Victory Motorcycles Classic Cruiser 2002 Service Manual
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Victory Motorcycles Classic Cruiser 2002 Service Manual

Victory Motorcycles Classic Cruiser 2002 Service Manual

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  • Page 2 2002 - 2004 SERVICE MANUAL Part Number 9918960 Foreword This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept available for reference in the shop area. All references to left and right side of the motorcycle are from the operator’s perspective when seated in a normal riding position.
  • Page 3 General Maintenance Frame/ Body/ Exhaust Lubrication & Cooling Fuel System / Fuel Injection Engine Removal & Installation Cylinder Head & Valves Cylinder & Piston Clutch, Primary, & Shift Linkage Transmission & Crankshaft Drive Line Front Wheel & Suspension Rear Wheel & Suspension Tires Brakes Charging System...

  • Page 4: Table Of Contents

    UNDERSTANDING SAFETY LABELS & INSTRUCTIONS ....DANGER, WARNINGS, & CAUTION SYMBOLS ..... . . GENERAL SAFETY / SERVICE RULES .

  • Page 5: Understanding Safety Labels & Instructions

    GENERAL TRADEMARKS Victory acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shocks Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg.

  • Page 6: General Safety / Service Rules

    GENERAL SERVICE RULES In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual and familiarize themselves with the procedures before beginning. Photographs and illustrations have been included with text as an aid. Notes, Cautions and Warnings have also been included for clarification of text and safety concerns.

  • Page 7: Victory Touch Up Paint And Refinishing Kits

    GENERAL VICTORY TOUCH-UP AND REFINISHING PAINT Service Paint products are available in three different sizes and applications. Some paint colors require up to 3 components to create a color. Prices subject to change without notice. Dealer is responsible for freight on paint and paint products.
  • Page 8 GENERAL VICTORY PAINT COLORS BY MODEL NOTE: The 8th Position in the model number is a letter that designates the country / region: C=Canada; D=49State; L=California; U=United Kingdom The last letter is the color designator. Refer to the chart below for model / color. Paint ordering information is available on the dealer web site.

  • Page 9: Vehicle Identification Number (Vin)

    GENERAL VEHICLE IDENTIFICATION NUMBER Chassis: Series: C =Kingpin Type: C = Canada B = Standard T = Touring D = Domestic (49 State) G = Vegas L = California N = ANSS SAE- - assigned U = United Kingdom Serial Number World Manufacturing Identifier *5VPCB16D032000000* Engine Size:...

  • Page 10: Break-In Procedures

    GENERAL BREAK-IN PROCEDURES There is never a more important period in the life of a new Victory motorcycle than the period between zero and 500 miles (805 km). A Victory motorcycle is manufactured using the best possible materials and manufacturing techniques, but the final machining process is the break-in.

  • Page 11: Emission Control Systems

    Carbon monoxide must be controlled because it is toxic. EXHAUST EMISSION CONTROL Victory Motorcycles utilizes an electronic engine management system which controls fuel delivery and ignition timing to control hydrocarbons and carbon monoxide. No adjustments should be made to the system. If components are replaced that affect idle speed follow the instructions in Chapter 5.

  • Page 12: Multi-Function Display (Mfd)

    GENERAL Multi- -Function Display (MFD) Modes and Operation The MFD lets the user toggle via the mode button to view the odometer, the trip odometer, the clock, the fuel gauge, the voltmeter, the instrument cluster light dimmer, the headlamp high beam indicator light dimmer, and the check engine indicator.
  • Page 13 GENERAL Multi-Function Display (MFD) Modes and Operation Instrument Cluster Light Dimmer “DIM” appears as part of the display when in instrument cluster light dimmer mode. To change the intensity of the instrument cluster light, press the MFD Set button to select from six (6) intensity levels. The engine does not need to be running to change the light intensity.

  • Page 14: Mfd Function Flow Chart

    GENERAL MFD FUNCTION FLOW CHART 1.10...

  • Page 15: Special Service Tools

    GENERAL SPECIAL TOOLS SPECIAL TOOLS - - GENERAL & PRECISION MEASUREMENT PART NUMBER Bearing & Seal Driver Set PV-43558 Blind Bearing Remover Set Commercially Available Bore Gauge Set PV-3017 Decal, Service Bulletin Completion 7170107 (Order from Victory Parts Dept.) Dial Caliper (Metric, 0--150mm) PV-26900-7 Dial Caliper (Electronic.
  • Page 16 GENERAL SPECIAL TOOLS SPECIAL TOOLS - - ENGINE / CLUTCH / TRANS PART NUMBER Clutch Hub Holding Tool PV-43518 Clutch Shaft Holder PV-45028 Crankcase Assembly Tool (Same as Mainshaft / PV-46299 Crankcase Installer) Crankshaft Bearing Protector PV-43504 Crankshaft Rotation Socket (2003-current) PV-46988 Crankcase Puller (Crankcase Separation) Used on PV-45029...
  • Page 17 GENERAL SPECIAL TOOLS STEERING / SUSPENSION PART NUMBER (Cont.) Gas Shock Re-Charging Kit (Includes items below) 2200421 Kit Part Charging Needle 7052069 Kit Part Air Chuck 7052068 Kit Part Gas (Low) Pressure Hose 2110003 Kit Part Re-Charging Valve 7051004 Kit Part Female / Male Fitting 7052066 Kit Part...

  • Page 18: Cable & Harness Routing

    GENERAL CABLE & HARNESS ROUTING Refer to following pages for tie strap location Crank Position Sensor Wiring Clutch Cable Rear Brake Line Starter Cable & Regulator/Rectifier Wiring To Battery Clutch Cable Fast Idle Cable Throttle Cable Fast Idle Cable Clutch Cable Throttle Cables Throttle Return Cable...
  • Page 19 GENERAL CABLE & HARNESS ROUTING Left View Strap Includes: To Crankshaft Subframe and Rear Harness Position Sensor Bundle in Strap Strap Includes: Subframe, Harness Bundle, Rear Harness Bundle, Starter Cable, and Charging Lead in Strap Torque: 9.5 Nm (7 lb. ft.) Strap includes frame and harness only Strap Includes:...
  • Page 20 GENERAL CABLE & HARNESS ROUTING Tie Strap includes frame, harness, fast idle cable, and throttle “open” cable only Tie Strap includes frame, harness, and throttle “close” cable only Tie Strap includes frame & wire harness only Included in strap: Included in strap: Speedometer Bracket Speedometer Bracket RH Controls Harness...
  • Page 21 GENERAL SPECIFICATIONS, 2002 MODELS ......GENERAL SPECIFICATIONS, 2003-2004 MODELS ....PERIODIC MAINTENANCE INTERVAL CHART .
  • Page 22 MAINTENANCE GENERAL SPECIFICATIONS - 2002 2002 V92C 2002 V92C Deluxe 2002 V92TC 2002 V92TC Deluxe Oil Capacity 6 Qt (5.7 Ltr) 6 Qt (5.7 Ltr) 6 Qt (5.7 Ltr) 6 Qt (5.7 Ltr) Fuel Capacity 5 US Gal (19 Ltr) 5 US Gal (19 Ltr) 5 US Gal (19 Ltr) 5 US Gal (19 Ltr)

  • Page 23: General Specifications

    MAINTENANCE GENERAL SPECIFICATIONS - 2002 2002 V92C V92C 2002 V92TC V92TC Deluxe Deluxe Transmission Type Manual 5 Speed Manual 5 Speed Manual 5 Speed Manual 5 Speed Clutch Type Wet Multi-Disk Wet Multi-Disk Wet Multi-Disk Wet Multi-Disk Diaphragm Spring Diaphragm Spring Diaphragm Spring Diaphragm Spring Primary Drive Reduction...
  • Page 24 MAINTENANCE GENERAL SPECIFICATIONS 2003-2004 Classic Touring Cruiser Oil Capacity 6.5 Qt (6.15 Ltr) 6.5 Qt (6.15 Ltr) Fuel Capacity 5 US Gal (19 Ltr) 5 US Gal (19 Ltr) Wheelbase 63.3 in (161 cm) 65.5 in (166 cm) Seat Height 28.3 in (72 cm) 28.3 in (72 cm) Footrest Height...
  • Page 25 MAINTENANCE GENERAL SPECIFICATIONS 2003-2004 Classic Touring Cruiser Transmission Type Manual 5 Speed Constant Mesh Manual 5 Speed Constant Mesh Clutch Type Wet Multi-Disk Wet Multi-Disk Diaphragm Spring Diaphragm Spring Primary Drive Reduction Wet Multi- -Gear Wet Multi- -Gear S Primary Drive Gear Ratio 1.5:1 1.5:1 Front Wheel...
  • Page 26 MAINTENANCE PERIODIC MAINTENANCE INTERVAL CHART ODOMETER READING in MILES (KILOMETERS) Component (see operation codes below) Air FIlter Auxiliary Lights Brake Fluid** Battery Brake Pads Clutch Lever Control Cables Crankcase Ventilation System Drive Belt Drive Sprocket and Sprocket Nut Engine Oil* Engine Oil Filter* Engine Compression Evaporative Emission Control...
  • Page 27 MAINTENANCE TUNE UP SPECIFICATIONS ITEM SPECIFICATION Lubrication Oil Pressure @ 3000 rpm 552 kPa (80 psi) Cooling Oil Pressure @ 3000 rpm 414 kPa (60 psi) Drive Belt Deflection All Except Touring Cruiser Models 8 mm (.315″) With 10-12 lb Load @ Center Span Touring Cruiser Models 9 mm (.354″) With 10-12 lb Load @ Center Span Throttle Grip Freeplay...
  • Page 28 MAINTENANCE FASTENER TORQUE SPECIFICATIONS, TUNE-UP TORQUE APPLY / APPLY / DESCRIPTION Lb-ft NOTES (Lb-in) Air Box to Throttle Body (85) Air Box Cover (10) Air Filter Cover (10) Axle Nut Axle Adjuster Jam Nut Brake Lever Pivot Nut (Front ) (60) Clutch Lever Pivot Nut (48)
  • Page 29 MAINTENANCE ENGINE OIL LEVEL INSPECTION 1. Warm the engine for several minutes until operating temperature is reached. 2. Stop engine and wait for 3-5 minutes. 3. Place the machine on a level area and hold it in an upright position. 4.
  • Page 30 MAINTENANCE CABLE LUBRICATION The cables used on the motorcycle require periodic lubrication for smooth operation and longevity. Inspect cables for smooth movement and external damage. Inspect the exposed inner cable (A) for fraying, damage or rust. Replace any damaged cables. Disconnect one end of the cable to be lubricated.
  • Page 31                  ...

This manual is also suitable for:

Classic cruiser 2004Touring cruiser 2002Touring cruiser 2004Classic cruiser 2003

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