Polaris 2003 Victory Classic Cruiser- Manuals

3 FOREWORD Thank you for choosing a Polaris Victory motorcycle!This owner’s manual contains information for the Classic Cruiser and the Touring Cruiser. Some of the photographs and illustrations used in the manual are generalizations, so your model may be slightly different than what is shown.If you...

4 TABLE OF CONTENTS FOREWORD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE OF CONTENTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

5 INTRODUCTION Read the Owner’s Manual Your Victory owner’s manual contains information that’s essential to safe riding and proper maintenance of the motorcycle. Anyone who uses the motorcycle (operators and passengers) must read the owner’s manual before riding.Carefully read and understand the inf...

6 SAFETY Symbols and Terms Used in the Owner’s Manual The following safety signal words and symbols appear throughout the owner’s manual. Your safety and the safety of others are involved when these words and symbols are used. Become familiar with their meanings before reading the manual. ! The safe...

7 SAFETY Safe Riding Practices Improper use of this motorcycle can result in serious injury or death to you, your passenger andothers. To minimize the risk of injury, read and understand the information contained in thissection before operating the motorcycle. This section contains safety informatio...

8 SAFETY Safe Riding Practices The following design characteristics affect how you should ride the Victory motorcycle: S The motorcycle is designed for on-road use with one rider and one passenger. Do not exceed the gross vehicle weight rating (see the specifications section, beginning on page 168, ...

9 SAFETY Safe Riding Practices Follow these general safe riding practices: S Before each ride, make the checks described in the Pre-Operation Check section beginning on page 64. Op- erating the motorcycle without completing the pre-operation check may cause damage to the motorcycle or result in an a...

10 SAFETY Safe Riding Practices S The most common cause of accidents involving a motorcycle and an automobile is the automobile driver’s failure to see the motorcycle. Ride defensively, as if you are invisible to other motorists, even in broad daylight. Ride where you’re clearly visible to other mot...

11 SAFETY Safe Riding Practices S Reduce your speed when: - The weather is windy, rainy or otherwise causing slippery or rapidly changing conditions.- The traffic is heavy, congested, not allowing sufficient space between vehicles or otherwise not flowing smoothly. - You are being passed in either d...

12 SAFETY Safe Riding Practices S Ground clearance is reduced when the motorcycle leans. Do not allow components to contact the road surface when leaning the motorcycle in a curve, as this could cause loss of control. S Retract the sidestand fully before riding. If the sidestand is not fully retract...

13 SAFETY Safe Riding Practices Protective Apparel To decrease the risk of injury and increase riding comfort, wear protective riding apparel. S Wear a Department of Transportation (DOT) or SNELL approved helmet. Some state laws require that you wear an approved helmet. In accidents involving motorc...

14 SAFETY Gross Vehicle Weight Rating (GVWR) Gross vehicle weight is the total combined weight of the motorcycle, the operator and the passenger. S The weight of the motorcycle includes the motorcycle and all of its fluids, any accessories and their contents, and any additional cargo on the motorcyc...

15 SAFETY Example 1: Classic Cruiser with no accessories or cargo Gross Vehicle Weight Rating 1150 lbs (522 kg) Item Weight Classic Cruiser - with full capacity of all fluids 675 lbs (306 kg) Operator - with recommended riding apparel 220 lbs (100 kg) Passenger - with recommended riding apparel 155 ...

16 SAFETY Example 3: Touring Cruiser with no cargo Gross Vehicle Weight Rating 1210 lbs (549 kg) Item Weight Touring Cruiser - with full capacity of all fluids 759 lbs (344 kg) Operator - with recommended riding apparel 220 lbs (100 kg) Passenger - with recommended riding apparel 155 lbs (70 kg) Tot...

17 SAFETY Carrying Cargo Use the following guidelines when attaching cargo or accessories to the motorcycle. Where applicable, these guidelines also refer to the contents of any accessories. S Keep cargo and accessory weight to a minimum, and keep items as close to the motorcycle as possible to mini...

18 SAFETY Saddlebags When operating a motorcycle with saddlebags: S Never ride at speeds exceeding 80 mph (120 km/h). Depending on load and weather conditions, the maximum safe operating speed may be less than 80 mph (120 km/h). Saddlebags, combined with the lifting or buffeting effects of wind, can...

19 SAFETY Parking the Motorcycle When leaving the motorcycle unattended, turn the engine off, engage the steering lock and remove the ignition key. See page 90.Park the motorcycle where people are not likely to touch the hot engine or exhaust system or place combustible materials in close proximity ...

20 SAFETY Accessory Selection and Installation Because Victory cannot test and make specific recommendations concerning every accessory or combination of accessories sold, the operator is responsible for determining that the motorcycle can be safely operated with any accessories or additional weight...

21 SAFETY Gasoline and Exhaust For complete fueling procedures, see page 81.Gasoline is highly flammable and can be explosive in certain conditions. Observe the following precautions when you refuel or service the fuel system: S Turn off the engine. S Use a well-ventilated area. S Remove the fuel ca...

22 SAFETY Maintenance Maintain the motorcycle according to the following requirements: S Before each ride, complete a pre-operation check as outlined beginning on page 64. Operating the motorcycle without completing the pre-operation check can cause damage to the motorcycle or result in an accident....

24 SAFETY Location of Safety and Vehicle Information Labels (Classic Cruiser) B D A C Refer to page 25

25 SAFETY Location of Safety and Vehicle Information Labels (Classic Cruiser) Location A Information on this decal will vary by model, features, and options. Refer to actual decal on the vehicle. Location B Location C Location D (U.S. Models) Location D (California Models) Location D (Canada Models)

26 SAFETY Location of Safety and Vehicle Information Labels (Classic Cruiser) A C D B Refer to page 27

27 SAFETY Location of Safety and Vehicle Information Labels (Classic Cruiser) Location A (on subframe) Location B (on subframe) (Information will vary by model) Engine Identification Number Label Location D (on left crankcase half) Location C (in fuse box cover) HEADLAMP RELA Y (RELAIS DE PHARE) PCM...

28 SAFETY Location of Safety and Vehicle Information Labels -- Classic Cruiser (Shown with options) A C B Refer to page 29

30 SAFETY Location of Safety and Vehicle Information Labels (Touring Cruiser) A B C D Refer to page 31

32 SAFETY Location of Safety and Vehicle Information Labels - Touring Cruiser (Shown with options) S) (Deluxe Touring Cruiser only) (Deluxe Touring Cruiser only) A B C D Refer to page 33

33 SAFETY Location of Safety and Vehicle Information Labels (Touring Cruiser) Location C (Inside Saddlebag) Location B (Both Sides) Location A Location D

35 SAFETY Location of Safety and Vehicle Information Labels (Touring Cruiser) Location A (Under Seat) Location B (Information Will Vary By Model) Engine Identification Number Label Location D (On Left Crankcase Half) Location C (In Fuse Box Cover) HEADLAMP RELA Y (RELAIS DE PHARE) PCM DIODE PCM RELA...

36 SAFETY Reporting Safety Defects If you believe that your vehicle has a defect that could result in a crash or cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Polaris Industries in writing.If NHTSA receives si...

37 COMPONENT IDENTIFICATION Use the information on the following pages to identify and locate the major components of the Victory motorcycle, including the vehicle and engine identification numbers, model number and ignition key number. Handlebar Components 1. Clutch Cable2. Instrument Cluster3. Fue...

38 COMPONENT IDENTIFICATION Classic Cruiser Components 1. Front Forks2. Front Turn Signal/Running Light3. Headlamp4. Air Filter5. Spark Plug (2)6. Ignition Switch/Seat Release7. Side Cover8. Battery (under side cover)9. Operator’s Seat10. Seat Strap11. Passenger’s Seat12. Rear Brake Caliper13. Rear ...

40 COMPONENT IDENTIFICATION Touring Cruiser Components 1. Seat Strap2. Drive Belt (under guard)3. Rear Shock Absorber (under seat)4. Side Cover5. Engine Oil Fill Cap/Dipstick6. Headlamp7. Steering Lock8. Front Turn Signal/Running Light9. Front Fork10. Oil Cooler11. Rear Brake Pedal12. Operator’s Foo...

42 COMPONENT IDENTIFICATION Vehicle Identification Number The vehicle identification number (VIN) is stamped into the front of the steering head and also appears on the certification label. You will need the vehicle identification number to title, register, license or insure the motorcycle, or to or...

43 COMPONENT IDENTIFICATION Engine Identification Number The engine identification number is a combination of the engine model and serial numbers. The engine identification number is located on top of the crankcase behind the rear cylinder. The engine serial number is stamped into the rear of the cr...

45 INSTRUMENTS, FEATURES AND CONTROLS Ignition Key The ignition key operates the ignition switch and the steering lock as well as the seat latch (Classic Cruiser only) and the saddlebag locks (Touring Cruiser only). Steering Lock The motorcycle is equipped with a steering lock to deter others from m...

46 INSTRUMENTS, FEATURES AND CONTROLS Ignition Switch/Seat Release The ignition switch/seat release energizes the ignition, the lighting system, and all electrical switches and buttons. It is also used to release the operator’s seat (on Classic Cruiser). Off Position In the OFF position, all electri...

47 INSTRUMENTS, FEATURES AND CONTROLS Ignition Switch/Seat Release Park Position (P) In the PARK position, the taillight and running lights illuminate, the emergency flashers can be activated, and the ignition key can be removed. You must push the ignition key into the switch while selecting the Par...

48 INSTRUMENTS, FEATURES AND CONTROLS Instrument Cluster The instrument cluster includes the speedometer, the tachometer, the indicator lights and the multi-function display. 1. Speedometer 5. Neutral Indicator 2. Tachometer 6. Turn Signal Indicators 3. Low Oil Pressure Indicator 7. Headlamp High Be...

49 INSTRUMENTS, FEATURES AND CONTROLS Indicator Lights Low Oil Pressure Indicator The low oil pressure indicator illuminates when engine oil pressure drops below safe operating pressure. If this indicator illuminates while the engine is running, turn the engine off immediately and check the oil leve...

50 INSTRUMENTS, FEATURES AND CONTROLS Indicator Lights Turn Signal Indicators The left turn signal indicator flashes when the left turn signals are active. The right turn signal indicator flashes when the right turn signals are active.Both turn signal indicators flash when the emergency flashers are...

51 INSTRUMENTS, FEATURES AND CONTROLS Multi-Function Display (MFD) Use the MFD to view the odometer, trip odometer, clock, fuel gauge, voltmeter, instrument cluster light dimmer, headlamp high beam indicator light dimmer and check engine indicator. The MFD operates only when the ignition switch is i...

52 INSTRUMENTS, FEATURES AND CONTROLS Multi-Function Display (MFD) Clock A clock icon appears in the display when in clock mode. When the clock is operating normally, the colon between the hour and minutes flashes.To set the clock, the ignition switch must be in the ON position with the MFD in clock...

53 INSTRUMENTS, FEATURES AND CONTROLS Multi-Function Display (MFD) Instrument Cluster Light Dimmer “DIM” appears in display when in instrument cluster light dimmer mode. To change the intensity of the instrument cluster light, press the SET button to select from six (6) intensity levels. The engine ...

54 INSTRUMENTS, FEATURES AND CONTROLS Multi-Function Display (MFD) Check Engine Indicator The check engine indicator will flash “CH ENG” any time the ignition switch is in the ON position and the engine control module sensors report abnormal sensor or engine operation. The check engine indicator wil...

56 INSTRUMENTS, FEATURES AND CONTROLS Left Handlebar Controls Fast Idle Lever The fast idle lever increases the engine idle speed when starting a cold engine (see page 82). To engage the fast idle lever, move the lever toward the rear of the motorcycle until the lever stops. Headlamp High/Low Beam S...

57 INSTRUMENTS, FEATURES AND CONTROLS Left Handlebar Controls Horn Button To sound the horn, press the horn button. Clutch Lever To disengage the clutch, pull the clutch lever toward the handlebar. To engage the clutch, gradually release the clutch lever. For smooth clutch operation, pull the lever ...

58 INSTRUMENTS, FEATURES AND CONTROLS Right Handlebar Controls Engine Stop/Run Switch The engine stop/run switch completes or interrupts the ignition, starter, and fuel pump circuits. To complete the circuits, allowing the engine to start and run, press the lower portion of the engine stop/run switc...

59 INSTRUMENTS, FEATURES AND CONTROLS Right Handlebar Controls Front Brake Lever The front brake lever is located on the far side of the right handlebar grip. To apply the front brake, pull the front brake lever toward the handlebar. For braking procedures in various riding conditions, see “Braking”...

60 INSTRUMENTS, FEATURES AND CONTROLS Gear Shift Pedal The gear shift pedal is located on the left side of the motorcycle. To shift to a lower gear, press down on the front of the gear shift pedal. To shift to a higher gear, press down on the rear, or lift up on the front of the gear shift pedal.For...

61 INSTRUMENTS, FEATURES AND CONTROLS Fuel Cap The fuel cap is right-hand threaded (turn clockwise to tighten, turn counterclockwise to loosen). When tightening the fuel cap, continue turning the cap until a clicking sound is heard, indicating proper tightness. Continue turning the fuel cap clockwis...

63 INSTRUMENTS, FEATURES AND CONTROLS Side Covers Your motorcycle is equipped with two removable side covers. Remove the left side cover to access the battery. Remove the right side cover to access the fuses and the rear brake fluid reservoir.To remove either side cover, remove the operator’s seat (...

65 PRE-OPERATION CHECK Check Electrical Equipment To perform a pre-operation check on the electrical equipment, set the ignition switch to the ON position. Set the ignition switch to the OFF position after completing the electrical equipment portion of the pre-operation check. Instrument Cluster The...

66 PRE-OPERATION CHECK Check Electrical Equipment Turn Signals/Running Lights The two amber front running lights should illuminate (US and Canadian models only). Move the turn signal switch to the left. The front and rear left turn signals and the left turn signal indicator in the instrument cluster...

67 PRE-OPERATION CHECK Check Engine Oil Level A dipstick attached to the oil fill cap registers the engine oil level. We recommend the use of only Victory brand Semi-Synthetic 20W-40 Motor Oil or equivalent.1. With the transmission in neutral, start and run the engine for several minutes. 2. Shut th...

68 PRE-OPERATION CHECK Check Fuel Components Fuel Level 1. Straddle the motorcycle on level ground and bring it to a vertical position.2. Turn the ignition switch to the ON position and press the MFD MODE button until the fuel gauge appears in the MFD. 3. Check the fuel level.4. Estimate your next f...

69 PRE-OPERATION CHECK Check Tires Tire Pressure Normal riding warms the tires and increases the tire air pressure. For an accurate reading, check the tire pressure before you ride. Adjust tire pressure as required for the total weight of your intended load. Refer to the tire pressure table on page ...

70 PRE-OPERATION CHECK Check Brakes Front Brake Lever Movement Squeeze the front brake lever toward the handlebar and release it. It should move freely and smoothly and should return to its rest position quickly when released. You should feel a firm resistance in the lever within the first 3/4-inch ...

71 PRE-OPERATION CHECK Check Brakes Rear Brake Pedal Freeplay and Movement Rear brake pedal freeplay, the amount of brake pedal movement from the rest position to the point of contacting the master cylinder, should be 3/16-5/16 inch (5-8 mm). Adjust pedal freeplay as necessary (see page 123).Press a...

72 PRE-OPERATION CHECK Check Brakes Check Hoses and Connections Inspect all brake hoses and connections for dampness or stains from leaking or dried fluid. Tighten any leaking connections and replace components as necessary. Check Brake Pads Look into the front brake caliper(s) from underneath to vi...

73 PRE-OPERATION CHECK Check Clutch 1. Squeeze the clutch lever toward the handlebar and release it. It should move freely and smoothly and should return to its rest position quickly when released. 2. Clutch freeplay, the amount of clutch lever movement from the rest position to the point of cable r...

75 PRE-OPERATION CHECK Check Rear Suspension Proper rear suspension adjustment is essential for a safe and comfortable ride. Check the rear shock absorber movement and preload to ensure that the motorcycle has the correct amount of suspension travel and ground clearance (see page 107). Inadequate gr...

76 PRE-OPERATION CHECK Check Sidestand Straddle the motorcycle and bring it to a vertical position. Move the sidestand to its stored (up) position, then to its fully extended (down) position and back again. It should move smoothly and quietly. When the sidestand is in its stored position, the sidest...

78 OPERATION The operation section describes how to operate your Victory motorcycle for best performance and longevity. Important areas covered include: S Engine Break-in Period S Fueling and Fill Height S Starting the Engine S Shifting Gears S Accelerating S Braking S Stopping the Engine S Parking ...

79 OPERATION Engine Break-in Period During the first 500 miles (800 kilometers), critical engine parts require special wear-in procedures so they seat and mate properly. Read, understand and use the following rules for operating the motorcycle during the first 500 miles (800 kilometers) to ensure yo...

80 OPERATION Engine Break-in Period 0-90 miles (0-145 kilometers) S Do not operate the motorcycle for extended periods of time at throttle positions above 1/3 throttle. Vary the en- gine speed of the motorcycle. Do not operate the motorcycle for extended periods of time at any one set throttle posit...

81 OPERATION Engine Break-in Period Fueling and Fill Height Fuel the motorcycle with the sidestand down and on level ground. Use only the recommended fuel (see “Fuel Specifications” on page 172). Fill the fuel tank to a level just below the bottom of the fuel filler insert. • Do not allow gasoline t...

82 OPERATION Engine Break-in Period Starting the Engine The Victory motorcycle has a starter interlock system. The engine can be started only when the transmission is in neutral or when the transmission is in gear and the clutch is disengaged.Follow these steps to start the motorcycle:1. Unlock the ...

83 OPERATION Engine Break-in Period Starting the Engine 7. Leaving the throttle closed, press and hold the starter button until the engine starts. If the engine does not start within a few seconds after you press the starter button, release the button and wait several seconds. Then press and hold th...

84 OPERATION Shifting Gears The clutch must be fully disengaged (clutch lever pulled completely in toward the handlebars)before you attempt to shift gears. Forced shifting (shifting without the clutch disengaged) maydamage the engine, transmission and drive train, causing loss of control of the moto...

86 OPERATION Shifting Gears • Downshifting at a speed in excess of the recommended downshift point may severely damage the transmission or cause the rear wheel to lose traction. It could also result in engine damage from running at excessive rpm. Reduce speed before downshifting and do not downshift...

87 OPERATION Accelerating To accelerate, open the throttle (roll the throttle control grip toward you). For even acceleration, open the throttle with a smooth, continuous motion. When you reach the recommended speed for upshifting, shift up one gear according to the instructions in “Shifting Gears” ...

88 OPERATION Braking To slow the motorcycle with the brakes, close the throttle and apply the front and rear brakes evenly. As the motorcycle slows, either disengage the clutch or downshift each time your speed reaches a downshift point. Applying slightly more front brake than rear brake generally g...

89 OPERATION Stopping the Engine Before stopping the engine, bring the motorcycle to a complete stop either in neutral or with the clutch disengaged. Once the motorcycle is at a complete stop, if it is not already in neutral, shift into neutral. To stop the engine, set the engine stop/run switch to ...

92 MAINTENANCE This section includes information for maintaining your Victory motorcycle. It includes recommended periodic maintenance intervals, which outlines the regular service required to keep your motorcycle in the best operating condition. Regular service increases motorcycle durability, safe...

93 MAINTENANCE Initial Maintenance Perform the initial maintenance after you’ve ridden your new motorcycle 500 miles (800 kilometers). This maintenance is one of the most important services your motorcycle requires and should be performed by an authorized Victory dealer. Initial maintenance includes...

5000 (8 ,000) 7,500 (12,000) 2,500 (4 ,000) 500 (800) 10,000 (16,000) 12.500 (20,000) 15,000 (24,000) 17,500 (28,000) 20,000 (32,000) 22,500 (36,000) 25,000 (40,000) 27,500 (44,000) 30,000 (48,000) 32,500 (52,000) 35,000 (56,000) 37,500 (60,000) 40,000 (64,000) 42,500 (68,000) 45,000 (72,000) 47.500...

97 MAINTENANCE Engine Oil Changing Engine Oil and Oil Filter 1. Start and run the engine until it reaches normal operating temperature. Stop the engine. 2. Securely support the motorcycle on the sidestand.3. Place an oil drain pan under the drain plug and oil filter (center rear of the engine). 4. R...

98 MAINTENANCE Engine Oil Change Engine Oil and Oil Filter After an oil change, the low oil pressure indicator remains illuminated longer than usual before goingout. Revving the engine while the low oil pressure indicator is illuminated can damage the engine. Caution 11. Stop the engine and make sur...

99 MAINTENANCE Engine Oil Check Engine Oil Level 1. With the engine at normal operating temperature, straddle the motorcycle on level ground and bring it to a vertical position. Remove the oil fill cap and wipe the dipstick clean. Reinstall the dipstick and turn the cap clockwise until it seats. 2. ...

100 MAINTENANCE Inspect Air Filter The standard Victory air filter element is a dry paper design and does not require the use of air filter oil. Notice Inspect the air filter often if riding in unusually wet or dusty conditions.1. Remove the air filter access cover and the air filter element.2. To r...

101 MAINTENANCE Inspect Drive Sprocket and Sprocket Nut 1. Remove the drive sprocket cover. Notice On some models you may have to remove portions of the exhaust system to access all of the drive sprock- et cover screws (see the Victory Service Manual or an authorized Victory dealer). 2. Inspect driv...

102 MAINTENANCE Drive Belt Check Drive Belt Condition Replace the drive belt if it is cracked or has broken teeth or frayed edges. No matter its condition, the drive belt should be replaced at periodic intervals (see the Victory Service Manual or an authorized Victory dealer). Check Drive Belt Tensi...

103 MAINTENANCE Drive Belt Check Drive Belt Tension 2. Position the small O-ring on the belt tension gauge directly over the 10 lbs. mark on the plunger as shown. 3. Place a tape measure or rule next to the drive belt as shown.4. Place the base of the tension gauge bracket squarely against the lower...

104 MAINTENANCE Drive Belt Adjust Drive Belt Tension Notice Before adjusting drive belt tension, be sure the rear axle is properly aligned (see “Align Rear Wheel” page 105).1. Remove and discard the rear axle cotter pin. Loosen the rear axle castle nut and the rear axle adjuster jam nuts.2. Turn bot...

105 MAINTENANCE Align Rear Wheel This procedure involves using the rear wheel alignment tool, part no. PV-43528, which is designed specifically for aligning the rear wheel. Do not rely on the rear axle reference marks for wheel alignment. A skewed rear axle can damage the drive belt, causing it to f...

106 MAINTENANCE Align Rear Wheel 7. Turn the axle adjuster on the side with the longer measurement counterclockwise one flat (1/6 revolution). Turn the axle adjuster on the side with the shorter measurement clockwise one flat (1/6 revolution). Recheck rear wheel alignment as outlined in steps 2-5. R...

107 MAINTENANCE Rear Suspension Adjust Rear Shock Absorber This procedure involves using the shock absorber preload wrench PV-43507, which is designed specifically for adjusting the shock absorber preload. Notice The distance measured while the motorcycle is elevated will not change, and needs only ...

109 MAINTENANCE Rear Suspension Inspect Swing Arm and Rear Axle 1. Remove the swing arm pivot covers and tighten the swing arm pivot nut. Torque: 85 ft-lbs (115 Nm) 2. Reinstall the pivot nut covers.3. Sit in the operator’s seat and slowly bounce the rear suspension a few times. Make sure the suspen...

110 MAINTENANCE Front Suspension and Steering Check Front Forks 1. To check the front suspension, straddle the motorcycle and bring it to a vertical position. 2. Apply the front brake and push down hard on the handlebars several times. The front suspension should operate smoothly and quietly. 3. Pla...

111 MAINTENANCE Front Suspension and Steering Inspect Steering and Front Axle 1. Elevate the front of the motorcycle until the front wheel is off of the ground. Use an appropriate motorcycle lift or a block of wood or steel placed securely under the frame. 2. Turn the handlebars from stop to stop. T...

112 MAINTENANCE Fuel System Check Fuel Hose, Rail, and Connections Inspect the fuel hoses for cracks or damage. Inspect the hose connection at the fuel pump and at the fuel rail for dampness or stains from leaking or dried fuel. Check Crankcase Ventilation Hose and Connections Remove the operators s...

113 MAINTENANCE Fuel System Fuel can damage painted surfaces and plastic parts. Wipe spilled fuel immediately from the motorcycleusing a clean, dry, soft cloth. Caution 5. Loosen hose clamp and disconnect the fuel line (1).6. Disconnect the tank vent line (2).7. To reinstall the fuel tank, reverse t...

114 MAINTENANCE Fast Idle Lever Check Fast Idle Lever and Cable 1. Move the fast idle lever. It should move smoothly from its rest position to its completely open position and back again 2. Fast idle lever freeplay - the amount of lever movement from the rest position to the point of cable resistanc...

115 MAINTENANCE Throttle Check Throttle Control Grip and Cable 1. Rotate the throttle control grip. It should rotate smoothly from its rest position to its completely open position and back again. It should return to its rest position quickly when released. 2. Throttle freeplay - the amount of throt...

116 MAINTENANCE Clutch Check Clutch Lever and Cable 1. Squeeze the clutch lever toward the handlebar and release it. It should move freely and smoothly and should return to its rest position quickly when released. 2. Clutch freeplay - the amount of clutch lever movement from the rest position to the...

117 MAINTENANCE Clutch Lubricate Clutch Lever 1. Remove the operator’s seat.2. Remove the front and rear fuel tank screws.3. Raise the rear of the fuel tank high enough to expose the clutch cable. Support the rear of the fuel tank with a block of wood. 4. Slide the rubber cover off the cable adjuste...

118 MAINTENANCE Clutch Adjust Clutch Freeplay 1. Remove the operator’s seat.2. Remove the front and rear fuel tank screws.3. Raise the rear of the fuel tank high enough to expose the clutch cable. Support the rear of the fuel tank with a block of wood. 4. Slide the rubber cover off the cable adjuste...

119 MAINTENANCE Lubricate Control Cables The following cables used on the motorcycle require periodic lubrication for smooth operation and longevity: S Throttle Cables S Clutch Cable S Fast Idle Lever Cable S Seat Release Cable (Classic Cruiser) 1. Loosen the adjuster of the cable to be lubricated, ...

120 MAINTENANCE Brakes Check Front Brake Lever Movement Squeeze the front brake lever toward the handlebar and release it. It should move freely and smoothly and should return to its rest position quickly when released. You should feel a firm resistance in the lever within the first 3/4-inch (19 mm)...

121 MAINTENANCE Brakes Check Front Brake Fluid Level 1. To check the front brake fluid level, rest the motorcycle on the sidestand and on level ground. Turn the handlebars until the front brake fluid reservoir is level. 2. View the brake fluid through the sight glass. The fluid should be clear and a...

122 MAINTENANCE Brakes • Do not operate the front brake while its reservoir cover is removed. Fluid could overflow from the reservoir and cause air to enter the fluid system. Air in the brake fluid system could cause the brakes to malfunction. • Use only DOT 4 brake fluid from a sealed, clean contai...

123 MAINTENANCE Brakes Adjust Rear Brake Pedal Freeplay 1. Loosen the brake linkage rod locknuts.2. Turn the linkage rod in or out as necessary.3. Tighten the linkage rod locknuts.4. Check the brake pedal freeplay. Check Rear Brake Fluid Level 1. To check the rear brake fluid level, remove the right...

124 MAINTENANCE Brakes Add Rear Brake Fluid 1. Bring the motorcycle to a vertical position with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame. 2. Remove the right side cover. 3. Wipe the area around the reservoir cover with a clean cloth. 4. Wipe the brak...

126 MAINTENANCE Brakes Check Brake Pads Look into the front brake caliper(s) from underneath, and into the rear brake caliper from behind, you should see at least 1/16 inch (1.6 mm) of friction material on each of the brake pads. If in doubt, measure remaining friction material. Replace brake pads h...

127 MAINTENANCE Gear Shift Pedal Adjust Gear Shift Pedal Height 1. Loosen the gear shift linkage rod locknuts.2. Turn the linkage rod in or out as necessary.3. Tighten the linkage rod locknuts.4. Check the gear shift pedal height. Do not remove and reposition the shift arm on the shift shaft to adju...

128 MAINTENANCE Tires Check Tire Pressure Normal riding warms the tires and increases the tire air pressure. For an accurate reading, check the tire pressure before you ride. Adjust tire pressure as required for the total weight of your intended load. Tire Pressure Table Classic Cruiser Up to 200 lb...

129 MAINTENANCE Tires Check Tire Condition Inspect the tire sidewalls, road contact surface, and tread base for cuts, punctures, and cracking. Replace damaged tires immediately (see your Victory Service Manual or an authorized Victory dealer). Check Tread Depth Raised areas at the base of the tread,...

130 MAINTENANCE Check Wheel Spokes If your motorcycle is equipped with spokes, inspect both wheels for loose, bent, broken or missing spokes. To identify loose spokes, grasp each spoke and try to move it side to side or up and down. All spokes should be equally tight and have the same amount of flex...

131 MAINTENANCE Check or Replace Spark Plugs The spark plugs must be removed from the engine to inspect them. Spark plugs with bright white deposits, sooty black deposits, or with damaged insulators or electrodes can indicate engine problems. If these conditions exist, or if the condition of one plu...

132 MAINTENANCE Check or Replace Spark Plugs 4. Remove the spark plug from the cylinder head with a 5/8 inch spark plug socket. Both spark plugs should have the same light or medium tan color deposits on the insulator around the electrode tip. The spark plug electrode tip and bridge should have shar...

133 MAINTENANCE Check Engine Compression An accurate periodic engine compression check documents engine wear and condition. For engine compression check procedures and special tools required, see the Victory Service Manual or contact an authorized Victory dealer. Check Exhaust System Check the exhau...

134 MAINTENANCE Check Exhaust System Check the exhaust system for stains from leaking exhaust gasses. Replace exhaust gaskets if necessary (see the Victory Service Manual or an authorized Victory dealer). Check all exhaust system fasteners. 1. Tighten exhaust header flange nuts. Torque: 12 ft-lbs (1...

135 MAINTENANCE Seat Removal and Installation The Classic Cruiser has two separate seats, the operator’s seat and the passenger’s seat. The Touring Cruiser has a combined operator and passenger seat. Always make sure the seats are securely locked before riding the motorcycle. An unlocked seat could ...

136 MAINTENANCE Battery The battery contains sulfuric acid, which can cause severe burns. Do not allow sulfuric acid tocontact skin, eyes, or clothing.Antidotes: • External: Flush with water. • Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs, or vegetable...

137 MAINTENANCE Battery Battery Removal 1. Remove the left side cover and remove the battery hold-down strap.2. Disconnect the negative ( - ) battery cables (cable ends are exposed).3. Disconnect the positive ( + ) cables (cable ends are covered with a red boot). Disconnecting the positive cable fir...

138 MAINTENANCE Battery Battery Charging The battery may contain explosive gases. • Keep sparks, cigarettes, or any flame away from the battery. • Shield eyes and protect skin and clothing when handling or working near the battery. • Make sure ventilation is adequate when charging or using the batte...

139 MAINTENANCE Battery Battery Installation 1. Before installing the battery, make sure it is fully charged and clean. 2. Slide the battery into position in the battery tray. 3. Connect the positive ( + ) battery cables, tighten securely and install the red boot). 4. Connect the negative ( - ) cabl...

140 MAINTENANCE Fuses Use only recommended amperage fuses or you can damage the electrical system. Caution 1. Remove the seat and the right side cover.2. Release the tabs on each side of the fuse box cover, and remove the cover. 3. Remove the damaged fuse from the fuse box and seat the new fuse firm...

141 MAINTENANCE Headlamp Adjustment The headlamp should shine straight ahead of the motorcycle. The top of the headlamp High beam should be just below the center of the lamp at a distance of 25 feet (7.62 m).1. Check and adjust the tire pressure.2. Verify suspension sag is 19-32mm (see page 107) bef...

142 MAINTENANCE Auxiliary Lights Adjustment (Touring Models) Each lamp should shine straight ahead or slightly to the right of the motorcycle. The top of each lamp beam should be just below the center of the lamp at a distance of 25 feet (7.62 m).1. Check and adjust the tire pressure and rear shock ...

143 MAINTENANCE Saddlebag Removal and Installation Leather Saddlebags 1. Remove the screws, washers, and spacers from inside the saddlebag, and remove the saddlebag from the motorcycle. 2. To reinstall the saddlebag, return all spacers and fasteners to their original location and tighten. Torque: 12...

144 MAINTENANCE Saddlebag Removal and Installation Hard Saddlebags 1. Remove the two (2) upper saddlebag mounting screws located inside the saddlebag. 2. Pull trim straight outward to expose wiring harness connector.3. Disconnect the wiring harness connector.4. Disengage bracket on bottom of bag fro...

145 MAINTENANCE Sidestand Straddle the motorcycle and bring it to a vertical position. Move the sidestand to its stored (up) position, then to its fully extended (down) position, and back again. It should move smoothly and quietly. When the sidestand is in its stored position, the sidestand return s...

146 MAINTENANCE Sidestand Sidestand Lubrication 1. Bring the motorcycle to a vertical position with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame. 2. Move the sidestand to its stored (up) position and remove the sidestand return spring. Wear face protecti...

147 MAINTENANCE Check Fasteners Visually inspect the entire motorcycle chassis and engine for loose, damaged, or missing fasteners. Tighten loose fasteners to the proper torque (see the Specifications section of the Owner’s Manual , or the Victory Service Manual ). Replace stripped, damaged, or brok...

148 CLEANING This section explains how to properly clean the various parts of your Victory motorcycle to keep it in good working order and appearance. General Cleaning Clean your motorcycle regularly to protect it from corrosion and to keep it looking new. As you clean your motorcycle you perform a ...

149 CLEANING Washing and Drying the Motorcycle Before washing the motorcycle, make sure the exhaust pipes are not hot. Cover each exhaust pipe opening with a plastic bag and attach the bag to the pipe with a strong rubber band. To prevent contamination from water, check that the spark plugs, spark p...

150 CLEANING Washing and Drying the Motorcycle Use as little water as possible when washing near the air cleaner or the exhaust pipe openings. An excessively wet air cleaner, or water in the exhaust pipes, may cause the engine to start and run poorly. Dry these components thoroughly before using the...

151 CLEANING Waxing, Polishing and Applying Protectants (Items Other Than Windshields and Leather Saddlebags) After washing and drying the motorcycle, you can help extend the life and appearance of its components by waxing painted surfaces, polishing chrome surfaces, and applying a protectant to exp...

152 CLEANING Windshield Care A windshield is included with some Victory models.Wash the windshield using a soft cloth or sponge soaked in a solution of mild detergent and warm water, applying minimal pressure as you wash. Let the detergent do the cleaning, not the pressure you apply. Excessive washi...

153 CLEANING Leather Saddlebag Care Leather saddlebags are included with some Victory models.Natural leather has “character.” Each piece used in the construction of these saddlebags is unique, and will settle into its own distinct form over time and miles. Mature leather is one-of-a-kind, and if pro...

154 STORAGE If you will not operate the motorcycle for several months, such as during the winter, store the motorcycle to prevent damage to the fuel system and the battery and to protect components from corrosion or deterioration. During storage you might use products that are potentially hazardous;...

155 STORAGE Fuel Stabilizer 1. Using a mixture of fuel and the recommended amount of Victory Premium Carbon Clean Plus or other gasoline stabilizer, fill the fuel tank only to the top of the filler insert. 2. Start and run the engine for 15 minutes in a well ventilated area to pass the stabilized fu...

156 STORAGE Tire Inflation Inflate the tires to normal pressure. Battery Care 1. Remove the battery (see “Remove Battery” page 137).2. To clean oxidation from the battery posts and cable connectors, use a wire brush. Wash the posts and cable connectors with a solution of 1 part baking soda to 16 par...

157 STORAGE Removal from Storage 1. Remove the cover and unlock the front forks.2. Check the tire pressure and inflate the tires if necessary.3. Reinstall the battery (see page 139).4. Wash and dry the entire motorcycle (see page 149).5. Prior to starting the engine, change the engine oil and filter...

158 WARRANTIES Motorcycle Noise Regulation Tampering with noise control systems is prohibited. Federal law prohibits the following acts or causing thereof: S The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of...

159 WARRANTIES Emissions Control System Warranty Victory Motorcycles, Polaris Sales Inc. - Emission Control System Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Victory Motorcycle Division, Polaris Sales Inc. (hereinafter Victory) are pleased to expla...

160 WARRANTIES Owner’s Warranty Responsibilities As the motorcycle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Victory recommends that you retain all receipts covering maintenance on your motorcycle, but Victory cannot deny warranty solel...

163 WARRANTIES III. Limited Liability A. The liability of Victory under this Emission Control System Warranty is limited solely to the remedying of defects in material or work-manship by an authorized Victory motorcycle dealer at its place of business during customary business hours. This warranty d...

164 WARRANTIES IV. Legal Rights THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARYFROM STATE TO STATE. V. This Warranty Is In Addition To The Victory Limited Motorcycle Warranty.VI. Additional Information. Any replacement part that is equivalent in performan...

165 WARRANTIES Victory Motorcycle Warranty Policy Limited Warranty Victory Motorcycle Division, Polaris Sales Inc., P.O. Box 47700, Hamel, Minnesota 55340-9960, gives a ONE YEAR LIMITED WARRANTY on all components of the Victory Motorcycle against defects in material or workmanship. This warranty cov...

166 WARRANTIES Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies The warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also ...

168 SPECIFICATIONS Model Year 2003 Classic Cruiser Touring Cruiser Dimensions Overall Length 94 in (239 cm) 98 in (249 cm) Overall Width 29.5 in (75 cm) 42 in (107 cm) Overall Height 44.5 in (113 cm) 60.8 (154 cm) Seat Height 28.3 in (72 cm) 28.3 in (72 cm) Wheelbase 63.3 in (161 cm) 65.5 in (166 cm...

172 SPECIFICATIONS Fuel Specifications Use only unleaded gasoline, 92 pump octane minimum.DO NOT USE GASOLINE CONTAINING METHANOL.Using gasoline/methanol blends can result in poor starting and driveability, and may damage critical fuel system components.Gasoline containing up to 15% Methyl Tertiary ...

173 SPECIFICATIONS Engine Oil Specifications Polaris recommends the use of Victory Brand Semi-Synthetic 20W-40 Motor Oil or equivalent. Service Manual Available You can purchase a genuine 2003 Victory Service Manual through your dealer. Order part number 9918370.

174 IDENTIFICATION NUMBERS Record important numbers below. Vehicle Identification Number: ________________________________________ (Located on right side of steering head, see page 42) Engine Identification Number: ________________________________________ (Located on top of crankcase behind rear cyl...

175 INDEX A Accelerating 87 . . . . . . . . . . . . . . . . . . . . Accessory Selection and Installation 20 . . Air Filter 100 . . . . . . . . . . . . . . . . . . . . . . Auxiliary Lights Adjustment 142 . . . . . . . Axle Front 111 . . . . . . . . . . . . . . . . . . . . Axle Rear 109 . . . . . . . ...