Polaris 2004 Victory Kingpin- Manuals

3 FOREWORD Thank you for choosing a Polaris VICTORY motorcycle! This owner’s manual contains information for the VICTORY KINGPIN motorcycle. 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 misplace o...

4 TABLE OF CONTENTS FOREWORD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

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 152, ...

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 47. Operating the motorcycle without completing the pre-operation check may cause damage to the motorcycle or result in an acc...

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: KINGPIN with no accessories or cargo Gross Vehicle Weight Rating 1170 lbs (531 kg) Item Weight KINGPIN- with full capacity of all fluids 685 lbs (311 kg) Operator - with recommended riding apparel 220 lbs (100 kg) Passenger - with recommended riding apparel 155 lbs (70 kg) Total...

16 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...

17 SAFETY Saddlebags When operating a motorcycle with original equipment or accessory 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 o...

18 SAFETY Parking the Motorcycle When leaving the motorcycle unattended, turn the engine off and remove the ignition key. See page 72.Park the motorcycle where people are not likely to touch the hot engine or exhaust system or place combustible materials in close proximity to these hot areas. Do not...

19 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...

20 SAFETY Gasoline and Exhaust For complete fueling procedures, see page 63.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 Open the fuel cap ...

21 SAFETY Maintenance Maintain the motorcycle according to the following requirements: S Before each ride, complete a pre-operation check as outlined beginning on page 47. Operating the motorcycle without completing the pre-operation check can cause damage to the motorcycle or result in an accident....

23 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...

24 SAFETY Location of Safety and Vehicle Information Labels See page 25 for decal type and description. B C A D E

25 SAFETY Location of Safety and Vehicle Information Labels Location A (FUEL WARNING) Information on this decal will vary by model, features, and options. Refer to actual decal on the vehicle. Location B (MANUFACTURING DATE) Information varies by model Location C (NOISE EMISSION) Engine Identificati...

26 SAFETY Location of Safety and Vehicle Information Labels See page 27 for decal type and description. F

27 SAFETY Location of Safety and Vehicle Information Labels Location F FUSE and RELAY LOCATION (under side cover, on top of fuse box cover) FUSE BOX REMOVAL (on base of fuse box)

28 SAFETY Location of Safety and Vehicle Information Labels See page 29 for decal type and description. G H I

29 SAFETY Location of Safety and Vehicle Information Labels (49 State Models) Location G (TIRE SAFETY) Location H (EMISSION CONTROL INFORMATION) (California Models with catalyst) Location I (PATENT NOTICE) (LH Rear of subframe down tube) (Canada Models)

30 COMPONENT IDENTIFICATION Use the information on the following pages to identify and locate the major components of the VICTORY KINGPIN motorcycle, including the vehicle and engine identification numbers, model number and ignition key number. Handlebar Components 1. Clutch Cable2. Indicator Lamps3...

31 COMPONENT IDENTIFICATION Components 1. Front Fork2. Front Turn Signal3. Headlamp4. Speedometer5. Air Filter6. Spark Plug (2)7. Ignition Switch8. Left Side Cover9. Battery (under side cover)10. Taillight11. Rear Turn Signal12. Rear Axle Adjuster (1 each side)13. Rear Brake Caliper14. Passenger’s F...

33 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...

34 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 left crankcase behind the rear cylinder.The engine serial number is stamped into the rear of th...

35 INSTRUMENTS, FEATURES AND CONTROLS Ignition Key The ignition key operates the ignition switch and parking lights. Ignition Switch The ignition switch energizes the ignition, the lighting system, and all electrical switches and buttons. Off Position In the OFF position, all electrical circuits are...

36 INSTRUMENTS, FEATURES AND CONTROLS Instrument Cluster The instrument cluster includes the speedometer and the tachometer (if a tachometer is equipped as an accessory). 1. Speedometer2. Odometer / Trip Odometer 3. Odometer--Trip Odometer Toggle / Trip Odometer Reset Speedometer (1) The speedometer...

37 INSTRUMENTS, FEATURES AND CONTROLS Tachometer (Accessory) An accessory tachometer (1) is available through your VICTORY dealer. The tachometer reports current engine speed in revolutions per minute (RPM). A red line on the gauge indicates maximum safe engine RPM. Do not operate the engine over 56...

38 INSTRUMENTS, FEATURES AND CONTROLS Indicator Lights Neutral Indicator (1) The neutral indicator illuminates when the transmission is in neutral, and the ignition key is ON. Headlamp High Beam Indicator (2) The headlamp high beam indicator illuminates when the headlamp switch is set to high beam (...

40 INSTRUMENTS, FEATURES AND CONTROLS Left Handlebar Controls Fast Idle Lever (1) The fast idle lever increases the engine idle speed when starting a cold engine (see page 64). To engage the fast idle lever, move the lever toward the rear of the motorcycle until the lever stops. Headlamp High/Low Be...

42 INSTRUMENTS, FEATURES AND CONTROLS Right Handlebar Controls Engine Stop/Run Switch (1) 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 s...

43 INSTRUMENTS, FEATURES AND CONTROLS Right Handlebar Controls Starter Button (3) The starter button works only when the engine stop/run switch is in the RUN position and the transmission is in neutral or the clutch is disengaged. To engage the engine starter motor, press the right side of the start...

45 INSTRUMENTS, FEATURES AND CONTROLS Fuel Cap The fuel cap must be opened and closed with the ignition key. Lift the key slot cover (1) on the cap and insert key. Turn clockwise while pushing down lightly to release latch and open the cap. To close the fuel cap, turn key clockwise and press down on...

46 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, pull the lower corners of th...

48 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. Indicator Lights The l...

49 PRE-OPERATION CHECK Check Electrical Equipment Turn Signals Move the turn signal switch to the left. The front and rear left turn signals and the turn signal indicator light on the panel should flash. Push the switch button IN to cancel the turn signal. The turn signals and turn signal indicator ...

50 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...

51 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 watch the fuel indicator light on the panel. NOTE: The light will stay on if less than .4-.6 gallons (1.51-2.27 l...

52 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 ...

53 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 ...

54 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 .080 - .160 inch (2-4 mm). Adjust pedal freeplay as necessary (see page 109).Press...

55 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 at the front brake caliper pads at (1), and at rear r...

59 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...

60 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 ...

61 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...

62 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...

63 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 151). Fill the fuel tank to a level just below the bottom of the fuel filler insert. • Do not allow gasoline to ...

64 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. Perform th...

65 OPERATION Engine Break-in Period Starting the Engine 6. 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...

66 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...

67 OPERATION Shifting Gears 1. To engage first gear, start the engine (see Starting the Engine on page 64).2. With the engine at idle speed, engage the front brake (squeeze the brake lever) and disengage the clutch (squeeze the clutch lever). 3. Push the front peg of the shift pedal down with your t...

68 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...

69 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, p...

70 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...

71 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 ...

72 OPERATION Parking the Motorcycle When parking the motorcycle, choose a flat, firm surface. Bring the motorcycle to a complete stop and, with the transmission in neutral, stop the engine. Fully extend the sidestand, turn the handlebars to the left, and lean the motorcycle to the left until the sid...

74 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...

75 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...

79 MAINTENANCE MAINTENANCE RECORD MAINTENANCE PERFORMED MILES / KM NOTES PERFORMED BY:

81 MAINTENANCE Engine Oil Change Engine Oil and Oil Filter (Oil Change Kit PN 2873551) A hot engine or hot exhaust pipes can be hazardous. The engine and exhaust pipes are hot forsome time after the engine is stopped. Touching the engine or exhaust pipes while hot can causeserious burns. Allowing fl...

82 MAINTENANCE Engine Oil Change Engine Oil and Oil Filter 8. Make sure the new oil filter gasket is properly seated in the oil filter, and apply a thin film of clean engine oil to the gasket. Screw the new filter on until the gasket contacts the filter mounting plate. Tighten the filter by hand an ...

84 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 air filter element using the un...

85 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 sprocket cover screws (see the VICTORY Service Manual or an authorized VICTORY dealer). 2. Inspect drive s...

86 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). DO NOT attempt to check...

87 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...

88 MAINTENANCE Drive Belt Adjust Drive Belt Tension Care should be taken to be sure the motorcycle will not tip or fall while elevated. Severe personalinjury or death may occur if the motorcycle tips or falls. WARNING Notice Before adjusting drive belt tension, inspect wheel alignment. (See Align Re...

89 MAINTENANCE Rear Wheel Alignment A skewed rear axle can damage the drive belt, causing it to fail and loss of control of themotorcycle. WARNING Care should be taken to be sure the motorcycle will not tip or fall while elevated. Severe personalinjury or death may occur if the motorcycle tips or fa...

92 MAINTENANCE Rear Suspension Adjust Rear Shock Absorber This procedure involves using the shock absorber preload wrench, a special spanner tool available from your dealer (P/N PV-46993). The tool is designed specifically for adjusting shock spring preload on your motorcycle. Notice The distance me...

93 MAINTENANCE Rear Suspension Adjust Rear Shock Absorber 5. Load the motorcycle with all the things you intend to carry (cargo and accessories). With the motorcycle in an upright position, sit on the operator’s seat with your riding gear on, and if you plan on carrying a passenger, have that person...

94 MAINTENANCE Rear Suspension Adjust Rear Shock Absorber (Cont.) 10. The uppermost spanner nut on the shock is the locknut (1). The spanner nut closest to the spring is the adjuster nut (2). Loosen the locknut by turning it counterclockwise (as viewed from the top of shock absorber). 11. Adjust sho...

95 MAINTENANCE Rear Suspension Inspect Swing Arm and Rear Axle 1. Remove the swing arm pivot covers and tighten the swingarm pivot nut (located on the right side) while holding the left side of the pivot axle. Torque: 85 ft-lbs (115 Nm) 2. Reinstall the pivot nut covers.3. Sit in the operator’s seat...

96 MAINTENANCE Front Suspension and Steering Care should be taken to be sure the motorcycle will not tip or fall while elevated. Severe personalinjury or death may occur if the motorcycle tips or falls. WARNING Check Front Forks 1. To check the front suspension, straddle the motorcycle and bring it ...

97 MAINTENANCE Front Suspension and Steering Care should be taken to be sure the motorcycle will not tip or fall while elevated. Severe personalinjury or death may occur if the motorcycle tips or falls. WARNING Inspect Steering and Front Axle 1. Elevate the front of the motorcycle until the front wh...

98 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 se...

99 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 (2).6. Disconnect the tank vent line and carefully remove fuel tank.7. To reinstal...

A B 100 MAINTENANCE 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. Measure fast idle lever free-play (A), which is the amount of lever movement from the rest position to the point of cable resistan...

101 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...

102 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...

103 MAINTENANCE Clutch Lubricate Clutch Lever 1. Remove the right side cover. 2. Slide the rubber cover off the cable adjuster, and loosen the adjuster jam nut.3. Turn the cable adjuster all the way in. 4. Remove clutch lever pivot nut and screw. 5. Disconnect the clutch cable from the clutch lever....

104 MAINTENANCE Clutch Adjust Clutch Freeplay 1. Remove the right side cover. 2 Hold cable (1) and loosen the adjuster jam nut (2). Turn cable adjuster (3) while holding cable. 3 Turn the cable adjuster in or out until the clutch freeplay (A) is .010-.030 inch (.25-.75 mm). 4 Tighten the adjuster ja...

105 MAINTENANCE Lubricate Control Cables The following cables used on the motorcycle require periodic lubrication for smooth operation and maximum service life: S Throttle Cables S Clutch Cable S Fast Idle Lever Cable 1. Loosen the adjuster of the cable to be lubricated, and disconnect one end of th...

106 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)...

107 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 (1). The fluid should be clear a...

108 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...

109 MAINTENANCE Brakes Adjust Rear Brake Pedal Freeplay 1 If the pedal freeplay is outside of specification, push the dust boot (1) back to expose top of actuator rod (2). 2 Hold the actuator rod and loosen the lock nut (3). 3 Rotate the actuator rod as necessary to achieve the correct brake pedal f...

110 MAINTENANCE Brakes Check Rear Brake Fluid Level 1. To check the rear brake fluid level, remove the right side cover. Straddle the motorcycle and bring it to a vertical position. 2. View the brake fluid through the reservoir. The fluid should be clear and at a level between MIN and MAX. Add brake...

111 MAINTENANCE Brakes • Do not operate the rear 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 contain...

112 MAINTENANCE Brakes Check Brake Pads Look at the front brake caliper pads at (1), and at rear rear brake caliper pads at (2). 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 having less...

113 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...

114 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 KINGPIN Up to 200 lbs (91 kg...

115 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,...

116 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...

117 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...

118 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...

119 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...

120 MAINTENANCE Seat Removal and Installation There are two separate seats, the operator’s seat and the passenger seat. It is not necessary to remove the passenger seat for regular maintenance. The passenger seat mounting screws are located on each side of the seat under the side covers. Always make...

121 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...

122 MAINTENANCE Battery Battery Removal 1. Remove the left side cover and battery cover.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 first can produce an ele...

123 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...

124 MAINTENANCE Battery Battery Installation 1. Before installing the battery, make sure it’s fully charged and clean.2. Slide the battery into position in the battery tray with positive (+) terminal to rear of motorcycle.3. Connect the positive ( + ) battery cables, tighten securely and install the...

125 MAINTENANCE Fuses Use only recommended amperage fuses to avoid damage to the electrical system. Caution 1. Remove the right side cover and release the fuse box from the bracket.2. Release the tabs on each side of the fuse box cover, and remove the cover.3. Remove the damaged fuse from the fuse b...

126 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...

127 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. Wear face protection. The sidestand return spring is unde...

128 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 (page 114)2. Verify suspension sag is 25-35mm (see pag...

129 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...

131 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 ...

132 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...

133 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...

134 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...

135 CLEANING Windshield Care If your motorcycle is equipped with an optional windshield: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. Excess...

136 CLEANING Leather Saddlebag Care If your motorcycle is equipped with optional leather saddlebags: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...

137 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;...

138 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...

139 STORAGE Tire Inflation Inflate the tires to normal pressure (see page 114). Battery Care 1. Remove the battery (see page 122).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 parts...

140 STORAGE Removal from Storage 1. Remove the cover and unlock the front forks (if locked with accessory lock). 2. Check the tire pressure (page 114) and inflate the tires if necessary. 3. Reinstall the battery (see page 124).4. Wash and dry the entire motorcycle (see page 132). 5. Prior to startin...

141 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...

142 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...

143 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...

146 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 orworkmanship by an authorized VICTORY motorcycle dealer at its place of business during customary business hours. This warranty doe...

147 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 performa...

148 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...

149 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 ...

151 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 ...

156 IDENTIFICATION NUMBERS Record important numbers below. Vehicle Identification Number: ________________________________________ (Located on right side of steering head, see page 33) Engine Identification Number: ________________________________________ (Located on top of crankcase behind rear cyl...

157 INDEX A Accelerating 69 . . . . . . . . . . . . . . . . . . . . Accessory Selection and Installation 19 . . Air Filter 84 . . . . . . . . . . . . . . . . . . . . . . . Axle Front 97 . . . . . . . . . . . . . . . . . . . . . Axle Rear 95 . . . . . . . . . . . . . . . . . . . . . . B Battery 121-1...