INSTALLATION SPECIAL TOOLS 1.) Motorcycle table lift with wheel vise (commercially available) 2.) Engine platform jack or platform lift (commercially available) 3.) Engine stand (commercially available) 4.) Engine Mounting Plates (PV-48737) PV-48737 ENGINE MOUNTING PLATES (Required for engine removal) ©...
Page 210: Torque Values
ENGINE MOUNTING - AIRBOX / MAIN FRAME ASSEMBLY ENGINE INSTALLATION (See page 6.11 - 6.12 for procedure) Apply Victory All Purpose Grease 2872187 1. Install all bolts in order A-D page 6.4 and 6.5. Do not tighten. 2. Torque bolts as specified in order 1 - 4 3.
Page 211: Engine Mounting - Rear Sub Frame Assembly
ENGINE REMOVAL & INSTALLATION ENGINE MOUNTING - REAR SUB FRAME ASSEMBLY (Torque the nut end) 111 Nm (82 lb-ft) M12 x 100mm Airbox / Main Frame Attachment Point Tie Strap 48 Nm (35 lb-ft) M10 x 70mm © 2009 Polaris Sales Inc.
Page 212: Engine Removal
ENGINE REMOVAL & INSTALLATION ENGINE REMOVAL 5. Remove LEFT floorboard assembly (C). PREPARATION FOR REMOVAL A number of different methods can be used to remove the engine depending on the equipment available to the technician. • Support motorcycle securely in an upright position during engine removal.
Page 213 ENGINE REMOVAL & INSTALLATION 8. Disconnect both O sensors at the connector (not at NOTE: If you plan to disassemble the engine the sensor) and remove exhaust system (Chapter 3). crankcase, remove drive sprocket (Chapter 11). 11. Remove crankcase breather hose (I). Unplug both Lambda Sensors 9.
Page 214 ENGINE REMOVAL & INSTALLATION 15. Disconnect engine harness. 18. Remove the battery (page 2.20). 19. Unplug and remove regulator / rectifier (P). NOTE: Regulator / Rectifier removal is not required, but it is recommended during engine removal to prevent from damaging the component. 16.
Page 215 ENGINE REMOVAL & INSTALLATION 21. Remove oil cooler mounting bolts (S). 26. Remove upper rear engine mount bolts and plates (V). 22. Pull cooler out of grommet (T) for removal with engine. 23. Remove positive cable from starter motor. 27. Install Engine Mounting Plates PV-48737 in place of original mount plates (page 6.3).
Page 216: Injector Removal
ENGINE REMOVAL & INSTALLATION 30. Remove the right-hand side cover and disconnect the 33. When all fasteners have been removed, ensure all cables from the throttle body (dark cable is pull cable hoses, wiring, and other components have been and located on the bottom). Lift cruise control cable disconnected or removed to allow engine removal.
Page 217: Engine Installation
ENGINE REMOVAL & INSTALLATION ENGINE INSTALLATION 4. Slide engine back onto dowel pins and adjust engine height as needed to align the pins and fully seat the throttle body into the airbox/frame seal. PREPARATION FOR INSTALLATION Refer to page 6.4 - 6.5 for torque values and assembly CAUTION views.
Page 218 41. When test ride is completed, check entire vehicle and bolts to 9.6 Nm (85 lb-in). engine for fluid leaks. NOTE: Drive belt is installed with “VICTORY” 42. Inspect oil level and adjust if necessary. readable from right side. Do not kink or twist the drive belt.
Page 219: Cylinder Head & Valve Train
CYLINDER HEAD & VALVE TRAIN CHAPTER 7 CYLINDER HEAD & VALVE TRAIN GENERAL INFORMATION ..........7.2 IMPORTANT NOTES .
Page 220: 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 221: Data - Cylinder Head
CYLINDER HEAD & VALVE TRAIN DATA - CYLINDER HEAD SPECIFICATIONS CYLINDER HEAD - 2008 - 2010 Valve Train Single Overhead Cam / 4 valves per cyl 2 Intake valves / 2 Exhaust valves Intake Valve Opens At 1 mm Lift BTDC Intake Valve Closes At 1 mm Lift ABDC...
Page 222: Torque Values And Assembly Views
CYLINDER HEAD & VALVE TRAIN TORQUE VALUES AND ASSEMBLY VIEWS CAM DRIVE & VALVE COVER 13 Nm (115 lb-in) Repeat Torque Sealant bead UP 14.6-19.5 Nm (10.8-14.5 lb-ft) (New plugs - with anti-seize compound applied to threads) 13.5 Nm (120 lb-in) Cam Chain Tensioners 75 Nm (55 lb-ft) 11.3 Nm (100 lb-in)
Page 223: Camshaft Carrier / Rocker Arm - 2008
CYLINDER HEAD & VALVE TRAIN CAMSHAFT CARRIER / ROCKER ARM: 2008 NOTES Apply Moly Assembly Paste (PN 2871460) Upper carrier half must be loose to allow upward movement when cylinder head nuts are torqued. (See Cylinder Head Installation on page 7.25) After cylinder head nuts have been torqued, torque upper cam carrier as follows: Lubricate nuts and washers with engine oil ...
Page 224 CYLINDER HEAD & VALVE TRAIN CAMSHAFT CARRIER / ROCKER ARM - 2009 - 2010 After assembly, rotate cams back and forth slightly to verify free rotation. Allow time for lifters to bleed FRONT down before performing this inspection. 2009-2010 6.8 Nm (60 lb-in).
Page 225: Cylinder Head
CYLINDER HEAD & VALVE TRAIN CYLINDER HEAD See page 7.26 (2008) or 7.29 for Temp Sensor cylinder head torque procedure. (Front Cylinder Head Left Side) 13.5 Nm (10 lb-ft) IMPORTANT! Gaskets and gasket Loctite 565 or Pipe Sealant surfaces must be oil free. (Replace sensor if removed) 20 Nm (15 lb-ft)
Page 226: Camshaft Timing Quick Reference
CYLINDER HEAD & VALVE TRAIN CAMSHAFT TIMING QUICK REFERENCE Use this page as a reference ONLY if you are familiar with the cam timing procedure. Refer to Page 7.30 for complete camshaft timing procedure The illustration below shows final cam timing configuration. The rear cylinder has been timed and the crankshaft rotated 410 from rear TDC.
Page 227: Cylinder Head Service
CYLINDER HEAD & VALVE TRAIN VALVE COVER REMOVAL CYLINDER HEAD SERVICE 1. Engine removal is required. Refer to Chapter 6. CAMSHAFT DRIVE COVER Remove all valve cover screws. 1. Remove cam drive cover. 3. Tap cover with a soft faced hammer until loose. 2.
Page 228: Cam Chain Tensioner Inspection
CYLINDER HEAD & VALVE TRAIN CAM CHAIN TENSIONER INSPECTION CAM CHAIN TENSIONER INSTALLATION 1. Visually inspect inner plunger (A) for damage, scoring, 1. Lubricate all parts with engine oil. or burrs. 2. Install damper (C) squarely into tensioner bore in 2.
Page 229: Camshaft Chain & Sprocket Removal
CYLINDER HEAD & VALVE TRAIN CAMSHAFT CHAIN & SPROCKET REMOVAL 7. Remove tensioner blade bolt (C) and guide bolt (D). 1. Remove engine from frame (Chapter 6). 2. Remove camshaft drive cover and CPS timing wheel (page 7.9). 3. Rotate crankshaft clockwise, past TDC on the compression stroke for front cylinder until bottom sprocket bolt (A) is accessible and remove it.
Page 230: Rocker Arm Removal - 2008
CYLINDER HEAD & VALVE TRAIN ROCKER ARM REMOVAL: 2008 ROCKER ARM & SHAFT INSPECTION: 2008 NOTE: Keep mated rocker arm shafts and rocker 1. Separate top and bottom half of rocker carrier. Tap arms together. Do not interchange mated parts. shaft out of top carrier until hole in shaft is exposed on Rocker arm carrier is marked “F”...
Page 231: Camshaft Inspection
CYLINDER HEAD & VALVE TRAIN 6. Measure O.D. of each rocker arm shaft (A) and CAMSHAFT INSPECTION: 2008 compare to specification. 1. Visually inspect camshaft journal surfaces (C) for scoring or signs of insufficient lubrication. Replace 7. Measure I.D. of each rocker arm (B). camshaft if heavy scoring or damage is noted.
Page 232: Camshaft Carrier Removal
CYLINDER HEAD & VALVE TRAIN CAMSHAFT CARRIER REMOVAL: 2009-2010 ROCKER ARM & SHAFT INSPECTION: 2009-2010 NOTE: Base and head gasket seal is released when removing camshaft carrier. Replacement of both head 1. Remove button head screw (C) and pin (D). Slide and base gasket is recommended to prevent oil camshaft out of carrier.
Page 233 CYLINDER HEAD & VALVE TRAIN CAMSHAFT INSPECTION (ALL - TYPICAL) 1. Visually inspect camshaft journal surfaces (A) for scoring or signs of insufficient lubrication. Replace camshaft if heavy scoring or damage is noted. 2009-2010 Shown (2008 similar) 2. Measure O.D. of each camshaft journal. 3.
Page 234: Cylinder Head Removal - 2008
CYLINDER HEAD & VALVE TRAIN CYLINDER HEAD REMOVAL: 2008 CYLINDER HEAD REMOVAL: 2009-2010 1. Remove engine (Chapter 6). 1. Remove engine (Chapter 6), valve covers (page 7.9), and camshaft sprockets (page 7.11). 2. Remove camshafts (page 7.11). 2. Remove camshafts (page 7.14). 3.
Page 235: Cylinder Head Disassembly
CYLINDER HEAD & VALVE TRAIN CYLINDER HEAD DISASSEMBLY 2. Remove upper valve spring retainers (B), springs (C), and valves (E). CAUTION 3. Remove and discard valve guide seals (D). 4. Clean carbon deposits from combustion chamber. Wear eye protection while removing valve springs. NOTE: Keep mated parts together for assembly.
Page 236: Cylinder Head Inspection
CYLINDER HEAD & VALVE TRAIN CYLINDER HEAD INSPECTION VALVE SPRING FREE LENGTH INSPECTION 1. Visually inspect cylinder head for cracks or damage. 1. Measure free length of valve springs. Replace springs that do not meet specification on page 7.3. Pay close attention to the areas around spark plug and valve seats.
Page 237 CYLINDER HEAD & VALVE TRAIN 5. Inspect that each valve moves up and down smoothly without binding in guide. 6. Measure valve stem deflection for each valve to determine if valve or valve guide requires replacement. Raise valve 10mm (0.400") off of seat. B.
Page 238 CYLINDER HEAD & VALVE TRAIN VALVE INSPECTION VALVE INSPECTION CONDITION ILLUSTRATION POSSIBLE CAUSE CORRECTIVE ACTION Uneven seat width Bent valve stem, worn Replace valve and reface valve guide seat Damaged valve face Burnt, pitted, foreign Replace valve and reface material damage seat Contact area too high Wear, settling of valve seat...
Page 239: Valve Guide Removal / Installation
CYLINDER HEAD & VALVE TRAIN VALVE GUIDE REMOVAL / INSTALLATION 4. Drive or press new guides from camshaft side of head. Drive or press guides in until circlip (A) seats against head surface (B). CAUTION Replacement of valve guides requires an oven, special equipment and experience to do the job correctly.
Page 240: Valve Seat Inspection
CYLINDER HEAD & VALVE TRAIN VALVE SEAT INSPECTION VALVE SEAT RECONDITIONING 1. Remove carbon deposits from valves and seats. NOTE: Valve seat reconditioning should be performed by a technician proficient in cylinder head reconditioning 2. Inspect valve face for burning, pitting or uneven techniques using grinding stones.
Page 241: Cylinder Head Assembly
CYLINDER HEAD & VALVE TRAIN CYLINDER HEAD ASSEMBLY A. Keeper B. Spring Retainer C. Spring D. Seal E. Valve Valve Installed Height (From Head Surface, Seal Removed) Valve Spring Installed Height (Measure with Seal Installed) Valve Guide Installed Height (From Head Surface, Seal Removed) INSTALLED HEIGHT MEASUREMENT REFER TO PAGE 7.3 FOR SPECIFICATIONS 7.23...
Page 242 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 243: Cylinder Head Installation - 2008
CYLINDER HEAD & VALVE TRAIN CYLINDER HEAD INSTALLATION: 2008 4. Install cylinder head onto cylinder. NOTE: Base gasket seal is broken upon cylinder head CAUTION removal and must be replaced at this time. Refer to Chapter 8 for cylinder base gasket replacement. The camshaft carrier can be installed as an assembly, 1.
Page 244: Camshaft / Rocker Installation - 2008
CYLINDER HEAD & VALVE TRAIN 6. Install (E) on cylinder head. 10. Follow torque procedure below to ensure accurate final torque: CYLINDER HEAD TORQUE PROCEDURE: 2008 Step 1 Apply engine oil to nut thread and nut bases. Step 2 Follow torque pattern shown. Step 3 Tighten 10 mm nuts (1-4) to 30 Nm (22 lb.
Page 245 CYLINDER HEAD & VALVE TRAIN 3. Turn cam until lobes are pointing down. CYLINDER HEAD INSTALLATION: 2009-2010 4. Inspect each rocker arm and position flat side of NOTE: Base gasket seal is broken upon cylinder head hydraulic adjuster down as shown at right (D). removal and must be replaced at this time.
Page 246 CYLINDER HEAD & VALVE TRAIN 5. Camshaft carriers are marked “F” (FRONT) or “R” 13. Install washers and nuts on cylinder studs. Tighten (REAR) for installation in their respective cylinder finger tight. heads (C). Lobes Down 2009-2010 2009-2010 14. Slowly and evenly tighten cylinder head nuts following torque sequence in Fig.
Page 247 CYLINDER HEAD & VALVE TRAIN 15. Fully torque cylinder head following the procedure below to ensure accurate final torque: CYLINDER HEAD TORQUE PROCEDURE 2009-2010 (Camshaft carriers installed and seated in head) Step 1 Lubricate 8mm studs, washers, and nuts with engine oil and install hand tight.
Page 248: Camshaft Timing - Rear Cylinder
CYLINDER HEAD & VALVE TRAIN CAMSHAFT TIMING - REAR CYLINDER 5. Be sure rear camshaft lobes are pointing down. The single mark on cam (D) must be facing UP as shown NOTE: Rear cam chain must be installed first. below. 6.
Page 249: Camshaft Timing - Front Cylinder
CYLINDER HEAD & VALVE TRAIN  CAMSHAFT TIMING - REAR CYLINDER 15. Insert an 8 mm (5/16 ) pin through crankcase hole to hold the crankshaft in position at front cylinder TDC. (cont.) Timing sprocket key (A) will be aligned with pin and front cylinder centerline.
Page 250 CYLINDER HEAD & VALVE TRAIN 19. Torque guide tensioner blade bolts 24. Apply engine oil to front cam chain tensioner and specification. damper. Push damper (F) squarely into tensioner bore in cylinder, and push it past the first 4 or 5 threads. 11.3 Nm (100 lb-in) 20.
Page 251 CYLINDER HEAD & VALVE TRAIN 30. Fill cam carrier area of both front and rear cylinders with Victory engine oil. 31. Rotate crankshaft clockwise approximately three complete revolutions and stop on front cylinder TDC on the compression stroke. 32. Again compare camshaft timing to Ill. 1 on page 7.8 to verify the timing is correct.
Page 252: Troubleshooting, Cylinder Head And Valve Train
CYLINDER HEAD & VALVE TRAIN TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test. Other problems associated with this area of the engine are external fluid leaks, excessive use of oil or abnormal noises. Troubleshooting involves the use of: •...
Page 253 CYLINDER HEAD & VALVE TRAIN PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED Poor Idle Quality Air leak Mounting Surfaces, Hoses Repair Air Leak IAC System Fault Inspect IAC System Hoses Repair Air Leak or restriction in IAC System Fuel Mixture Rich F.I.
Page 254 CYLINDER HEAD & VALVE TRAIN PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED Poor high speed running Air Intake Problem Refer to Chapter 5 F.I. System Problem Refer to Chapter 5 Ignition Problem Refer to Chapter 17 Valve Float Weak Valve Springs Replace Insufficient Valve Travel Worn Camshaft/Rocker Arms...
Page 255: Cylinder And Piston
CYLINDER & PISTON CHAPTER 8 CYLINDER & PISTON CYLINDER & PISTON ........... . 8.2 GENERAL.
Page 256: General
CYLINDER & PISTON CYLINDER & PISTON GENERAL NOTE: Clean the machine thoroughly before removing engine from frame. • This section covers service of the cylinder, piston and rings. The engine must be removed from the frame to perform the procedures in this section. Refer to Chapter 6 for engine removal and installation. •...
Page 257: Specifications
CYLINDER & PISTON SPECIFICATIONS CYLINDER & PISTON Item Standard Service Limit I.D. 100.987 - 101.013 Check taper and ( 3.9759" - 3.9769”) out-of-round Out of Round Measure 66mm up from base 0.05 mm ( .002" ) Cylinder gasket surface Taper 0.05 mm ( .002"...
Page 258: Cylinder Removal
CYLINDER & PISTON CYLINDER REMOVAL CYLINDER INSPECTION Remove engine from frame (Chapter 6). 1. Visually inspect cylinder bores for scratches and wear. 2. Remove cylinder head(s) (Chapter 7). 2. Inspect gasket surfaces for scratches or other damage that may cause an oil leak. CYLINDER BORE MEASUREMENT Measure each cylinder bore in 6 places to determine: •...
Page 259: Piston To Cylinder Clearance Worksheet
CYLINDER & PISTON PISTON TO CYLINDER CLEARANCE WORKSHEET Front Cylinder Recorded Measurement Specification Top “X” Middle “X” Bottom “X” Top “Y” Middle “Y” Bottom “Y” Difference between largest “Y” Taper for “Y” axis: Taper Service Limit: .05mm (.002") measurement and smallest “Y” measurement Difference between largest “X”...
Page 260: Cylinder Warpage Measurement
CYLINDER & PISTON CYLINDER WARPAGE MEASUREMENT 6. Spread rings only wide enough to remove them from piston. Spreading rings too wide will damage them. Inspect cylinder for warpage at cylinder head surface 7. Clean piston ring grooves. Break or cut a piston ring in and base gasket surface.
Page 261: Piston Pin / Pin Bore Inspection
CYLINDER & PISTON 5. Use a piston to push each ring squarely into cylinder PISTON PIN / PIN BORE INSPECTION bore from bottom (push rings 25-50mm into cylinder). Measure piston pin hole I.D. in four locations with a telescoping gauge. Record the smallest. Cylinder 25-50 mm Piston Ring...
Page 262: Cylinder Stud Replacement
CYLINDER & PISTON CYLINDER STUD REPLACEMENT PISTON RING INSTALLATION 1. Use a stud remover to remove 10mm studs (A) and 8mm studs (B). CAUTION 10 mm Studs Rings may be damaged if expanded more than necessary 34 Nm (25 lb-ft) to install them.
Page 263: Piston Installation
CYLINDER & PISTON PISTON INSTALLATION 5. Push piston pin through rod and piston pin hole until it is stopped by circlip. The pistons are marked with an arrow on the crown. Install pistons on connecting rods with arrow (A) facing the 6.
Page 264: Cylinder Installation
CYLINDER & PISTON CYLINDER INSTALLATION 7. Place a small amount of engine oil to inside surfaces of a piston ring compressor band. NOTE: Be sure all top end parts are ready for assembly. Sealant on crankcase parting line must not be allowed to Piston Ring Compressor Band:PV-43570-2 dry before top end is assembled and torqued.
Page 265: Troubleshooting, Cylinder & Piston
CYLINDER & PISTON TROUBLESHOOTING, CYLINDER & PISTON PROBLEM POSSIBLE CAUSE AFFECTED PART(s) REPAIR RECOMMENDED Engine Hard Starting (or) Low Compression Lifter(s) Locked Refer to Chapter 7 Engine Will Not Start Collapsed Hydraulic Refer to Chapter 7 Lifter(s). Lifter Extremely Noisy. Worn Valve Guide(s) Refer to Chapter 7 Poor Seating of Valve(s)
Page 266: Troubleshooting (Cont.)
CYLINDER & PISTON TROUBLESHOOTING (Cont.) PROBLEM POSSIBLE CAUSE AFFECTED PART(s) REPAIR RECOMMENDED Engine Idles Poorly Fuel Management Air leaks intake tract Refer to Chapter 5 Incorrect IAC system malfunction, air Refer to Chapter 5 leak, or restriction Low Compression Collapsed Hydraulic Refer to Chapter 7 Lifter(s).
Page 267 CLUTCH, PRIMARY, & SHIFT LINKAGE CHAPTER 9 CLUTCH, PRIMARY, & SHIFT LINKAGE GENERAL ............. 9.2 SPECIFICATIONS .
Page 268: 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 269: Assembly Views & Torque Values
CLUTCH, PRIMARY, & SHIFT LINKAGE ASSEMBLY VIEWS & TORQUE VALUES HYDRAULIC CLUTCH HOSE ROUTING 1.6 Nm (14 lb-in) Torque rear screw first 10.8 Nm (96 lb-in) Torque front screw last Tie strap hose to 10.8 Nm (96 lb-in) wire harness Install New 24.5 Nm (18 lb-ft) Route...
Page 270: Hydraulic Clutch System Components
CLUTCH, PRIMARY, & SHIFT LINKAGE HYDRAULIC CLUTCH SYSTEM COMPONENTS See page 15.20 for clutch master cylinder service. The slave cylinder is not serviceable. SPECIAL GREASE (009-Z00-115) 1.6 Nm (14 lb-in) Application: External: Lever pivot screw, contact surface of lever to pushrod, end of pushrod to piston.
Page 271: Clutch (Cable) Routing
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH (CABLE) ROUTING Route through lower handlebar tie strap Cable clamp Torque rear 0.2 Nm (1.8 lb-in) screw first 9.0 Nm (80 lb-in) 5.4 Nm (48 lb-in) 6.0 Nm (53 lb-in) Strap 5.4 Nm (48 lb-in) ©...
Page 272: Shift Linkage / Footrest - Fastener Torque
CLUTCH, PRIMARY, & SHIFT LINKAGE SHIFT LINKAGE / FOOTREST - FASTENER TORQUE Lubricate with mild soap and water to install 9.5 Nm (84 lb-in) 9.5 Nm (84 lb-in) 47.5 Nm (35 lb-ft.) 9.5 Nm (84 lb-in)  92.5mm (3.65  +/- 3 Adjustment: 1.
Page 273: Primary Cover
CLUTCH, PRIMARY, & SHIFT LINKAGE PRIMARY COVER Sealant bead faces cover 2 Nm (15 lb-in.) 5.7 Nm (50 lb-in.) 5.7 Nm (50 lb-in.) 5 Nm (40 lb-in.) 13 Nm (115 lb-in.) 15  5 Stator Wire Detail (Stator removed for clarity) Cover Route wires installed...
Page 274: Shift Mechanism
CLUTCH, PRIMARY, & SHIFT LINKAGE SHIFT MECHANISM Hold detent arm away until shift star is installed and screw (# 5) is torqued. Straight end of spring in slot on crankcase. Hooked end on arm. Hold clutch shaft with PV-45028 Install new bolt upon assembly 34 Nm (25 lb-ft) 9.6 Nm (85 lb-in.) Loctite ...
Page 275: Service Procedures
CLUTCH, PRIMARY, & SHIFT LINKAGE SERVICE PROCEDURES CLUTCH PINION SHAFT REMOVAL 1. Protect finish of pinion shaft (E). Use an adjustable CAP PLATE & CAP PLATE SEAL REMOVAL wrench to rotate arm toward clutch slave cylinder and remove slave cylinder pull rod pinion shaft. 1.
Page 276: Clutch Pinion Shaft Seal Removal & Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH PINION SHAFT SEAL REMOVAL & CLUTCH PINION SHAFT INSTALLATION INSTALLATION 1. Lubricate and install clutch pinion shaft. Rotate release rack with screwdriver until flat side of rack is 1. Remove clutch pinion shaft (page 9.9). UP and rack teeth align with teeth of pinion shaft.
Page 277: Primary Cover Removal
CLUTCH, PRIMARY, & SHIFT LINKAGE PRIMARY COVER REMOVAL 8. Remove primary cover screws. 1. Refer to exploded view on page 9.7. NOTE: Note position of shorter screw (A) in the hole just to the rear of the shift shaft. 2. Remove shift linkage and footrest as an assembly (page 9.6).
Page 278: Shift Ratchet Removal & Inspection
CLUTCH, PRIMARY, & SHIFT LINKAGE SHIFT RATCHET REMOVAL & INSPECTION 7. Inspect compression spring (D) for tension. The spring should apply enough tension on the shift ratchet 1. Shift transmission into neutral. mechanism to keep it extended. 8. Inspect fit of rivet (E) on shift ratchet assembly. It should allow for free movement, but not be excessively loose.
Page 279: Shift Ratchet Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE SHIFT RATCHET INSTALLATION SHIFT SHAFT BEARING & SEAL REPLACEMENT Refer to Shift Mechanism Assembly View on page 9.8. 1. Apply Loctite 242 (Blue) to clean threads of detent 1. Remove primary cover (page 9.11). Carefully pry shift roller screw.
Page 280: Primary Cover Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE PRIMARY COVER INSTALLATION 7. Install pinion shaft (page 9.10). 8. Install cap plate with seal (page 9.9). 1. Clean gasket surfaces of crankcases and cover. 9. Install slave cylinder pull rod on pinion shaft arm. 2.
Page 281: Clutch Service
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH SERVICE CLUTCH ASSEMBLY VIEW & TORQUE Friction Washer Install new 170 Nm (125 lb-ft) Install New 9.6 Nm (85 lb-in) 9.15 © 2009 Polaris Sales Inc.
Page 282: Clutch Removal
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH REMOVAL 4. Remove clutch nut, lock washer, and flat washer. Discard lock washer and nut. 1. Remove primary cover (page 9.11). 2. Using an internal snap ring pliers, remove clutch rack. 5. Remove clutch assembly from clutch shaft. 3.
Page 283: Clutch Disassembly
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH DISASSEMBLY 4. Remove retaining ring seat (B) (stepped washer). Special tool: Clutch spring compressor PV-45032 CAUTION Clutch is under spring pressure. WEAR EYE PROTECTION. 1. Install clutch spring compressor threaded rod and secure it with the snap ring (A). 5.
Page 284: Clutch Inspection
CLUTCH, PRIMARY, & SHIFT LINKAGE 11. Remove (9) identical steel plates that separate the (8) 5. Rotate hub bearing. Check for smooth rotation. Inner identical friction plates. race should no detectable radial movement (C). 12. Remove judder friction plate, judder spring, and judder 6.
Page 285 CLUTCH, PRIMARY, & SHIFT LINKAGE 10. Replace steel plates if grooved, distorted or discolored. Diaphragm Spring Inspect plates for distortion by placing each plate on a precision flat surface. Insert a feeler gauge (G) 14. Inspect clutch diaphragm spring (I) for cracks or between plate and flat surface in several places.
Page 286: Clutch Assembly
CLUTCH, PRIMARY, & SHIFT LINKAGE 19. If bearing (K) fails inspection, remove it from housing CLUTCH ASSEMBLY (L) using an arbor press. Support housing evenly in 1. Refer to exploded views on page 9.15. Apply engine areas (M) during bearing removal. oil to judder spring seat (A) and spring (B).
Page 287 CLUTCH, PRIMARY, & SHIFT LINKAGE NOTE: Feel the edge of steel plates and friction plates 7. Install clutch diaphragm spring (D) with concave side with your finger. One side of plate is machined at the down on top of pressure plate. edges and the other side is a rolled edge (rounded).
Page 288: Clutch Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE CLUTCH INSTALLATION Replace with new Replace with new 170 Nm (125 lb-ft) Replace with new 1. Install a NEW friction washer (A) on clutch shaft. DO 5. Install lock tool under split gear or lock crankshaft as shown on page 9.14.
Page 289: Primary Drive Assembly View & Torque
CLUTCH, PRIMARY, & SHIFT LINKAGE PRIMARY DRIVE ASSEMBLY VIEW & TORQUE Replace nut if loosened or removed. Align timing marks during assembly (Pre-applied locking agent, M20x1.5) 170 Nm (125 lb-ft) Moly Lube 102 Nm (75 lb-ft) See NOTE: below Replace screws if loosened or removed.
Page 290: Torque Compensator Removal
CLUTCH, PRIMARY, & SHIFT LINKAGE TORQUE COMPENSATOR REMOVAL 6. Remove gear (A) with compensator sleeve (B), and washer (C). The washer must be positioned correctly See Torque Compensator Assembly View (page 9.23). If upon assembly. See assembly procedure page 9.25. split gear removal is required, see page 9.27 after compensator is removed.
Page 291: Torque Compensator Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE TORQUE COMPENSATOR INSTALLATION 7. Install sleeve (E) into gear and place washer (F) over the protruding end of the sleeve on back side of gear. NOTE: Engine must be upright for this procedure. It is very important that washer (A) does not fall off the sleeve (B) during assembly.
Page 292: Rotor (Flywheel) Removal
CLUTCH, PRIMARY, & SHIFT LINKAGE 12. Grease edges of springs and retainer plate. Illustration ROTOR (FLYWHEEL) REMOVAL below shows correctly assembled springs, with 1. Remove primary cover (page 9.11) and rotor retaining concave edge facing each other. The assembled sets bolt (counterclockwise).
Page 293: Rotor (Flywheel) Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE ROTOR (FLYWHEEL) INSTALLATION 8. Insert a 1/4” pin punch in gear alignment hole (B) to relieve spring pressure on gear teeth. 1. Clean taper of rotor and crankshaft thoroughly. 2. Install key in key way on crankshaft. 3.
Page 294: Split Gear Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE SPLIT GEAR INSTALLATION 7. Push split gear inward until fully seated and flush with crankshaft gear. Verify proper balance shaft timing. 1. Rotate balance shaft until “boss” spline (D) (double wide spline) is at 12:00 o’clock position. 2.
Page 295: Starter Drive
CLUTCH, PRIMARY, & SHIFT LINKAGE STARTER DRIVE STARTER GEAR INSPECTION 1. Inspect gear teeth for chips, cracks or excessive wear. STARTER DRIVE REMOVAL NOTE: The starter gear and primary drive (crankshaft) gear must be removed before the starter idler gear or ...
Page 296: Primary Drive Gear
CLUTCH, PRIMARY, & SHIFT LINKAGE PRIMARY DRIVE GEAR 9. Pull torque limiter clutch shaft out through cover opening with washer. PRIMARY DRIVE GEAR REMOVAL / NOTE: Stepped side of washer faces out (toward gear) INSPECTION and flat side of washer is against limiter clutch (inset). 10.
Page 297: Primary Drive Gear Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE PRIMARY DRIVE GEAR INSTALLATION 8. Install drive gear. If split gear is installed, rotate drive gear clockwise against spring pressure until split gear 1. Clean mating surfaces of crankshaft and gear. teeth align. Push gear in and rotate until pin on crankshaft aligns with hole on the back of drive gear.
Page 298: Starter Gear / Starter Clutch Installation
CLUTCH, PRIMARY, & SHIFT LINKAGE STARTER GEAR / STARTER CLUTCH 4. Install retaining ring (D). INSTALLATION 1. Install one-way clutch with raised edge (A) inward (toward primary gear). 5. Install rotor (page 9.27). 6. Install primary cover (page 9.14). 2. Install starter gear (B). When properly installed, the 7.
Page 299: Troubleshooting
CLUTCH, PRIMARY, & SHIFT LINKAGE TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED Clutch Lever Pulls Clutch lever pivot, bushings, Clutch Lever Pivot Point Lubricate Excessively Hard ferrules need lubrication Master cylinder or Slave Contaminated hydraulic system Inspect cylinder Drive plates catching on primary Clutch Primary Driven Gear/ Replace Necessary Parts...
Page 300 CLUTCH, PRIMARY, & SHIFT LINKAGE PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED Transmission Will Not Broken Shift Drum Shift Drum Replace shift drum Shift Bent Shift Forks Shift Fork Replace shift forks Worn Shift Drum Shift Drum Replace shift drum Broken Gears Transmission Gears Replace broken gear(s)
Page 301 TRANSMISSION & CRANKSHAFT CHAPTER 10 TRANSMISSION & CRANKSHAFT GENERAL ............10.2 SERVICE INFORMATION .
Page 302: Transmission & Crankshaft
TRANSMISSION & CRANKSHAFT GENERAL SERVICE INFORMATION • Remove engine from frame to service internal transmission and/or crankshaft components (Chapter 6). • The crankcase must be separated to access internal transmission components and crankshaft. Remove: •Cylinder heads •Cylinders & pistons •Gear shift linkage •Primary cover and components (as required depending on needed access to other components).
Page 303: Connecting Rod And Crankshaft Specifications
TRANSMISSION & CRANKSHAFT CONNECTING ROD AND CRANKSHAFT SPECIFICATIONS CRANKSHAFT and COMPONENTS Part Part Specific Standard Service Limit Connecting Rod Connecting Rod to .22 - .42 mm .65 mm Crankshaft Side Clearance (.0087 - .0165") (.025") Connecting Rod Bearing to .0254 - .0635 mm .11 mm Crankshaft Oil Clearance (.001 - .0025")
Page 304: Assembly Views & Torque Values
TRANSMISSION & CRANKSHAFT ASSEMBLY VIEWS & TORQUE VALUES CRANKCASE COMPONENTS Install with chamfer side to bore. Press until seated Press until seated. Center reed valve 13x10 over hole in case Replace bearing retainer plate screws if removed! Press bearings by outer race only! 85 lb-in.
Page 305: Crankshaft / Connecting Rod / Crankcase Torque Pattern
TRANSMISSION & CRANKSHAFT CRANKSHAFT / CONNECTING ROD / CRANKCASE TORQUE PATTERN Arrow on piston crown or circlip access notch faces FRONT of engine Place gap of circlip at 12 O’clock position (UP) LEFT connecting rod to rear cylinder “OUT” on LH rod faces left end of crank Torque connecting rod caps: 1) Evenly to 7 Nm (5 lb-ft) to seat cap 2) To 54 Nm (40 lb-ft) final torque...
Page 306: Service Procedures
TRANSMISSION & CRANKSHAFT SERVICE PROCEDURES 9. Loosen remaining crankcase bolts evenly and remove from case. Note the two different bolt lengths and the locations of each (page 10.5). CRANKCASE SEPARATION 10. Install the crankshaft bearing protector over the cam 1. Drain engine oil. chain drive gear on the crankshaft.
Page 307 TRANSMISSION & CRANKSHAFT 12. Lift crankcase off and remove bearing protector from cam chain drive sprocket. NOTE: Components such as the crankshaft, oil pump, balance shaft, transmission, and shift drum can be removed individually for service. Refer to the following pages as required: •...
Page 309: Mainshaft / Clutch Shaft Assembly View
TRANSMISSION & CRANKSHAFT MAINSHAFT / CLUTCH SHAFT ASSEMBLY VIEW MAINSHAFT / CLUTCH SHAFT 10.9 © 2009 Polaris Sales Inc.
Page 310: Countershaft Assembly View
TRANSMISSION & CRANKSHAFT COUNTERSHAFT ASSEMBLY VIEW A: Outside Diameter: 27.976-27.986mm B: Outside Diameter: 27.990-28.000mm C: Outside Diameter: 24.982-24.995mm D: Inside Diameter: 32.005-32.021mm E: Inside Diameter: 32.005-32.021mm 10.10 © 2009 Polaris Sales Inc.
Page 311: Shift Drum And Shift Fork Assembly View
TRANSMISSION & CRANKSHAFT SHIFT DRUM AND SHIFT FORK ASSEMBLY VIEW (Left End) 10.11 © 2009 Polaris Sales Inc.
Page 312: Power Delivery
TRANSMISSION & CRANKSHAFT POWER DELIVERY VIEWED FROM FRONT OF ENGINE Indicates movement of sliding gear for engagement Idle in Neutral Output Shaft Clutch Shaft 1st Gear Counter Shaft Neutral 3rd Gear 2nd Gear 4th Gear 5th Gear Sixth Gear (O/D) 10.12 ©...
Page 313: Transmission Removal
TRANSMISSION & CRANKSHAFT TRANSMISSION REMOVAL 5. Remove shift forks, shift drum, mainshaft and countershaft from crankcase. 1. If not removed previously, remove countershaft 6. Carefully lift crankshaft out of left case. locating bolt and washer (A). Use clutch shaft older PV-45028 to prevent shaft rotation.
Page 314: Transmission Inspection
TRANSMISSION & CRANKSHAFT TRANSMISSION INSPECTION Refer to exploded views on page 10.8. Standard specifications for shaft and gears are on page 10.9 (main and clutch shaft) and page 10.10 (countershaft). Shafts 1. Measure outside diameter of shafts in bearing areas for wear and concentricity as shown on page 10.9 and 10.10.
Page 315: Crankshaft Removal
TRANSMISSION & CRANKSHAFT 8. Visually inspect the shift drum bearing (D) in the left 13. Inspect right side shift drum bearing (G). crankcase for wear or damage. The bearing must be 14. Temporarily install shift drum in right hand case fully seated in the case and held in position by the bearing and inspect fit.
Page 316: Connecting Rod Side Clearance Inspection
TRANSMISSION & CRANKSHAFT CONNECTING ROD SIDE CLEARANCE 2. Remove connecting rod bolts and connecting rod bearing caps. INSPECTION NOTE: It may be necessary to lightly tap the caps with a 1. Move connecting rods to one side of crankshaft. Insert plastic mallet to loosen them.
Page 317: Connecting Rod Inspection (Big End)
2. Remove bearings and install caps on connecting rods. Be sure mating surfaces (A) of rod and cap are clean. 3. Apply Victory engine oil to threads of rod bolts and nuts. Torque evenly in 2 steps to specification (page 10.19).
Page 318: Connecting Rod Bearing Clearance Inspection (Typical)
TRANSMISSION & CRANKSHAFT CONNECTING ROD BEARING CLEARANCE CONNECTING ROD BEARING SELECTION INSPECTION (Typical) 1. There are 3 sizes of connecting rod bearings available: Black, Orange and Blue (see chart below). 1. Assemble the connecting rod cap with bearings and torque to specification below. 2.
Page 319: Crankshaft Inspection
TRANSMISSION & CRANKSHAFT CRANKSHAFT INSPECTION Measure O.D. of main bearing journals. Record all measurements and compare to specifications on page 10.3. Replace crankshaft if any measurement is worn beyond the service limit. 1. Measure the width of the rod bearing journal. Right Left CONNECTING ROD INSTALLATION...
Page 320: Crankshaft Cleaning
TRANSMISSION & CRANKSHAFT 6. Tighten rod cap bolts: 2. After cleaning passages, apply Loctite 262 to blind plug threads and install plugs into crankshaft to • To 7 Nm (5 lb-ft) to seat caps and bearings. specified torque. Plug should be flush with surface of crankshaft.
Page 321: Left Crankcase Assembly
TRANSMISSION & CRANKSHAFT LEFT CRANKCASE ASSEMBLY 2. Press balance shaft bearing from the primary side using an arbor press (B). Prepare LEFT crankcase for assembly: Refer to exploded view on page 10.4 for torque values, bearing press depth, and locking agent. Clean crankcase and oil passages (A) thoroughly.
Page 322: Right Crankcase Assembly
TRANSMISSION & CRANKSHAFT RIGHT CRANKCASE ASSEMBLY CRANKCASE REED VALVE ASSEMBLY REMOVAL & INSPECTION Prepare RIGHT crankcase for assembly: 1. Separate engine cases (page 10.6). Refer to exploded view on page 10.4 for torque values, bearing press depth, and locking agent. 2.
Page 323: Transmission Installation
2. Be sure clutch shaft (A) is fully seated in bearing. crankcase assembly 3. Lubricate parts with Victory engine oil. Apply Moly 10. Install balance shaft, oil pump with pipes (Chapter 4), Assembly Paste (PN 2871460) to ends of transmission and crankshaft (page 10.22) if removed.
Page 324: Balance Shaft
TRANSMISSION & CRANKSHAFT BALANCE SHAFT 4. Install chain and sprocket onto oil pump shaft. Align flats to seat sprocket. BALANCE SHAFT REMOVAL & INSPECTION 1. Remove bolt (A) from oil pump drive sprocket. Use engine lock tool between balance shaft weight and crankcase to hold shaft.
Page 325: Crankcase
TRANSMISSION & CRANKSHAFT CRANKCASE 6. Install crankshaft bearing protector over the cam chain drive sprocket CRANKCASE ASSEMBLY & SEALING Special Tool: Crankcase Bearing Protector PV-47207 NOTE: Place transmission is in 5th gear prior to crankcase assembly. 1. Clean crankcase mating surfaces to remove all grease, oil, and old sealant.
Page 326 TRANSMISSION & CRANKSHAFT 8. Install crankcase installation tool onto the output shaft. 11. Install crankcase bolts with starter motor as shown below. 9. Pull crankcase together by tightening nut and tapping on crankcase with a soft mallet. NOTE: The cases will mate before the mainshaft is drawn fully into bearing.
Page 327 TRANSMISSION & CRANKSHAFT 13. Clean threads of countershaft and bolt with Loctite NOTE: Use an 8mm or a 5/16 diameter pin punch in Primer N. Apply 2 drops of Loctite 262 to threads of timing hole and shift transmission into 1st gear to hold countershaft bolt or use a new bolt with pre-applied crankshaft while tightening sprocket nut.
Page 328: Troubleshooting
TRANSMISSION & CRANKSHAFT TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED Transmission Will Not Shift Broken Shift Cam Shift Cam Replace shift cam Bent Shift Forks Shift Fork Replace shift fork(s) Worn Gearshift Pawl Shift Cam Replace shift cam Broken Gears Transmission Gears Replace necessary parts...
Page 329 TRANSMISSION & CRANKSHAFT PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED Transmission Hard to Shift Improper Clutch Operation Clutch Refer to chapter 9 Incorrect Oil Viscosity Engine oil and filter Refer to chapter 3 Incorrect Clutch Adjustment Clutch Adjustment Refer to chapter 3 Bent, Rubbing, Sticky, Shifter Ratchet Assembly Refer to chapter 9...
Page 331 DRIVE LINE / REVERSE SYSTEM CHAPTER 11 DRIVE LINE / REVERSE SYSTEM SPECIAL TOOLS ............11.2 DRIVE LINE SPECIAL TOOLS.
Page 332: Special Tools
DRIVE LINE / REVERSE SYSTEM SPECIAL TOOLS DRIVE LINE SPECIAL TOOLS Output Shaft Seal Installation Tool: PV-43505A  8mm (5/16 ) Pin Punch (to hold crankshaft for drive sprocket removal / installation): Commercially available Torque Wrench with 250 Nm (185 lb-ft.) range: Commercially available CAUTION Some drive line repair or maintenance involves supporting the machine with the rear end elevated.
Page 333: Drive Sprocket Fastener Torques
Install 5/16” (8 mm) pin in either of the crankshaft TDC lock holes for removal and installation. Adhesive bead toward cover 9.5 Nm (85 inch lbs.) Place transmission in 5th gear. Apply Victory All 5/16 or 8mm Purpose grease 11.3 © 2009 Polaris Sales Inc.
Page 334: Belt Guard / Fastener Torque
DRIVE LINE / REVERSE SYSTEM BELT GUARD / FASTENER TORQUE Drive Belt (Install so VICTORY can be read from RIGHT side of motorcycle) Screws M6 X 12 10.8 Nm (96 inch lbs.) Seal O-ring Seal Sleeve Sprocket Nut 244 Nm (180 lb-ft.)
Page 335: Drive Belt
DRIVE LINE / REVERSE SYSTEM DRIVE BELT BELT INSTALLATION 1. Inspect sprockets and verify sprocket fasteners are BELT INSPECTION tight. 1. Refer to Chapter 2 for belt inspection procedures. 2. Place belt onto drive sprocket and rear sprocket. 2. Inspect belt tension and adjust if necessary. Refer to 3.
Page 336: Drive Sprocket Inspection
DRIVE LINE / REVERSE SYSTEM 6. Rotate crankshaft (arrow) using Crankshaft Rotation 3. Inspect the back surface of sprocket hub (C) where it contacts the seal sleeve. Replace if worn or if surface Socket PV-48736 until key way is aligned with one of is rough.
Page 337 DRIVE LINE / REVERSE SYSTEM 4. Clean shaft threads and sprocket nut to remove all 9. Install lock plate. previous thread locking agent and apply Loctite™ NOTE: The lock plate can be installed in many positions Primer N. and either side of the plate can be used. If the plate still does not align, tighten sprocket nut slightly and try to fit the lock plate again.
Page 338: Rear Sprocket
DRIVE LINE / REVERSE SYSTEM REAR SPROCKET not required unless uncharacteristic damage is noted, or if the mileage service interval is reached. Most often, belt REAR SPROCKET REMOVAL: 2008 or sprocket damage is due to foreign debris getting 1. Remove rear wheel (Chapter 13) and set spacer between belt sprocket,...
Page 339: Rear Sprocket Inspection
DRIVE LINE / REVERSE SYSTEM REAR SPROCKET REMOVAL: 2009-2010 3. Inspect sprocket mating surface (D) for galling, roughness, or cracks. Surface must be flat, with no 1. Remove rear wheel (Chapter 13). burrs or surface irregularities. 2. Loosen all sprocket bolts evenly in a star pattern and discard.
Page 340: Reverse System (2009 - 2010 If Equipped)
DRIVE LINE / REVERSE SYSTEM REVERSE SYSTEM (2009 - 2010 IF EQUIPPED) REVERSE DRIVE MECHANISM NOTE: See page 19.40 for reverse electrical system function, component location, and diagnostics. Maintenance (reverse idler shaft lubrication) is on page 2.7. Drive Pinion Gear Idler Gear Reverse Switch Linkage Rod...
Page 341: Reverse Gear Case Assembly View
DRIVE LINE / REVERSE SYSTEM REVERSE GEAR CASE ASSEMBLY VIEW 11.11 © 2009 Polaris Sales Inc.
Page 342: Reverse Linkage Adjustment
DRIVE LINE / REVERSE SYSTEM REVERSE LINKAGE ADJUSTMENT 6. Rotate linkage rod to lengthen it until reverse idler gear lightly bottoms out against gearcase cover. Be sure Linkage Rod Adjustment lever shaft does not begin to rotate off the fully DOWN position.
Page 343: Reverse System Test
DRIVE LINE / REVERSE SYSTEM REVERSE SYSTEM TEST REVERSE COUPLER SHAFT KEY REPLACEMENT 1. Seated in a normal riding position on motorcycle, The reverse gear drive shaft (coupler) has an inner and an place transmission in Neutral and move reverse lever outer drive key.
Page 344: Troubleshooting
DRIVE LINE / REVERSE SYSTEM TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED Belt Shows Excessive Wear On One Out-of-Alignment Align rear wheel Side Belt Squeal / Noise Belt too tight Adjust to 32mm Deflection @ 10 lbs. load (All 2008-2010) Out-of-Alignment Align rear wheel Broken Sprocket Teeth...
Page 345 FRONT WHEEL / SUSPENSION CHAPTER 12 FRONT WHEEL / SUSPENSION GENERAL ............12.2 IMPORTANT INFORMATION.
Page 346: Front Wheel / Suspension
Wheel Bearing / Stem Bearing Race PV-43515 load conditions as listed on the tire inflation decal. Installation Set Tubeless tires are used on certain Victory models. Stem Bearing Remover PV-43551 Operating the motorcycle with damaged rims creates a Spanner Socket (Steering Stem)
Page 347: Specifications
FRONT WHEEL / SUSPENSION SPECIFICATIONS FRONT FORK SERVICE SPECIFICATIONS  2008 - 2010 VICTORY VISION Item Standard Service Limit Axle Runout .20 mm (.008") Front Wheel Runout Axial .50 mm (.020") 2.0 mm (.080”) (Billet and Cast Type) Radial .50 mm (.020") 2.0 mm (.080”)
Page 348: Assembly Views & Torque Values
FRONT WHEEL / SUSPENSION ASSEMBLY VIEWS & TORQUE VALUES FRONT FENDER Disassembly Order: Assembly Order: 11 Nm (96 lb-in) 12.4 © 2009 Polaris Sales Inc.
Page 349: Front Fork Type Identification
FRONT FORK TYPE IDENTIFICATION Two types of front forks and triple clamps are used on 2009-2010 Victory Vision models. All 2008 models are TYPE 1. TYPE 1 parts and fork oil are NOT interchangeable with TYPE 2. Identify type before starting service work and before ordering service parts.
Page 350: Assembly View, Triple Clamp & Front Axle
FRONT WHEEL / SUSPENSION ASSEMBLY VIEW, TRIPLE CLAMP & FRONT AXLE ! IMPORTANT! See Fork Type Identification on page 12.5 to identify fork type before you begin service or repair. Detailed fork tube installation procedure is on page 12.30 Detailed front wheel installation is on page 12.17 12.6 ©...
Page 351: Assembly View, Front Fork -Type 1 (Marz / 45Mm Tube Diameter)
FRONT WHEEL / SUSPENSION ASSEMBLY VIEW, FRONT FORK -TYPE 1 (MARZ / 45mm Tube Diameter) ! IMPORTANT! See Fork Type Identification on page 12.5 to identify fork type before you begin service or repair. ALL 2008 Models Some 2009-2010 TYPE 1 Tube Diameter is 45mm.
Page 352: Assembly View, Front Fork -Type 2 (Kyb) (46Mm Tube Diameter)
FRONT WHEEL / SUSPENSION ASSEMBLY VIEW, FRONT FORK -TYPE 2 (KYB) (46mm Tube Diameter) ! IMPORTANT! See Fork Type Identification on page 12.5 to identify fork type before you begin service or repair. Some 2009 -2010 Fork Cap 15 - 30 Nm (11 - 22 lb-ft) O-Ring Washer...
Page 353: Assembly View, Front Wheel
FRONT WHEEL / SUSPENSION ASSEMBLY VIEW, FRONT WHEEL O-Ring 5.0 Nm (45 lb-in) Slot See Chapter 14 for installation 5.0 Nm 1.35 Nm (45 lb-in) (12 lb-in) Chrome - No Slot Chrome - With Slot 12.9 © 2009 Polaris Sales Inc.
Page 354: Assembly View, Front Wheel / Hub Cut-Away
FRONT WHEEL / SUSPENSION ASSEMBLY VIEW, FRONT WHEEL / HUB CUT-AWAY 12.10 © 2009 Polaris Sales Inc.
Page 356: Handlebar Removal
FRONT WHEEL / SUSPENSION SERVICE PROCEDURES 9. Remove cruise control switch from mounting plate. Remove plate from right switch block. HANDLEBAR REMOVAL 10. Loosen throttle cable adjusters to add maximum cable freeplay. CAUTION 11. Remove plate from bottom of right switch cube, then remove switch cube screws and switch cube.
Page 357: Front Wheel Removal
FRONT WHEEL / SUSPENSION 6. Lightly grease throttle cable ends and connect ends FRONT WHEEL REMOVAL to throttle grip. Do not bend or kink cables. 1. Refer to illustration on page 12.6. 7. Install top of right switch cube over the grip and insert (2) screws on the bottom.
Page 358: Front Axle Inspection
FRONT WHEEL / SUSPENSION Front Wheel Removal (Cont.) FRONT AXLE INSPECTION 5. Loosen lower pinch bolts (B) on right-hand fork leg. 1. Place axle in V-blocks and inspect runout. Compare to specifications on page 12.2. 2. Replace axle if it fails inspection. Do not attempt to straighten a bent axle.
Page 359: Brake Disc Removal
FRONT WHEEL / SUSPENSION BRAKE DISC REMOVAL FRONT WHEEL BEARING INSPECTION NOTE: Disc must be inspected before removing NOTE: Inspect bearings installed in wheel. Do not from wheel. Refer to Chapter 15 for disc inspection. remove to inspect. Bearings cannot be repacked. Replace both wheel...
Page 360: Front Wheel Bearing Removal
FRONT WHEEL / SUSPENSION FRONT WHEEL BEARING REMOVAL FRONT WHEEL BEARING INSTALLATION NOTE: Replace both wheel bearings as a set. Do not NOTE: Refer to illustration below for Steps 3-9. replace only one wheel bearing. 1. Clean inside of wheel hub and bearing spacer. 1.
Page 361: Front Wheel Installation
11. Rotate inner races of bearings to check for free, smooth rotation. 12. Install brake discs (see “Brake Disc Installation”). Clean discs with Victory Disc Brake Cleaner. CAUTION Do not allow brake cleaner to contact painted surfaces. 6. Push axle through the wheel and axle spacers and into the left fork tube.
Page 362: Front Fork Removal
FRONT WHEEL / SUSPENSION 11. Apply and hold front brake. Pump forks to move FRONT FORK REMOVAL suspension through full range of travel at least 4 1. Securely support front end of motorcycle so front times. wheel is off the ground. NOTE: Fork action should be smooth without binding.
Page 363: Front Fork Disassembly
FRONT WHEEL / SUSPENSION 7. Loosen upper triple clamp pinch bolt for each fork FRONT FORK DISASSEMBLY tube. NOTE: See Front Fork Type Identification on page 12.5. This procedure covers both TYPE 1 and 8. If disassembling the fork tube(s), loosen the fork TYPE 2 forks.
Page 364 FRONT WHEEL / SUSPENSION 3. Mount special socket PV-49464 spring 6. Rotate tube until cap is unscrewed completely from compressor. Center it in holding fixture with all thumb fork tube. screws (C). • TYPE 1 forks: 17mm side of socket faces down. •...
Page 365 FRONT WHEEL / SUSPENSION 9. Slowly compress spring by turning drive bolt of 12. Remove spring from fork tube. compressor until cartridge rod nut is accessible. DO 13. Pour fork oil out of tube assembly. NOT use air or power tools to rotate drive bolt. 14.
Page 366 FRONT WHEEL / SUSPENSION Cartridge Removal 17. TYPE 2 FORKS ONLY: Hold cartridge through top of fork inner tube with octagonal end (K) of Universal 16. TYPE 1 FORKS ONLY: Remove cartridge screw and Cartridge Shaft Holder PV-49452. Loosen cartridge sealing washer using an extended 8 mm internal hex screw with an extended 8mm internal hex socket as socket.
Page 367 FRONT WHEEL / SUSPENSION Fork Seal Removal 24. Remove the lower bushing from the inner tube. 20. Fully compress the fork tube. Carefully lift dust seal out of outer fork tube with a small flat screwdriver. TYPE TYPE 1 2 forks have access notch to remove dust seal. 25.
Page 368: Front Fork Inspection
FRONT WHEEL / SUSPENSION 27. Remove oil seal and backing washer. FRONT FORK INSPECTION 1. Inspect inner fork tube for scoring, heavy scratches, dents due to rocks or other road debris, or excessive TYPE 1 and TYPE 2 wear. Replace tube if scratched, pitted, or dented. 2.
Page 369: Front Fork Assembly
FRONT WHEEL / SUSPENSION FRONT FORK ASSEMBLY 3. Rotate bushing so gap (D) will be opposite the gap of slider bushing previously installed (arrow). NOTE: Differences in assembly procedure are noted for TYPE 1 and TYPE 2 forks as required. Refer to Front Fork Assembly Views on page 12.7 (for TYPE 1 forks) or page 12.8 (for TYPE 2 forks).
Page 370 FRONT WHEEL / SUSPENSION 5. Lubricate the surface of the inner fork tube and slide 8. Wipe away any excess grease or oil. Install dust seal backing washer and new oil seal down tube and into (use opposite end of fork seal driver PV-49494) until outer fork leg.
Page 371 (G) until they stop (at bottom of travel) and remove 14. Tip fork leg at an angle to reduce air bubbles. Slowly damper rod extension tool. add about 350 cc of Victory fork oil. TYPE 1: P/N 2874828 TYPE 2: P/N 2874568 NOTE: The oil quantity slightly exceeds the capacity of the fork.
Page 372 FRONT WHEEL / SUSPENSION 23. Insert fork oil level tool into fork. Be sure fork leg is standing upright and fork tube is fully compressed. WARNING 24. Draw excess oil out to the specified level. Wear eye / face protection. Be sure spring is engaged properly with pegs of tool as you compress the spring in the following steps.
Page 373: Fork Guard Replacement
FRONT WHEEL / SUSPENSION 34. Hold cap and screw jam nut up damper rod until it thread damage. stops against cap. 35. Hold jam nut and torque fork cap. 27 Nm (20 lb-ft) TYPE 1: 27 Nm (20 lb-ft) TYPE 2: 13.5-16.5 Nm (10-12 lb-ft) 40.
Page 374 FRONT WHEEL / SUSPENSION FRONT FORK TUBE INSTALLATION Also refer to illustration on page 12.6. 1. Clean the fork tubes and the clamping surfaces of the triple clamps to remove any oil or grease. 2. Install one fork tube assembly into lower triple clamp. 3.
Page 375: Assembly View, Steering Stem / Triple Clamps
FRONT WHEEL / SUSPENSION ASSEMBLY VIEW, STEERING STEM / TRIPLE CLAMPS 12.31 © 2009 Polaris Sales Inc.
Page 376: Triple Clamp Removal
NOTE: Support lower triple clamp while removing stem nut. 8. Remove adjustment nut from steering stem with Victory spanner socket (PV-43508). 9. Remove upper bearing from frame (see assembly view page 12.31). 10. Remove lower triple clamp with steering stem and lower bearing.
Page 377: Triple Clamp Installation / Steering Head Bearing Adjustment
2. Replace bearings and races as a set. procedure until no play can be felt. 3. Apply Victory All Purpose grease to lower bearing and 13. Verify fork tube height in upper triple clamp. Fork cap install lower triple clamp into frame.
Page 378: Steering Stem Bearing Removal (Typical Example)
FRONT WHEEL / SUSPENSION STEERING STEM BEARING REMOVAL 4. Install two long bolts into bearing collar. The two long bolts should be threaded into bearing collar (TYPICAL EXAMPLE) approximately 8 turns each or until flush with the bottom of the tapped hole. 1.
Page 379: Steering Stem Bearing Installation (Typical Example)
Victory All Purpose Grease: 2872187 2. Clean the stem thoroughly and inspect bearing support surface for nicks or damage. 3. Install lower bearing over steering stem.
Page 380: Lower Bearing Race Removal
FRONT WHEEL / SUSPENSION LOWER BEARING RACE REMOVAL Center Screw 1. Remove triple clamps (page 12.32). Washer 2. Drive bearing race evenly out of frame using a long Tool Bearing flat punch through access notch. LOWER BEARING RACE INSTALLATION Bearing Plate 1.
Page 381: Troubleshooting
FRONT WHEEL / SUSPENSION TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Heavy Steering Steering Stem Nut Over Tightened Adjust Front Tire Damaged or Worn Replace Low Tire Pressure Inflate to specification Damaged / Worn Steering Stem Replace Bearings or Races Bent Steering Stem Replace Pulls to One Side or Wanders...
Page 382: Troubleshooting (Cont.)
FRONT WHEEL / SUSPENSION TROUBLESHOOTING (cont.) PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Front Suspension Too Soft Weak Fork Springs Replace Low Fork Oil Level Determine Cause/Replace Fork Oil Wrong Weight Fork Oil Replace Contaminated and/or Deteriorated Replace Fork Oil Low Tire Pressure Set Correctly Front Suspension Too Hard Tire Pressure Too High...
Page 383 REAR WHEEL & SUSPENSION CHAPTER 13 REAR WHEEL & SUSPENSION GENERAL INFORMATION ..........13.2 WARNINGS AND PRECAUTIONS.
Page 384: Rear Wheel & Suspension
Do not attempt to repair or straighten damaged rims. Always use genuine Victory parts or equivalent so that quality is not compromised. The use of tire valves and valve cores other than original equipment replacement Victory parts could cause tire deflation which may lead to loss of control, resulting in injury or death.
Page 385: Specifications
Clean hub threads, bolt threads, and mating Victory Billet Wheels: 75.0 Nm (55 lb-ft) surfaces of hub to remove Hub Bolts (Billet Wheels Only) Ness Billet Wheels: 88.0 Nm (65 lb-ft) grease, oil, and old locking agent.
Page 386: Assembly Views & Torque
REAR WHEEL & SUSPENSION ASSEMBLY VIEWS & TORQUE ASSEMBLY VIEW - REAR AXLE & ADJUSTERS Refer to the illustration below for fastener torque Apply Victory All Purpose grease Retainer 10.8 Nm (8 lb-ft) Adjuster 88 Nm (65 lb-ft) Forward 13.4...
Page 387: Assembly View - Swingarm & Suspension
REAR WHEEL & SUSPENSION ASSEMBLY VIEW - SWINGARM & SUSPENSION Apply Victory All Purpose grease 24.5 Nm (18 lb-ft) See page 13.17 Shock Pressure - DO NOT EXCEED  110 PSI when filling  72 PSI (496 kPa) operating pressure...
Page 388: Rear Wheel - Cast
REAR WHEEL & SUSPENSION REAR WHEEL - CAST LH (Disc) FORWARD Apply Victory All Purpose Grease Metal Stem 5.0 Nm (45 lb-in) RH (Sprocket) O-Ring Slot 0 - 1mm (0 - .040) 0 - 1mm (0 - .040) Seal Seal...
Page 389: Rear Wheel - Billet
REAR WHEEL & SUSPENSION REAR WHEEL - BILLET LH (Disc) FORWARD Apply Victory All Purpose Grease Slotted Metal Stem 5.0 Nm (45 lb-in) O-Ring RH (Sprocket) No Slot Metal Stem - No Slot See Chapter 14 for installation 1.35 Nm...
Page 390: Rear Wheel Service
REAR WHEEL & SUSPENSION REAR WHEEL SERVICE REAR WHEEL REMOVAL Fig.1 WARNING Rear wheel removal involves supporting the machine with the rear end elevated. Take precautions so that the motorcycle is securely supported when the rear tire is off the ground. Severe personal injury or death can occur if the motorcycle tips or falls.
Page 391: Rear Axle Inspection
REAR WHEEL & SUSPENSION 7. Elevate the motorcycle until the swingarm shock REAR AXLE INSPECTION mount is raised a minimum of 12 inches (305 mm). 1. Place rear axle in V-blocks and measure runout. Compare to service limit on page 13.3 2.
Page 392: Rear Wheel Inspection
REAR WHEEL & SUSPENSION REAR WHEEL INSPECTION WHEEL BEARING REMOVAL (Typical) NOTE: Wheel bearings must be in good condition. CAUTION 1. Set up a dial indicator to measure axial and radial runout of the wheel. Refer to Chapter 14 for Do not reuse bearings that have been removed.
Page 393 REAR WHEEL & SUSPENSION WHEEL BEARING REMOVAL - TYPICAL (Cont.) 7. Remove spacer. 3. Protect hub. Pry seals out of hub on both sides. 4. Remove snap ring from disc side. 8. Extract or drive bearing from the other side. 5.
Page 394: Wheel Bearing Installation
REAR WHEEL & SUSPENSION WHEEL BEARING INSTALLATION (TYPICAL) 5. Install the other 51mm bearing tool (F) in bearing bore on right side of hub with flat washer and nut. Pull left 1. Clean inside of wheel hub and bearing spacer. bearing into hub by tightening nut on left side of tool Replace spacer if worn beyond the service limit.
Page 395 10. Keep the wheel positioned as shown to keep spacer 16. Install brake disc (page 13.14). Clean discs with centered during installation of right bearing. Victory Disc Brake Cleaner. CAUTION Do not allow brake cleaner to contact painted surfaces. WARNING...
Page 396: Brake Disc Removal
REAR WHEEL & SUSPENSION BRAKE DISC REMOVAL REAR SPROCKET INSTALLATION 1. Remove rear wheel (page 13.8). 1. Clean sprocket stud threads (2008) or bolt threads in hub (2009-2010) to remove all grease or oil residue. 2. Position wheel with brake disc facing up. Support wheel so as not to damage the belt sprocket.
Page 397: Rear Wheel Installation
Verify caliper bracket tab (A) inserts into the slot on the left inside of swingarm once you start to lower it into position. Apply Victory All 6. Apply a thin film of grease to axle surface. Purpose grease 7.
Page 398 REAR WHEEL & SUSPENSION 10. Tighten axle nut until seated and back off one full turn. 15. Adjust belt tension and wheel alignment (Chapter 2). Tap axle forward on each side to be sure adjuster nuts are seated against swingarm. 16.
Page 399: 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 400: Rear Shock Removal
REAR WHEEL & SUSPENSION REAR SHOCK REMOVAL 7. Remove rear wheel (page 13.8). 8. Remove both pivot pin retaining fasteners. WARNING Shock absorber removal involves supporting the machine with the rear end elevated. Take precautions so that the motorcycle is securely supported when the rear tire is off the ground.
Page 401: Rear Shock And Pivot Inspection
REAR WHEEL & SUSPENSION REAR SHOCK AND PIVOT INSPECTION 8. Inspect the pivot mechanism and pivot pin. Bearing needles should turn freely and be free of corrosion or WARNING contamination. Thrust bearings should be free of cracks or wear. Inspect surface of pivot pin for roughness, galling or uneven surface.
Page 402: Shock Absorber Installation
7. Install lower shock bolt from left to right. Install nut. frame. 8. Install lower pushrod bolt from right to left. Install nut. 9. Torque (A) (nut side) to specification. Apply Victory All Purpose grease 3. Drop the shock assembly down through opening in Apply Victory All...
Page 403: Swingarm Service
REAR WHEEL & SUSPENSION SWINGARM SERVICE 3. Remove brake line guide from left-hand side of swingarm (A). SWING ARM REMOVAL 4. Remove swingarm pivot nut (C) and shaft (D). Collect the washer (E). 1. Remove rear wheel assembly (page 13.8). 5.
Page 404: Swing Arm Bushings / Bearing Replacement
5. Support the inside left edge of the swingarm pivot on a pressing surface. REPLACEMENT 1. Remove sleeve (A) from right side of swingarm. Apply Victory All Purpose grease 2. Remove seals (B) and bearing (C) from right side of swingarm.
Page 405: Swing Arm Installation
9. Tighten RIGHT side nut to 88 Nm (65 lb-ft). 15. Test ride motorcycle to be sure rear suspension operates smoothly without binding or abnormal noises. Apply Victory All Purpose grease 16. Adjust air pressure for rider weight and load (see Chapter 2).
Page 406: Troubleshooting
REAR WHEEL & SUSPENSION TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Rear Wheel Feels “Loose” or Wobbles Low tire pressure Inflate to specification Worn or damaged wheel bearings Replace wheel bearings Worn or damaged swing arm, rocker, Replace bushings or bearings pushrod, or shock bushings/bearings.
Page 407 TIRES / WHEELS CHAPTER 14 TIRES / WHEELS GENERAL / SAFETY........... . 14.2 WARNINGS / PRECAUTIONS .
Page 408: Tires / Wheels
- 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 409: Tire Data
TIRES / WHEELS WARNING It is dangerous to ride with a worn tire. When a tire reaches the minimum tread depth listed below, replace the tire immediately. FRONT TIRE MINIMUM TREAD DEPTH REAR TIRE MINIMUM TREAD DEPTH 1.6 mm (.063") (1/16 inch) 1.6 mm (.063") (1/16 inch) CAUTION Two of the biggest factors contributing to premature tire wear are overloading and under-inflation.
Page 410: Tire Inspection
TIRES / WHEELS TIRE INSPECTION TIRE WEAR PATTERNS & GENERAL CAUSES WEAR PATTERNS AND GENERAL CAUSES SYMPTOM CAUSE Wear on Left Side Riding on Crowned Roads Edges Worn Underinflation or Excessive Loads Excess Wear in the Middle of Tire Over-inflation or Tire Abuse Cracks in Tread Grooves Underinflation, Excessive Loads, Suspension Bottoming Tread Block Cupping (Usually Front Tire -See Below)
Page 411: Tire Changing
Each of the three generally acceptable methods to dismount and mount tires is permissible and recom- mended by Victory. However, careless or improper work habits can damage both the tire and rim regardless of which method is used.
Page 412: Tire Removal
TIRES / WHEELS TIRE REMOVAL NOTE: This procedure can be performed on an empty drum or similar fixture. The top lip of the drum should be covered with protective material or split hose to protect TIRE REMOVAL (TYPICAL) the rim. (Fig. 3) Remove wheel / tire assembly from motorcycle (front refer to Chapter 12, rear refer to Chapter 13).
Page 413: Wheel Inspection
TIRES / WHEELS 8. Stand opposite of rim protectors. Use your knee to WHEEL INSPECTION push tire bead down into the rim’s drop center at location (Fig. 6, A) while pulling bottom bead up into VISUAL INSPECTION & RUNOUT drop center. Beads must be kept in drop center during Refer to chapter 12 for complete front wheel following steps.
Page 414: Tire Repair Precautions
TIRES / WHEELS VALVE STEM INSTALLATION - METAL TIRE REPAIR PRECAUTIONS Remove tire from wheel and remove old stem. WARNING 2. Clean gasket or O-ring seal surface of wheel. 3. Place tire valve (with seal washer or O-ring installed) Only permanent plug-patch repairs of small tread area through hole in rim and secure it hand tight with nut.
Page 415: Tire Installation
(Fig. 12) of the rim (although this is not always the case). WARNING Victory does not recommend the use of liquid balancer/ sealers. These are a form of temporary repair which may adversely affect ply material and mask secondary Valve Stem damage caused by the penetrating object.
Page 416 TIRES / WHEELS 6. For tube type tires, also observe the following: will make tire inflation easier. (Fig. 13) TUBE TYPE TIRES: Apply baby powder to new tube and install by inserting valve stem through rim band and rim. Tube must be completely deflated at this time. Install the valve stem lock nut a few threads.
Page 417: Tire Balancing
TIRES / WHEELS Inspect the line molded onto the tire side walls. It must TIRE BALANCING be the same distance from the rim all the way around the tire. If the distance varies it indicates that tire is not TIRE BALANCING seated properly.
Page 418 TIRES / WHEELS 4. Repeat the spinning process to verify the heaviest part If more than the recommended weight is necessary to balance the wheel, dismount the tire and rotate it 90 of the wheel. (Fig. 17) without regard to the yellow balance dot, and re-balance the wheel / tire.
Page 419: Troubleshooting
TIRES / WHEELS TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED Rear Wheel (Wobbles) Bent rim Replace Worn or damaged wheel bearings Replace as a set Worn or damaged swing arm Replace as a set bushings. Damaged or incorrect tire Replace rear tire Wheel assembly out-of-balance Balance wheel Low tire pressure...
Page 421: Chapter 15 Brakes
BRAKES CHAPTER 15 BRAKES BRAKE SYSTEM SAFETY ..........15.2 SPECIAL TOOLS .
Page 422: 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 423: Special Tools
BRAKES SPECIAL TOOLS BRAKE SERVICE SPECIAL TOOLS Caliper Piston Pliers ..........Commercially Available Front Brake Lever Reserve Inspection Adapter, .
Page 424: Assembly Views & Routing
BRAKES ASSEMBLY VIEWS & ROUTING FRONT BRAKE SYSTEM ASSEMBLY VIEW ABS INFORMATION BEGINS ON PAGE 15.32 Disconnect negative (-) battery cable from battery before servicing ABS brake lines. 15.4 © 2009 Polaris Sales Inc.
Page 425 BRAKES FRONT BRAKE SYSTEM DETAIL VIEWS ABS INFORMATION BEGINS ON PAGE 15.32 Disconnect negative (-) battery cable from battery before servicing ABS brake lines. 15.5 © 2009 Polaris Sales Inc.
Page 427 BRAKES REAR BRAKE SYSTEM DETAIL VIEW ABS INFORMATION BEGINS ON PAGE 15.32 Disconnect negative (-) battery cable from battery before servicing ABS brake parts. 15.7 © 2009 Polaris Sales Inc.
Page 428: Master Cylinders
BRAKES MASTER CYLINDERS FRONT BRAKE / CLUTCH MASTER CYLINDER This symbol indicates special lubricant from Brake service kit must be applied to this part. Brake SPECIAL GREASE (009-Z00-115) CCI OIL (009-Z00-313) Brake Application: External: Lever pivot screw Application: Internal: Master cylinder bore, and contact surface of lever to master piston, and piston seal cups.
Page 429: Rear Brake Master Cylinder
BRAKES REAR BRAKE MASTER CYLINDER Supply Hose Reservoir Supply Fitting 2008-2009 Diameter: 5/8 in. (15.875 mm) 2010 Diameter: 11/16 in. (17.460 mm) Supply Fitting Stop Washer Lock Nut 17.2 Nm (12.5 lb-ft) Snap Ring Pushrod Clevis Snap Ring Boot 15.9 ©...
Page 430: Calipers
BRAKES CALIPERS FRONT BRAKE CALIPER This symbol indicates special lubricant from Brake service kit must be applied to this part. KS62F Brake SILICONE GREASE (009-Z00-111) KS62F Application: Internal: Caliper piston seals, piston dust seals. External: O-ring at the tip of the CCI OIL (009-Z00-313) Brake brake pad retaining pin.
Page 431: Rear Brake Caliper
BRAKES REAR BRAKE CALIPER This symbol indicates special lubricant from Brake service kit must be applied to this part. KS62F Brake SILICONE GREASE (009-Z00-111) KS62F Application: Internal: Caliper piston seals, piston dust seals. External: O-ring at the tip of the brake pad retaining pin.
Page 432: Brake System Operation
BRAKES BRAKE SYSTEM OPERATION MASTER CYLINDERS / BRAKE CALIPERS / DELAY VALVE / PROPORTION VALVE ABS INFORMATION BEGINS ON PAGE 15.32 Disconnect negative (-) battery cable from battery before servicing ABS brake parts. Conventional (Non-ABS) Linked Brake Configuration Shown Front Master Cylinder Rear Master Cylinder Under moderate to heavy braking, pressure will build and then be diverted to the front...
Page 433: Brake System Service
• Always torque banjo bolts and other brake system fasteners and components to specified torque. • Always install NEW genuine Victory parts. Apply special lubricant included in service kits where specified. • .Always perform a Brake Lever Reserve inspection after brake system bleeding or service.
Page 434: Brake Bleeding / Fluid Change
(B). 3. Place the other end of bleeder hose into container (B). Fig. 1 Use Only Victory DOT 4 Brake Fluid 2872189. Between fills, set reservoir cover on reservoir to prevent entry of contaminants. 4. Slowly pump the brake lever until pressure builds and then hold light pressure on the lever.
Page 435 BRAKES 10. Repeat this process for the front right caliper. REAR (LINKED) BRAKE SYSTEM BLEEDING NOTE: Bleed the right front lines and caliper first (closest to master cylinder), then bleed the left front lines and caliper (farthest from master cylinder), and bleed the rear lines and caliper last.
Page 436 BRAKES 10. Torque bleed screw to 5.4 Nm (48 lb-in). 20. After completing the bleeding procedure, inspect brake fluid level. Clean the reservoir cover, diaphragm, and 11. Repeat this process for the front left caliper. reservoir sealing surface. If diaphragm is extended, return it to normal (flat) position.
Page 437: Front Brake Pad Replacement
1. Loosen the brake pad retaining pin (A) and remove the brake caliper mounting bolts (B) and caliper. 7. Clean caliper body with Victory Brake Cleaner. 8. Install isolator on new inner brake pad. Be sure isolator 2. Using the existing brake pads, apply inward pressure plate does not protrude from the pad backing plate.
Page 438: Rear Brake Pad Replacement
BRAKES REAR BRAKE PAD REPLACEMENT 11. Install new brake pads with friction material toward disc. Be sure pads are fully seated in pad retainer. NOTE: Always replace brake pads as a set. The rear 12. Apply Silicone Grease (009-Z00-111) to O-ring on brake pads can be changed with the caliper installed brake pad retaining pin.
Page 439 5. Wipe brake disc clean with a shop towel sprayed with Victory Brake Cleaner. 13.5 Nm (120 lb-in) 6. Thoroughly clean the brake caliper body with Victory Brake Cleaner. 7. Install new inner brake pad. Be sure backing plate (C) (with insulation pad) is properly installed on new pad.
Page 440: Brake Disc Inspection
BRAKES BRAKE DISC INSPECTION FRONT BRAKE MASTER CYLINDER / CLUTCH MASTER CYLINDER SERVICE 1. Visually inspect disc for cracks or damage. 2. Measure brake disc thickness in several locations NOTICE: Brake fluid and brake cleaners could around disc with a micrometer, and along wear surface damage paint, plastics and some rubber compounds.
Page 441 BRAKES 7. Pull dust boot off piston and out of cylinder bore. 12. Measure the diameter of the bore. Replace master cylinder if worn beyond the service limit. 8. Remove snap ring. Brake Master Cylinder - Bore Diameter 9. Slide piston out with spring. Note spring orientation for Service Limit: 14.043 mm (.553”) assembly of new spring (new parts).
Page 442 BRAKES 14. Remove deflector (A) from reservoir. 18. Carefully install spring / piston assembly into master cylinder bore. Work the front piston seal carefully past the chamfer and into bore. Use care not to damage or fold the seal when working it past the chamfer. 19.
Page 443: Front Master Cylinder Installation
5. Cover brake line ends to prevent debris from entering. 7. Turn handlebars until top of reservoir is level. Fill reservoir with Victory DOT 4 Brake Fluid and bleed the 6. If servicing both front calipers, repeat this procedure to front hydraulic brake system (see page 15.14).
Page 444: Front Caliper Service
Victory brake cleaner or isopropyl alcohol. Dry with passage to force the pistons out of the bore. compressed air.
Page 445 BRAKES 8. Clean piston seal and dust seal bores (C) to remove 11. Measure the outside diameter of each caliper piston in residue that could cause the pistons to stick, resulting two spots 90 degrees apart, 5mm from outer edge. in brake drag.
Page 446 BRAKES 15. Install pistons in their respective bores. 18. Evenly tighten the bolts by hand until halves are secured together. 19. Torque bolts to 27 Nm (20 lb-ft). 20. Install the brake pad retainer onto the caliper guide pin bracket as shown. 16.
Page 447: Front Caliper Installation
8. Fill and bleed the front brake hydraulic system 2. Clean mounting surfaces of caliper and fork leg. (page 15.14). 3. Apply Victory brake cleaner or isopropyl alcohol to a clean shop towel and wipe brake disc(s) clean. WARNING 4. Separate brake pads and install caliper assembly over brake disc.
Page 448: Rear Master Cylinder Removal
BRAKES REAR MASTER CYLINDER REMOVAL 5. Install the brake line with new sealing washers and torque banjo bolt to 24.4 Nm (18 lb-ft). NOTICE: Brake fluid and brake cleaners will damage paint, plastics and some rubber compounds. Cover or remove plastic and painted parts before working on the brake system.
Page 449: Rear Caliper Service
(B) for assembly. Adjustment Nuts 8. Fill the reservoir with Victory DOT 4 brake fluid and 6. Slide caliper bracket off pins and remove spring plate. bleed the system as outlined on page 15.13. WARNING...
Page 450 BRAKES 9. Clean caliper thoroughly with isopropyl alcohol. Dry 13. Apply special assembly oil to outer surface of all with compressed air. Clean seal grooves thoroughly. pistons. Any residue left behind in the grooves could cause Pistons: caliper pistons to stick and result in brake drag. Apply special OIL included 10.
Page 451: Rear Caliper Installation
BRAKES 20. Install inner pad with backing plate. REAR CALIPER INSTALLATION 1. Install caliper and bracket (see “REAR WHEEL INSTALLATION” on page 13.15). 2. Install brake hose, and banjo bolt with new sealing washers. 3. Torque banjo bolt to 24.4 Nm (18 lb-ft.) 21.
Page 452: Anti-Lock Brake System (Abs)
ABS SYSTEM SAFETY PRECAUTIONS • Panic braking Before working on a Victory motorcycle equipped with anti- • Slick surface braking (such as wet road surfaces) lock brakes, review and understand all general brake • Surface transitions (from asphalt to oily asphalt or system and brake fluid precautions on page 15.2, and the...
Page 453: Abs System Components
BRAKES ABS SYSTEM COMPONENTS ABS OVERVIEW OF OPERATION The following parts function in the same manner as the The ABS system is active and available when vehicle same component in a non-ABS system, although parts are speed exceeds 6 mph (10 kph). not necessarily interchangeable.
Page 454: Abs System Components
BRAKES ABS SYSTEM COMPONENTS Master Cylinder (Front) Master Cylinder (Rear / Linked) Calipers Wheel Speed Sensor (Rear) Pulse Ring (Front) Pulse Ring (Rear) Wheel Speed Sensor (Front) Proportion Valve ABS Module (Rear) Delay Valve 15.34 © 2009 Polaris Sales Inc.
Page 455: Abs System Circuit Diagrams
BRAKES ABS SYSTEM CIRCUIT DIAGRAMS FRONT REAR / LINKED ABS WIRE HARNESS 15.35 © 2009 Polaris Sales Inc.
Page 458: Abs System - Wiring Harness / Tie Strap Location
BRAKES ABS SYSTEM - WIRING HARNESS / TIE STRAP LOCATION 15.38 © 2009 Polaris Sales Inc.
Page 460: Abs Brake Vacuum Bleeder
BRAKES ABS BRAKE VACUUM BLEEDER ABS REAR (LINKED) BRAKE BLEEDING NOTE: Bleed calipers of the linked brake in this A vacuum bleeder is recommended for ABS system order: Rear, Front Left, Front Right. The use of a bleeding and can also be used to bleed conventional (non- vacuum bleeder is recommended.
Page 461 BRAKES 8. Remove rubber cap from the lower bleed screw (D) of 15. Pump brake pedal repeatedly with smooth full strokes front left caliper and install an 8mm box end wrench. while adding brake fluid to the reservoir as required. For best results pump the pedal at a fairly rapid rate 9.
Page 462: Abs Front Brake System Bleeding
BRAKES ABS FRONT BRAKE SYSTEM BLEEDING 6. Pump brake lever repeatedly with smooth full strokes while adding brake fluid to the reservoir as required. NOTE: Bleed left front caliper first (upper bleed For best results pump the lever at a fairly rapid rate but screw) then right caliper (upper bleed screw).
Page 463: Abs Front Brake Supplementary Bleeding Procedure
BRAKES ABS FRONT BRAKE SUPPLEMENTARY BLEEDING PROCEDURE If air is still trapped after performing the bleeding procedure on ABS Front Brakes: This additional bleeding procedure will help purge trapped air from the front ABS brake system lines and must be performed if the front brake lever does not pass the Lever Reserve Inspection.
Page 464 BRAKES BRAKE LEVER RESERVE INSPECTION 5. Keep tool centered so it does not touch hand grip. Pull on scale to specified force. 1. Turn handlebars fully LEFT. 2. On levers with adjustable reach, set lever reach to position 5 (closest to handlebar). Hold handlebar forward Tool not touching grip Front Brake Lever Reserve Pull Force...
Page 465: Abs Trouble Codes
BRAKES ABS TROUBLE CODES Connect Digital Wrench to view codes. ABS CODE DESCRIPTION NUMBER C0020 ABS Motor Lock C1020 ABS Motor Stuck OFF C1021 ABS Motor Stuck ON C1022 ABS Pulsar Front C1023 ABS Pulsar Rear C1024 ABS Solenoid (RRI) Open or Shorted C1025 ABS Solenoid (RRO) Open or Shorted C1026...
Page 466: Troubleshooting
BRAKES TROUBLESHOOTING TROUBLESHOOTING - BRAKE SYSTEM ABS system troubleshooting chart is on page 15.48 Problem Symptom and/or Possible Cause Possible Repair Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component Erratic Braking Fluid Leakage (Internal of Master Cylinder) Replace Master Cylinder Replace Brake Pads Action...
Page 467 Rider Error (Operator Riding Brakes) Brake Squeal/Squeak If noise is minor and inconsistent, some brake Apply non oil-based solvent (such as Victory squeak / squeal is characteristic of disc brakes Brake Cleaner or isopropyl alcohol) to a clean and usually caused by dust / dirt on pads and / or shop towel and wipe dust / dirt from brake disc.
Page 468 BRAKES ABS SYSTEM TROUBLESHOOTING ABS SYSTEM TROUBLESHOOTING Problem Symptom and/or Possible Cause Possible Repair ABS light on at all Blown Fuse (ABS Fuse Open) Replace Fuse; Inspect wiring for cause times System Fault (Fault Code Active) Connect Digital Wrench - View Code(s) Sensor Fault;...
Page 469 BATTERY CHARGING SYSTEM CHAPTER 16 BATTERY CHARGING SYSTEM IMPORTANT INFORMATION ..........16.2 GENERAL.
Page 470: Battery Charging System
BATTERY CHARGING SYSTEM IMPORTANT INFORMATION GENERAL WARNING All electrical system and component service can be Battery electrolyte is poisonous. It contains sulfuric performed with the engine in the frame. acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: CAUTIONS TO OBSERVE DURING ELECTRICAL SYSTEM SERVICE: External: Flush with water.
Page 471: Special Tools
BATTERY CHARGING SYSTEM A battery will self-discharge when the motorcycle is not in CAUTION use. Make sure to properly store the battery as outlined later in this section. ELECTRONIC COMPONENTS Maximum voltage and service life is only achieved when Semiconductor parts used in electronic components the battery is properly serviced initially.
Page 472: Specifications
BATTERY CHARGING SYSTEM SPECIFICATIONS GENERAL Item Specifications Starting System Electric Charging System Permanent Magnet / 3 Phase / Full Wave Rectification Electrical (General) Regulator/Rectifier Solid State Three Phase Voltage Regulator/Rectifier Lighting System 12 V DC CHARGING SYSTEM & ALTERNATOR Item Specifications Alternator No Load AC Output (Minimum) 17.5 V AC @ Idle...
Page 473: Battery
BATTERY CHARGING SYSTEM BATTERY BATTERY CHARGING - GENERAL BATTERY REMOVAL 1. See page 2.20. BATTERY CHARGING - NEW BATTERY 1. Charge the battery at 1.8 amps for 5 to 10 hours. use a straight rate charger (not load sensing or battery tender type) for the initial charge of a new battery.
Page 474: Diagnostics
BATTERY CHARGING SYSTEM DIAGNOSTICS TROUBLESHOOTING NOTICE: The battery must be fully charged and in good condition to obtain accurate readings. Battery charging current is automatically reduced by the regulator / rectifier if the regulator / rectifier unit reaches a critical temperature (overheated).
Page 475: Battery Load Test
BATTERY CHARGING SYSTEM BATTERY LOAD TEST CURRENT DRAW INSPECTION (KEY OFF) 1. Perform a battery load test using a battery load tester. Current draw is suspect if battery discharges when Follow the load tester manufacturer’s instructions motorcycle is not in operation (short periods of storage). carefully.
Page 476: Regulated Voltage / Amperage Output Inspection
BATTERY CHARGING SYSTEM REGULATED VOLTAGE / AMPERAGE 6. Increase engine RPM to 2500. The ammeter should rise a slight amount, then stabilize. Volt meter should OUTPUT INSPECTION read above 14 V DC. 1. Remove negative battery leads and connect a 12V shunt as outlined in the instructions provided with 7.
Page 477: Stator No-Load Ac Voltage Output Inspection
BATTERY CHARGING SYSTEM STATOR NO-LOAD AC VOLTAGE OUTPUT 3. Set Digital Multimeter (DMM) to AC Volts scale. INSPECTION 4. Connect one lead of DMM to Pin A on wire connector that comes from stator. NOTE: DMM set to VAC (if meter has Vrms selection Vrms).
Page 478: Stator Resistance Inspection
BATTERY CHARGING SYSTEM STATOR RESISTANCE INSPECTION EXAMPLE: Connect meter leads together, meter reads 0.3 ohms. Measure stator resistance, meter reads .7 ohms. Subtract 0.3 ohms (meter/lead resistance) from .7 NOTICE ohms. True reading is: .7 ohms (observed reading when checking stator) Do not run the engine during this test.
Page 479: Voltage Drop: Rectifier / Regulator To Battery(+)
BATTERY CHARGING SYSTEM VOLTAGE DROP: RECTIFIER / REGULATOR RECTIFIER / REGULATOR CONNECTOR TO BATTERY(+) INSPECTION NOTE: Leave regulator / rectifier connected for this test. 1. Disconnect 3 pin connector. From stator (connected) RED (to circuit breaker) Red lead to ring Black (BK) terminal at circuit breaker...
Page 480: Diode Leakage Test
BATTERY CHARGING SYSTEM DIODE LEAKAGE TEST NOTE: Engine must be OFF. Perform this test at the 40A circuit breaker (under the electrical cover below the oil cooler). NOTE: Do not touch the meter leads when testing the regulator rectifier. Readings in the following chart are correct for a Fluke™...
Page 481: Regulator / Rectifier Test
BATTERY CHARGING SYSTEM REGULATOR / RECTIFIER TEST • Use DIODE CHECK function on the Fluke 73 DMM • Remove regulator / rectifier or completely • Perform all tests described in test table below. Test disconnect all wires (3-Pin stator connector, ground results describe a properly functioning part.
Page 482: Rectifier / Regulator Replacement
BATTERY CHARGING SYSTEM RECTIFIER / REGULATOR REPLACEMENT 1. Remove electrical cover (page 16.5). 2. Lift cover off circuit breaker (A) and remove engine ground screw. 7 Nm (60 lb-in.) 3. Remove regulator / rectifier ground wire (black) (B). 4. Remove nut securing regulator rectifier black/red (+) wire inner circuit...
Page 483: Stator Removal
BATTERY CHARGING SYSTEM STATOR REMOVAL STATOR INSTALLATION 1. Remove primary cover (page 9.11). 1. Clean stator mounting surface and screw holes in primary cover. 2. Place primary cover on bench with padded material between primary cover and bench top. 2. Place stator in primary cover taking care to route wires correctly in the channel.
Page 485: Chapter 17 Ignition
IGNITION CHAPTER 17 IGNITION GENERAL INFORMATION ..........17.2 SAFETY INFORMATION .
Page 486: General Information
IGNITION GENERAL INFORMATION SAFETY INFORMATION There are many hazards present when working on or around the ignition system. Read and pay close attention to the following warnings and cautions when working on any component in this section. The engine and exhaust system become very hot Never run an engine in an enclosed area.
Page 487: Torque Specifications
IGNITION TORQUE SPECIFICATIONS Fastener Torque Specifications - Ignition System Description Torque Nm Torque lb-ft (in-lb) Notes CPS Screws (to cover) 6.8 Nm (60 lb-in) Ignition Coil to Frame 11 Nm (100 lb-in) Spark Plug 11 Nm (100 lb-in) Apply Anti-Seize Timing Wheel Bolt (on RH 28 Nm 17 lb-ft...
Page 488: Ignition Circuit Diagram
IGNITION IGNITION CIRCUIT DIAGRAM W / BK W / GN VIO / Y R / BK VIO / BK 17.4 © 2009 Polaris Sales Inc.
Page 489: Test Lead Adapter Kit
IGNITION TEST LEAD ADAPTER KIT 1. Tests in this section may include the testing of voltage and / or resistance at the connectors for various sensor and system components. Use the appropriate test adapter lead when performing these tests at connector pin(s). 2.
Page 490: Ignition System Test Flowchart
IGNITION IGNITION SYSTEM TEST FLOWCHART Before proceeding: 1) Verify battery voltage is at least 12.5 Vdc (Test 1). 2) Check fuel pump fuse (10A) and engine fuse (15A) 3) Turn ignition key and Engine Stop Switch ON and listen for fuel pump. Pump should run for 2-3 seconds at initial power up.
Page 491: Battery Voltage Inspection - Test 1
IGNITION BATTERY VOLTAGE INSPECTION - Test 1 SPARK INSPECTION - TEST 2 1. Connect an inductive timing light to one spark plug 1. Access battery area at front of motorcycle. wire. 2. Set Digital Multimeter (DMM) to DC Volts. Inductive timing light PV-33277-A >...
Page 492: Coil High Tension Leads - Test 3
IGNITION COIL HIGH TENSION LEADS - Test 3 IGNITION COIL SIGNAL - Test 4 Power To Ignition Coil CAUTION Battery voltage must be present at the ignition coil during fuel pump initial cycle, during cranking, and with the engine running. Do not attempt to remove the spark plug caps from the spark plug high tension leads.
Page 493: Ignition Coil Resistance - Test 5
IGNITION Test 4 (Cont.) IGNITION COIL RESISTANCE - Test 5 ECM (Ground) Signal To Ignition Coil Ignition Coil Primary Winding ECM ground signal must be present at each of the outer terminals of the ignition coil primary harness connector. 1. Remove ignition coil (page 17.12). The signal will appear as a pulse on the meter bar graph with DMM selector in the OHMs position.
Page 494: Crankshaft Position Sensor (Cps) Resistance Inspection - Test
IGNITION Ignition Coil Secondary Windings (Cont.) CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION - Test 6 5. Repeat measurements on each secondary coil with meter leads reversed. NOTE: This test can also be performed at the ECM connector, to test the entire circuit with the sensor. 6.
Page 495: Crank Position Sensor Circuit And Signal Test 6A
IGNITION CRANK POSITION SENSOR CIRCUIT and 10. Remove spark plugs from engine. Install spark plugs into spark plug caps and ground the spark plug SIGNAL Test 6A electrodes securely to the engine. NOTE: A test lead adapter kit is required to prevent 11.
Page 496: Ignition Coil
IGNITION IGNITION COIL IGNITION COIL INSTALLATION 1. Installation procedure is the reverse of removal IGNITION COIL REMOVAL procedures. 1. Turn ignition switch OFF and remove key. 2. Apply light film of dielectric grease inside the spark plug boot of high tension leads. 2.
Page 497: Ignition Switch Removal / Clearance Adjustment
IGNITION IGNITION SWITCH REMOVAL / CLEARANCE ADJUSTMENT 1. Turn ignition switch OFF and remove key. 2. Remove bridge console (Chapter 3). 3. Lift glove compartment lock cable out of ignition switch bracket. Disconnect inner cable from release arm by carefully rotating cable to align inner cable wire with slot in the release arm and remove.
Page 499 ELECTRIC STARTER CHAPTER 18 ELECTRIC STARTER GENERAL ............18.2 SAFETY INFORMATION .
Page 500: Electric Starter
ELECTRIC STARTER GENERAL SAFETY INFORMATION WARNING Always disconnect the battery (negative terminal first) before servicing the starter motor. • Inspect the condition of the battery before troubleshooting the starter system. Also inspect main engine ground (on crankcase - upper left rear corner) and battery cable connections. SPECIFICATIONS STARTER SPECIFICATIONS ELECTRIC STARTER &...
Page 501: Special Tools
ELECTRIC STARTER SPECIAL TOOLS STARTER SYSTEM SPECIAL TOOLS SPECIAL TOOL PART NUMBER Digital Multi-Meter PV-43546 Optional Amp Meter Inductive Clamp PV-39617 Rotor Puller (Flywheel) PV-43533 Engine Stop Tool PV-43502 Connector Test Adapter Kit PV-43526 DIAGNOSTICS TROUBLESHOOTING FLOW CHART MENU Symptom Possible Cause Refer To: Starter motor does not turn with...
Page 502: Starter Circuit Diagram
ELECTRIC STARTER STARTER CIRCUIT DIAGRAM Reverse equipped see Chapter 19 Connector located behind rear cylinder near speed sensor harness Not used on 2010 models 18.4 © 2009 Polaris Sales Inc.
Page 503: Troubleshooting Flowchart
ELECTRIC STARTER TROUBLESHOOTING FLOW CHART 1 Starter Motor Does Not Turn Service battery or replace with known Inspect Battery Battery Condition Poor good battery. Inspect Charging (page 18.7) System (Chapter 16) Battery Condition Good Does Starter Relay Click When Button Is Pushed? Perform Neutral Switch Test (page 18.8) Repair or Replace Switch Starter turns...
Page 504: Troubleshooting Chart 3
ELECTRIC STARTER TROUBLESHOOTING FLOW CHART 2 Starter Motor Turns Slowly, Engine May or May Not Start Service battery or replace with Inspect battery: Battery condition poor known good battery. Inspect (page 18.7) Charging System (Chapter 16.) Battery condition good Lower than normal cranking speed Perform starter current draw and lower than normal amp draw (page 18.18)
Page 505: Battery Inspection & Charging Procedures
ELECTRIC STARTER BATTERY INSPECTION & CHARGING CIRCUIT & SWITCH TESTING PROCEDURES STARTER RELAY GROUND BYPASS CIRCUIT 1. Refer to Chapter 16. TEST BATTERY LOAD TEST WARNING 1. Load test battery using a commercially available battery load tester. Follow the battery load tester Verify that motorcycle...
Page 506: Neutral Switch Bypass Test
ELECTRIC STARTER NEUTRAL SWITCH BYPASS TEST 5. If the neutral lamp comes on, the gear position switch or wiring between connector and switch is at fault. The symptom of a faulty neutral switch circuit is: Continue to Step 6 to test the gear position switch. 6.
Page 507: Clutch Switch / Circuit Test
4. Connect red (+) lead of DMM to Blue/Yellow wire in connector on harness side using a test probe (A) from 9. Connect ohmmeter across the outer 2 terminals of Victory Connector Test Kit PV-43526. clutch switch: 5. Connect black meter lead to battery negative post or ground.
Page 508: Clutch Switch Removal
ELECTRIC STARTER CLUTCH SWITCH REMOVAL 2. Connect one clamp of a heavy-duty, automotive remote starter switch to positive terminal lug at starter 1. Disconnect wire harness at the switch (B). motor. 2. Remove retaining screw (C). Pull clutch lever and secure it to the handlebar.
Page 509: Starter Relay Positive Circuit Test
6. Connect red (+) lead of DMM to the Yellow / White wire of the starter relay wiring harness connector (A) using a test probe from Victory Connector Test Kit PV 43526. Remote Starter Switch 2. Remove the electrical cover to access the solenoid on the back of the battery box.
Page 510: Starter Relay To Starter Motor Positive Cable Bypass Test
ELECTRIC STARTER STARTER RELAY TO STARTER MOTOR 3. Connect other clamp of remote starter switch to positive terminal of battery. POSITIVE CABLE BYPASS TEST WARNING WARNING Do not allow any part of the jumper cable clamp to Secure motorcycle and place transmission in touch the chassis or any other ground.
Page 511: Positive Side Voltage Drop Test
ELECTRIC STARTER POSITIVE SIDE VOLTAGE DROP TEST 1. Remove spark plug caps. 2. Install test spark plugs or plugs with the gap CLOSED Symptoms: Starter motor does not turn or turns slowly into plug caps. when starter relay is bypassed. Starter motor works correctly when performing Starter Relay Positive Cable 3.
Page 512 ELECTRIC STARTER 11. Place one lead of DMM to positive battery post. Ensure 19. If corrosion is found, wash all connections with a DMM is set to read DC Volts. solution of baking soda and water, wire brush all contact areas, apply a light film of dielectric grease to the hardware and tighten connections.
Page 513: Negative Cable Bypass Test
ELECTRIC STARTER 25. Place one lead of DMM to starter motor side of relay. NEGATIVE CABLE BYPASS TEST Ensure DMM is set to read Volts DC. 1. Place transmission in neutral. Starter 2 pin connector 2 pin connector Starter Relay Relay Jumper Cable Starter Motor Case...
Page 514: Negative Side Voltage Drop Test
ELECTRIC STARTER NEGATIVE SIDE VOLTAGE DROP TEST NEGATIVE SIDE VOLTAGE DROP TESTS Location Allowable Voltage Drop Battery (-) To Starter Body (-) 0.3 Volts DC (300 mV) Battery (-) to Battery Cable Ground Connection At Engine 0.2 Volts DC (200 mV)* Battery Cable Ground Connection To Starter Body (-) 0.2 Volts DC (200 mV)* NOTE: *The total voltage drop of these two items must...
Page 515 ELECTRIC STARTER 10. Engage the starter and observe the meter display, it 18. Place the other lead on starter motor body. should read less than 0.2 Volts DC (200 mV DC). 19. Engage the starter and observe the meter display, it should read less than 0.2 Volts DC (200 mV DC).
Page 516: Starter Current Draw Test
ELECTRIC STARTER STARTER CURRENT DRAW TEST 4. Set DMM to Volts DC scale and connect red lead of meter to positive post of battery. WARNING 5. Connect black lead of meter to negative post of battery. 6. Turn ignition switch on and observe ammeter. It should Do not allow any part of the jumper cable clamp to register negative amps.
Page 517: Starter Motor Removal
ELECTRIC STARTER STARTER CURRENT DRAW RESULTS (Good Battery Condition Verified) Amperage Draw Battery Voltage Engine RPM Possible Problem 90 to 120 amps 9.6 Volts DC or Greater Greater Than 400 rpm Normal Less Than 90 amps 9.6 Volts DC or Greater Less Than 400 rpm Internal starter problems Greater Than 130 amps...
Page 519 WIRING / LIGHTING SYSTEMS CHAPTER 19 WIRING / LIGHTING SYSTEMS FUSES ............. . . 19.2 FUSE BOX LOCATION / FUSE REPLACEMENT .
Page 520: Wiring / Lighting Systems
WIRING / LIGHTING SYSTEMS FUSES FUSE REPLACEMENT FUSE BOX LOCATION To access relays and fuses: There are two fuse boxes under the windshield access 1. Remove windshield access panel (page 3.6). panel. Remove the panel to access fuses, auto-reset circuit breakers, and relays.
Page 521: Assembly View
WIRING / LIGHTING SYSTEMS PRIMARY HEADLIGHTS ASSEMBLY VIEW HID WIRING HARNESS CONNECTOR HID BALLAST MODULE 6.1 Nm (54 lb-in) RUBBER BOOT 2.7 Nm (24 lb-in) HALOGEN BULB COCKPIT SUB-FRAME HID WIRING HARNESS CONNECTOR HID DRIVING LAMP BULB 2.7 Nm (24 lb-in) HALOGEN DRIVING LAMP BULB 19.3 ©...
Page 522 WIRING / LIGHTING SYSTEMS HEADLIGHT CIRCUIT - LOW BEAM (2008-2010) The starter button must be pressed to power the headlight circuit on 2009-2010 models. See “HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010)” on page 19.6 for operation of the power and control relay. 2008 ONLY 19.4 ©...
Page 523 WIRING / LIGHTING SYSTEMS HEADLIGHT CIRCUIT - HIGH BEAM (2008-2010) The starter button must be pressed to power the headlight circuit on 2009-2010 models. See “HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010)” on page 19.6 for operation of the power and control relay. 2008 ONLY 19.5 ©...
Page 524 WIRING / LIGHTING SYSTEMS HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010) Starter Solenoid 2009-2010 Models - The starter button must be pressed to power the headlight circuit. When the starter button is pressed, the pull-in coil of the Headlight Control Relay stays energized by the output current (A).
Page 525: Turn Signal System (2008)
WIRING / LIGHTING SYSTEMS TURN SIGNAL SYSTEM (2008) TURN SIGNAL SYSTEM WIRING DIAGRAM (2008) Auto Cancel Module 19.7 © 2009 Polaris Sales Inc.
Page 526 WIRING / LIGHTING SYSTEMS TURN SIGNAL AUTO CANCEL MODULE OVERVIEW (2008) AUTO CANCEL MODULE INPUT / OUTPUT - 2008 Overview of Operation Function / Name Wire Color for 2009-2010 module) Number (See page 19.12 Switched Power Y / VIO Switched battery voltage supplied by turn signal / brake relay. Brake Input Power When the front or rear brake is applied, the module receives power on this wire W / PINK...
Page 527 WIRING / LIGHTING SYSTEMS AUTO CANCEL TURN SIGNAL SYSTEM Turn Signal Switch Mode: SELF-DIAGNOSTICS - 2008 5. Perform Steps 1-4 to enter the diagnostic mode. 6. When codes are blinking on rear turn signals, turn the The auto cancel module on 2008 models (located under hazard switch OFF.
Page 528 WIRING / LIGHTING SYSTEMS TURN SIGNAL DIAGNOSTIC BLINK CODES - 2008 BLINK CODE EXAMPLES 2 second One long pulse then two short pulses pause Time One long pulse then three short pulses Time BLINK CODE TABLE NOTE: Fault codes (13 and above) will only appear when actually present. A separate “code clearing” operation is not required. When a problem is corrected, the code will not be displayed when the sequence repeats.
Page 529: Turn Signal System (2009-2010)
WIRING / LIGHTING SYSTEMS TURN SIGNAL SYSTEM (2009-2010) TURN SIGNAL SYSTEM DIAGRAM (2009-2010) Under LH Side Cover Flasher Module (auto cancel is controlled by ECM) 19.11 © 2009 Polaris Sales Inc.
Page 530 WIRING / LIGHTING SYSTEMS TURN SIGNAL FLASHER MODULE (2009-2010) On 2009-2010 models, auto-cancel turn signal functions are performed in the ECM, not in the Auto Cancel Module as on 2008 models. The 12 pin module (was 16 pin on 2008) is used to flash the turn signal and hazard circuits, and also contains clutch circuit and ECM protection diodes (see wiring diagram).
Page 531: Speedometer
WIRING / LIGHTING SYSTEMS SPEEDOMETER SPEEDOMETER Speedometer Troubleshooting Flowchart Replace No Speed Perform Speed Sensor Test Is Sensor OK? Speed Indication below (see page 19.21) Sensor Check wiring (continuity) & connectors between ECM PIN 42, the Cruise Control Module, and the Speed Sensor connector Test constant power (on Pin 1) and (at Pin 2) of speedometer connector...
Page 532: Switch Testing
WIRING / LIGHTING SYSTEMS SWITCH TESTING REAR BRAKE LIGHT SWITCH TEST FRONT BRAKE LIGHT SWITCH TEST 1. Disconnect wires (B) from switch. 1. Remove electrical cover. 2. Connect ohmmeter to switch contacts and test for good continuity through switch when front brake is applied. SPECIFICATION: Continuity When Brake Applied 2.
Page 533 WIRING / LIGHTING SYSTEMS CLUTCH SWITCH TESTING 4. Perform the resistance tests in the table below and compare results. 1. Refer to page 18.9 to test the clutch switch and circuit. 5. 2008-2009: Ground path for the switch is through the GEAR POSITION SWITCH TESTING shift drum detent roller.
Page 534: Gear Position Switch Removal
WIRING / LIGHTING SYSTEMS GEAR POSITION SWITCH REMOVAL 8. 2008-2009: Test the ground path between the spring hole in the shift drum and engine ground (to a good Removal / Bench Test ground on crankcase. Resistance should be less than one Ohm.
Page 535: Cruise Control
WIRING / LIGHTING SYSTEMS CRUISE CONTROL OPERATION OVERVIEW - RESUME / ACCELERATE OPERATION OVERVIEW - SETTING SPEED Resume Review Cruise Control Safety & Operation in the Rider’s Manual before operating the Cruise Control. To set the cruise control (if equipped): Right Handlebar Accelerate Decelerate...
Page 536: Cruise Control Diagnostic Blink Codes (Overview)
WIRING / LIGHTING SYSTEMS CRUISE CONTROL DIAGNOSTIC BLINK CRUISE CONTROL DISENGAGE CODES CODES (OVERVIEW) FLASH SEQUENCE DESCRIPTION The eight most recent causes for cruise control Initial state / No dropout disengage (“drop out”) are stored in the cruise control Throttle grip at zero (throttle cable switch) module memory.
Page 537: Cruise Control Switch Diagnostics
WIRING / LIGHTING SYSTEMS CRUISE CONTROL SWITCH DIAGNOSTICS Test 4 (Brake Switch) The sensors and switches that supply information to the 14. Continuing from Test 3, apply the front or rear brake cruise control module can be tested to verify proper lever.
Page 538: Cruise Control Cable Replacement
WIRING / LIGHTING SYSTEMS CRUISE CONTROL CABLE REPLACEMENT 5. Locate cruise control cable at throttle body. NOTE: Always perform the “Lash Learn” procedure THROTTLE BODY after replacing the cruise control cable. 1. Locate cruise control module under the seat. REAR FRAME ASSEMBLY CRUISE CONTROL CABLE CABLE BRACKET THROTTLE LINKAGE FITTING...
Page 539: Cruise Control Cable "Lash Learn" Procedure
The cruise control actuator cable has no manual cable free play adjuster, so a “Lash Learn” procedure must be initiated by the Victory technician. This simple, automated process allows the cruise control module to take up any slack in the cruise cable which will ensure a smooth transition to SET speeds, and quicker reaction to changes in load (hills) and speeds.
Page 540 WIRING / LIGHTING SYSTEMS 6. After engine starts, watch cruise indicator lamp on 9. Listen for a brief increase in engine RPM as the cruise indicator display until it turns OFF. (If indicator lamp control module takes up any cable lash (free play) and does not illuminate and remain illuminated when the completes the Lash Learn process.
Page 541: Horn Relay Circuits
WIRING / LIGHTING SYSTEMS HORN RELAY CIRCUITS SYSTEM DIAGRAM 19.23 © 2009 Polaris Sales Inc.
Page 542: Windshield / Trunk Lamp Circuits
WIRING / LIGHTING SYSTEMS WINDSHIELD / TRUNK LAMP CIRCUITS SYSTEM DIAGRAM NOTE: Trunk lamp operation can be viewed by removing the seat and backrest pad from the front of the trunk. 19.24 © 2009 Polaris Sales Inc.
Page 543: Instrument Cluster
Reverse (2009 only) SEE CHAPTER 5 FOR INFORMATION ON “ERR” CODES DISPLAYED ON LCD SCREEN NOTE: INSTRUMENT CLUSTER SOFTWARE CAN BE REPROGRAMMED IF UPDATES ARE RELEASED BY VICTORY. FOLLOW AUXILIARY CONTROLLER REFLASH PROCEDURE IN THIS CHAPTER OR IN DIGITAL WRENCH. 19.25...
Page 544 WIRING / LIGHTING SYSTEMS INSTRUMENT CLUSTER 24 PIN CONNECTOR INPUT / OUTPUT (2008-2009) 19.26 © 2009 Polaris Sales Inc.
Page 545 WIRING / LIGHTING SYSTEMS INSTRUMENT CLUSTER 24 PIN CONNECTOR INPUT / OUTPUT (2010) 19.27 © 2009 Polaris Sales Inc.
Page 546: Heaters (Seat / Handgrip)
WIRING / LIGHTING SYSTEMS HEATERS HEATED SEAT & HANDGRIP WIRING DIAGRAM HEATED SEAT GRID TROUBLESHOOTING: Disconnect 2-Pin connector (under seat). Connect Ohmmeter to LT BU/PK and BK wires on seat side of 2-Pin connector. Turn both seat heater switches OFF. Test each switch / grid separately (turn other switch OFF).
Page 547: Console Switch Wire Connections
WIRING / LIGHTING SYSTEMS CONSOLE SWITCH WIRE CONNECTIONS Wire connections for console switches are shown below. FRONT OF CONSOLE DRIVING LAMP PK/GN & GN/PK Hand Warmer Power Lt BU / PK HAZARD BU/W & BK/W Hand Warmer Hand Warmer LOW - Brown High - Blue on front tab on rear tab...
Page 548 WIRING / LIGHTING SYSTEMS TIPOVER SENSOR (2009-2010) LOCATION The tipover sensor is mounted on the cruise control OVERVIEW OF OPERATION module bracket near the rear wheel closeoff panel. The Tipover Sensor (TOS) is used to disable the fuel Access the sensor by removing the right lower access pump, fuel injector, and ignition circuits in the event of a panel.
Page 549: Audio Systems
WIRING / LIGHTING SYSTEMS AUDIO SYSTEMS AUDIO SYSTEM DIAGRAM NOTE: DO NOT INSTALL 2008-2009 RADIO, CB RADIO, OR XM RADIO ON 2010 MODEL VISION (OR 2010 EQUIPMENT ON 2008-2009). FOR AUDIO / COM SYSTEM OPERATION, REVIEW INFORMATION IN CHAPTER 1. SEE TROUBLESHOOTING ON PAGE 19.39. (10th Anniversary or Accy) NOTE: Remove 25A fuse...
Page 550 (CB, XM, etc.) 1. Turn ignition switch to ACC. 2. Turn radio OFF (Victory, Victory Motorcycles or Ness SCREEN 2 - Button Diagnostics Signature Series is shown on display).
Page 551: Audio Systems Control Switch On-Board Diagnostics
1. Turn ignition switch to ACC. contact cleaner) and that the connector is latched together securely before replacing a switch. 2. Turn radio OFF (Victory Motorcycles or Ness A loose connection or even a small amount of Signature Series is shown on display).
Page 552: Button Function
WIRING / LIGHTING SYSTEMS AUDIO / COM BUTTON LOCATION TABLE - 2008 MODELS TABLE 1 - 2008 Model Audio / Com Control Input Location POSITION ON DISPLAY POSITION ON DISPLAY BUTTON FUNCTION TOP ROW BOTTOM ROW 1-16) 17-32) OSITIONS OSITIONS NOT DEFINED SOURCE (on both radio console and handlebar audio switch) MODE (on radio console button)
Page 553 WIRING / LIGHTING SYSTEMS AUDIO SYSTEMS CONTROL SWITCH - BENCH TEST On-board switch diagnostics should be used if available, however, the audio control switches can be bench tested with an Ohmmeter. Use extra care with the meter leads to ensure connector pins are not damaged when testing. 1.
Page 554: Reprogramming Procedure
WIRING / LIGHTING SYSTEMS AUDIO SYSTEM REPROGRAMMING ...or go to www.polarisdealers.com and click on the Digital Wrench Updates link under the Service and Warranty (AUXILIARY CONTROLLER REPROGRAM) drop down menu... The current radio software and hardware versions are displayed on Screen 1 when the radio is in diagnostic mode.
Page 555 WIRING / LIGHTING SYSTEMS 5. Select the item you want to re-program from the list. 8. Go to the dealer web site (www.polarisdealers.com). 9. Select the Service and Warranty drop-down menu. 10. Select “Reflash Authorization”. 6. Follow instructions on screen and click CONTINUE. 11.
Page 556 (radio, CB/ICOM, XM, etc.) is at the most current level, by performing the following steps: 25. Turn ignition switch to ACC and turn radio OFF. (VICTORY or VICTORY MOTORCYCLES is shown on display) 26. Turn ignition switch to OFF and then back to ACC.
Page 557: Audio Troubleshooting Tips
Damage can Speakers not genuine occur to the radio due to Victory. overheating. Install genuine Victory (4 Ohm) speakers. Headsets are not Headsets work only in genuine Victory. Replace entertainment modes with genuine Victory and not in ICOM.
Page 558: Reverse System
WIRING / LIGHTING SYSTEMS REVERSE SYSTEM WIRING DIAGRAM / REVERSE HARNESS 19.40 © 2009 Polaris Sales Inc.
Page 559: Reverse System Diagnostics
WIRING / LIGHTING SYSTEMS REVERSE SYSTEM DIAGNOSTICS OVERVIEW OF OPERATION In a Reverse system, the electric starter button serves a dual purpose. When the starter button is pressed, battery voltage is sent through the Reverse wiring harness to the Reverse Module. The module then decides whether to send power to the electric starter solenoid (for engine starting) or to the Reverse Drive Motor (for reverse operation).
Page 560 WIRING / LIGHTING SYSTEMS REVERSE SYSTEM DIAGNOSTICS (Cont.) REVERSE SYSTEM TROUBLESHOOTING Problem Possible Cause / Remedy Reference Reverse switch contacts closed. See below for switch contact test. Check reverse switch function and Adjust linkage rod (page 11.12). linkage adjustment. Reverse system inoperative. 25A fuse open (blown).
Page 561: Reverse Module / Fuse Access
WIRING / LIGHTING SYSTEMS REVERSE SYSTEM SAFETY NOTE: Do not attempt to engage or disengage the reverse system when the motorcycle is moving. BEFORE operating in reverse NEVER operate in reverse Always sit on the motorcycle with legs astride and both When not properly seated.
Page 562: Tachometer Signal Test
WIRING / LIGHTING SYSTEMS TACHOMETER SIGNAL TEST TESTING AT THE REVERSE MODULE: 1. Remove seat (page 3.27). A tachometer signal is sent out of ECM (Pin 22) on the 2. Shift transmission into NEUTRAL. Green / White wire. The signal can be tested at the cruise control module connector GN/W wire (2008-20010), the 3.
Page 563: Ground Locations
WIRING / LIGHTING SYSTEMS GROUND LOCATIONS ECM ground (C). Front left ECM mounting bolt (under seat). Symptoms of a loose, corroded, or broken ground wire vary depending on the wire and the location. Most often, a problem with a main ground wire location will affect multiple circuits.
Page 564 WIRING / LIGHTING SYSTEMS WIRE HARNESS (TOP VIEW)  DO NOT apply dielectric grease to sealed connectors = Apply Dielectric grease P/N 2871329 or to O sensor connectors or wires. P-Clip for main chassis wire harness bundle is attached to lower right instrument panel mounting bolt.
Page 566 WIRING / LIGHTING SYSTEMS ELECTRICAL CONNECTOR AND COMPONENT LOCATION Halogen Driving Light LH Headlight RH Headlight Windshield Control RH Fuse Box Fuel Pump LH Fuse Box Ambient Air Park Lamp Temp RH Turn Signal Park Lamp RH Speaker + / - LH Turn Signal LH Speaker + / - AM/FM Antenna...
Page 567 WIRING / LIGHTING SYSTEMS ELECTRICAL CONNECTOR AND COMPONENT LOCATION = Apply thin film of dielectric grease PN 2871329  DO NOT apply dielectric grease to sealed connectors or to oxygen sensor wiring. Driving Light Switch Instrument Cluster Hazard Switch Fog Lights HID Ballast Power Heated Grip Switch ACC Power...
Page 569 Chapter 15...
Page 570 Slide Lock End View From Wire Side Wire Harness End ECM CONNECTOR (Under Seat)
Page 571 Antenna tube on RH leg fairing Antenna wire: routed in tube Attached to windshield access panel Connector between RH fuse box and RH speaker volume. Must not contact metal. 2008 - 2010 INFORMATION / ENTERTAINMENT WIRING DIAGRAM Connect Antenna to CB radio before connecting the radio harness...
Page 572 CONNECTOR Wire End Slide Lock End Under LH Side Cover In Left Saddlebag...
Page 573 Under LH Side Cover...
Page 574: Chassis Wiring Diagram
 2008 VICTORY VISION CHASSIS WIRING DIAGRAM...
Page 575: Engine Wiring Diagram
 2008 VICTORY VISION ENGINE WIRING DIAGRAM ECM CONNECTOR (Under Seat) Wire Harness End Slide Lock End Under LH Side Cover (In Left Saddlebag)
Page 576  2009 - 2010 VICTORY VISION CHASSIS WIRING DIAGRAM Chapter 15...
Page 577  2009 - 2010 VICTORY VISION ENGINE WIRING DIAGRAM ECM CONNECTOR (Under Seat) Slide Lock End View From Wire Side Under LH Side Cover Wire Harness End ECM CONNECTOR (Under Seat) (In Left Saddlebag)
Page 578  2008 - 2010 VICTORY VISION INFORMATION / ENTERTAINMENT WIRING DIAGRAM Antenna wire routed in tube Antenna tube on RH leg fairing Attached to windshield access panel Connector located between RH fuse box and RH speaker volume. Must not contact metal.

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Victory Vision Street 2008 Service Manual

Table of Contents

Maintenance Chapter 2 Maintenance 2

Chapter 3 Frame-Body-Exhaust

Chapter 4 Lubrication & Cooling

Chapter 5 Fuel System / Fuel Injection

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Summary of Contents for Victory Vision Street 2008