Polaris 2004 Victory Vegas- Manuals

Page 2 - WARNING; The engine exhaust from this

WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Page 3 - We’ve created a web site just for YOU!; Technical tips

1 We’ve created a web site just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.victory-usa.com

Page 4 - VEGAS; t S; VEGAS ANSS

2 The text, photographs and illustrations used in this manual are based on the most current product information available at the time of publication. Product improvements or other changes may result in differences between this manual and the motorcycle. Polaris Industries reserves the right to make ...

Page 5 - FOREWORD; Thank you for choosing a Polaris VICTORY motorcycle!

3 FOREWORD Thank you for choosing a Polaris VICTORY motorcycle! This owner’s manual contains information for the VICTORY VEGAS and VEGAS Arlen Ness Signature Series (ANSS) models. Some of the photographs and illustrations used in the manual are generalizations, so your model may be slightly differen...

Page 6 - TABLE OF CONTENTS

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

Page 7 - INTRODUCTION; Read the Owner’s Manual; add to your enjoyment and keep you riding safely.

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...

Page 8 - SAFETY; Symbols and Terms Used in the Owner’s Manual; Notice

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...

Page 9 - Safe Riding Practices; operating the motorcycle.

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...

Page 10 - can make handling difficult, which could cause loss of control.

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 154, ...

Page 11 - Know your skills and limits, and ride within them.; VICTORY Service Manual

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

Page 12 - increase the possibility of losing control.; Reduce your speed when:

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...

Page 13 - Improper braking may cause loss

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...

Page 14 - and cause loss of control.; Carrying a Passenger; To carry a passenger safely, do the following:

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...

Page 15 - Protective Apparel; reducing head injuries.

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...

Page 16 - any additional cargo on the motorcycle.

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...

Page 17 - Example 1: VEGAS / VEGAS ANSS with no accessories or cargo; Total Weight; Item; Total Weight

15 SAFETY Example 1: VEGAS / VEGAS ANSS with no accessories or cargo Gross Vehicle Weight Rating 1135 lbs (515 kg) Item Weight VEGAS- with full capacity of all fluids 666 lbs (302 kg) Operator - with recommended riding apparel 220 lbs (100 kg) Passenger - with recommended riding apparel 155 lbs (70 ...

Page 18 - Carrying Cargo; guidelines also refer to the contents of any accessories.

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...

Page 19 - Saddlebags; Distribute weight evenly in each of the saddlebags.; Transporting the Motorcycle; If you must transport the motorcycle:

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...

Page 20 - Parking the Motorcycle; If in doubt, contact your authorized VICTORY Dealer.

18 SAFETY Parking the Motorcycle When leaving the motorcycle unattended, turn the engine off and remove the ignition key. See page 74.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...

Page 21 - Accessory Selection and Installation

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...

Page 22 - Gasoline and Exhaust

20 SAFETY Gasoline and Exhaust For complete fueling procedures, see page 65.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 ...

Page 23 - Maintenance; cycle or result in bodily injury.

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 49. Operating the motorcycle without completing the pre-operation check can cause damage to the motorcycle or result in an accident....

Page 27 - See page 26 for decal type and description.

25 SAFETY Location of Safety and Vehicle Information Labels (VEGAS / VEGAS ANSS) See page 26 for decal type and description. B D A C E

Page 28 - Information varies by model

26 SAFETY Location of Safety and Vehicle Information Labels (VEGAS / VEGAS ANSS) 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...

Page 29 - See page 28 for decal type and description.

27 SAFETY Location of Safety and Vehicle Information Labels (VEGAS / VEGAS ANSS) See page 28 for decal type and description. F

Page 30 - Location F

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

Page 31 - See page 30 for decal type and description.

29 SAFETY Location of Safety and Vehicle Information Labels (VEGAS / VEGAS ANSS) See page 30 for decal type and description. G H I

Page 32 - Location H (EMISSION CONTROL INFORMATION)

30 SAFETY Location of Safety and Vehicle Information Labels (VEGAS / VEGAS ANSS) Location G (TIRE SAFETY) Location H (EMISSION CONTROL INFORMATION) (California Models) (Canada Models) (49 State Models) Location I (PATENT NOTICE) (LH Rear of subframe down tube) (Catalyst Models Only)

Page 33 - Reporting Safety Defects; US Department of Transportation

31 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...

Page 34 - COMPONENT IDENTIFICATION; VEGAS / VEGAS ANSS Handlebar Components

32 COMPONENT IDENTIFICATION Use the information on the following pages to identify and locate the major components of the VICTORY VEGAS and VEGAS ANSS motorcycles, including the vehicle and engine identification numbers, model number and ignition key number. VEGAS / VEGAS ANSS Handlebar Components 1...

Page 35 - VEGAS / VEGAS ANSS Components

33 COMPONENT IDENTIFICATION VEGAS / VEGAS ANSS Components 1. Front Fork2. Front Turn Signal3. Headlamp4. Air Filter5. Spark Plug (2)6. Ignition Switch7. Left Side Cover8. Battery (under side cover)9. Rear Turn Signal10. Taillight11. Rear Brake Caliper12. Rear Axle Adjuster (1 each side)13. Horn14. P...

Page 37 - Vehicle Identification Number; or to order replacement parts.

35 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...

Page 38 - Engine Identification Number; VICTORY dealer can assist you in obtaining a replacement key.

36 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 cra...

Page 39 - INSTRUMENTS, FEATURES AND CONTROLS; Ignition Key; The ignition key operates the ignition switch and parking lights.; Ignition Switch; electrical switches and buttons.; Off Position; key can be removed. Turn the ignition switch to the OFF position and; On Position; flashers, turn signals and all other electrical features.; Caution

37 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...

Page 40 - Instrument Cluster; The instrument cluster includes the speedometer, the tachometer

38 INSTRUMENTS, FEATURES AND CONTROLS Instrument Cluster The instrument cluster includes the speedometer, the tachometer (accessory) and the multi-function display. 1. Speedometer2. Odometer / Trip Odometer 3. Odometer--Trip Odometer Toggle / Trip Odometer Reset Speedometer (1) The speedometer repor...

Page 41 - An accessory tachometer (1) is available through your VICTORY

39 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...

Page 42 - Indicator Lights; The neutral indicator illuminates when the transmission is

40 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 (...

Page 44 - Left Handlebar Controls

42 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 66). To engage the fast idle lever, move the lever toward the rear of the motorcycle until the lever stops. Headlamp High/Low Be...

Page 45 - The turn signal switch activates and cancels the turn signals. To; Clutch Lever; the transmission is in gear and the clutch is engaged (see page 66).

43 INSTRUMENTS, FEATURES AND CONTROLS Left Handlebar Controls Turn Signal Switch (3) The turn signal switch activates and cancels the turn signals. To activate the left turn signals, push the switch to the left; to activate the right turn signals, push the switch to the right. To cancel the turn sig...

Page 46 - Right Handlebar Controls

44 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...

Page 47 - Front Brake Lever

45 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...

Page 49 - Fuel Cap; The fuel cap must be opened and closed with the ignition key.

47 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...

Page 50 - Side Covers; The sidestand is located on the left side of the motorcycle.; the sidestand back into its fully retracted position.

48 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...

Page 52 - Check Electrical Equipment; neutral indicator should remain illuminated.; Headlamp; taillight brightness should increase.

50 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...

Page 53 - Turn Signals; Press the horn button. The horn should sound loudly.; Engine Stop/Run Switch; you use the motorcycle.

51 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 ...

Page 54 - Check Engine Oil Level; We recommend the use of only VICTORY brand Semi-Synthetic

52 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...

Page 55 - Check Fuel Components; Fuel Level; The light; Fuel Hose, Rail and Connections; dampness or stains from leaking or dried fuel.; Evaporative Emission Control System (California model only)

53 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 .8 gallons (3.0 liters) re...

Page 56 - Check Tires; Tire Pressure; tires immediately (see the; Tire Tread Depth

54 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 ...

Page 57 - Check Brakes; Front Brake Lever Movement

55 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 ...

Page 58 - Rear Brake Pedal Freeplay and Movement

56 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 112).Press...

Page 59 - Check Hoses and Connections; Check Throttle Control Grip and Cables

57 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...

Page 63 - Check Sidestand; position and back again. It should move smoothly and quietly. When; Check Fasteners; torque (see the specifications section of this manual or see the

61 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...

Page 64 - OPERATION

62 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 ...

Page 65 - Engine Break-in Period

63 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...

Page 66 - Owner’s Manual

64 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...

Page 67 - Fueling and Fill Height; the surrounding area.; switch from the STOP position to the RUN position 4-5 times.

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

Page 68 - Starting the Engine; restraints for tightness.

66 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...

Page 69 - motorcycle until the lever stops.

67 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...

Page 70 - Shifting Gears

68 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...

Page 71 - the clutch lever and open the throttle.

69 OPERATION Shifting Gears 1. To engage first gear, start the engine (see Starting the Engine on page 66).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 shift pedal down until you feel it stop in fi...

Page 72 - above that in the table of recommended shift points.; Recommended Shift Points

70 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...

Page 73 - Accelerating; the motorcycle accelerates.; open the throttle gradually.

71 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...

Page 74 - Braking; brakes gradually if you need to stop.

72 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...

Page 75 - Stopping the Engine; you may lose control.

73 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 ...

Page 76 - the motorcycle so that it is stable when it rests on the sidestand.

74 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...

Page 78 - MAINTENANCE

76 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...

Page 79 - Initial Maintenance; performance for its entire service life.; Periodic Maintenance Intervals

77 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...

Page 80 - Periodic Maintenance Interval Table

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 ...

Page 83 - MAINTENANCE RECORD

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

Page 85 - Engine Oil; Changing Engine Oil and Oil Filter (Oil Change Kit PN 2873551)

83 MAINTENANCE Engine Oil Changing 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 ...

Page 86 - Change Engine Oil and Oil Filter; by hand

84 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 ...

Page 87 - With the transmission in neutral, start and run the engine for

85 MAINTENANCE Engine Oil Check Engine Oil Level 1. With the transmission in neutral, start and run the engine for several minutes. 2. Shut the engine off and wait for 3-5 minutes.3. With the engine at normal operating temperature, straddle the motorcycle on level ground and bring it to a vertical p...

Page 88 - Inspect Air Filter; Wear face protection when using pressurized air.

86 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...

Page 89 - Inspect Drive Sprocket and Sprocket Nut

87 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...

Page 90 - Drive Belt; Check Drive Belt Condition; should be replaced at periodic intervals (see the; Check Drive Belt Tension; Make sure the drive belt is dry and at room temperature.

88 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...

Page 91 - zero force

89 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...

Page 92 - Adjust Drive Belt Tension; Before adjusting drive belt tension, inspect wheel

90 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...

Page 93 - Rear Wheel; Alignment

91 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...

Page 96 - Rear Suspension; Adjust Rear Shock Absorber

94 MAINTENANCE Rear Suspension Adjust Rear Shock Absorber This procedure involves using the shock absorber preload wrench, a special spanner tool available from your dealer. The tool is designed specifically for adjusting shock spring preload on your motorcycle. Notice The distance measured while th...

Page 97 - have that person sit on the passenger seat with riding gear on.

95 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...

Page 98 - spanner nut closest to the spring is the adjuster nut (2). Loosen the

96 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...

Page 99 - Inspect Swing Arm and Rear Axle; freely without binding.

97 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...

Page 100 - Front Suspension and Steering; Check Front Forks; times. The front suspension should operate smoothly and quietly.; Replace Front Fork Oil; procedures and special tools required, see the

98 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 ...

Page 101 - Inspect Steering and Front Axle; or a block of wood or steel placed securely under the frame.; steering head when checked (see the

99 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...

Page 102 - Fuel System; Check Crankcase Ventilation Hose and Connections; Remove the front and rear fuel tank mounting screws.

100 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...

Page 103 - line to the right of breather hose.; Replace Fuel Filter; tools required, see the

101 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 reinsta...

Page 104 - Fast Idle Lever and Cable; Move the fast idle lever. It should move smoothly from; Fast Idle Lever Freeplay

A 102 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 resistance...

Page 106 - Throttle; Check Throttle Control Grip and Cable

104 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...

Page 107 - Clutch; Check Clutch Lever and Cable

105 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...

Page 108 - Lubricate Clutch Lever; Remove clutch lever pivot nut and screw.

106 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 adjust...

Page 109 - Adjust Clutch Freeplay; Turn the cable adjuster in or out until the clutch freeplay (A)

107 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...

Page 110 - Lubricate Control Cables; Throttle Cables

108 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...

Page 111 - Brakes; Check Front Brake Lever Movement; see the; Lubricate Front Brake Lever

109 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)...

Page 112 - Check Front Brake Fluid Level; handlebars until the front brake fluid reservoir is level.; Add Front Brake Fluid; Wipe the area around the reservoir cover with a clean cloth.

110 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...

Page 113 - the brakes to malfunction.; Check Rear Brake Pedal Freeplay and Movement

111 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...

Page 114 - Adjust Rear Brake Pedal Freeplay; To check the rear brake fluid level, remove the right side

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

Page 115 - Add Rear Brake Fluid; placed securely under the frame.

113 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 brake ...

Page 117 - Check Brake Pads; VICTORY Service; Check Brake Disc

115 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...

Page 118 - Gear Shift Pedal; Adjust Gear Shift Pedal Height

116 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...

Page 119 - Tires; Check Tire Pressure

117 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 VEGAS / VEGAS ANSS Up to 200...

Page 120 - Check Tire Condition; tires immediately (see your; Check Tread Depth

118 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,...

Page 121 - Check Wheel Spokes

119 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...

Page 122 - Check or Replace Spark Plugs; condition of one plug is markedly different from the other, see the

120 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...

Page 123 - Remove the spark plug from the cylinder head with a 5/8 inch spark

121 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...

Page 124 - Check Engine Compression; check procedures and special tools required, see the; Check Exhaust System

122 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...

Page 125 - Seat Removal and Installation; cause a sudden shift in riding position, causing loss of control.

123 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 chrome covers. Always ma...

Page 126 - Battery; vegetable oil. Call physician immediately.; reason. Keep the battery connections clean and tight at all times.

124 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...

Page 127 - Battery Removal

125 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...

Page 128 - Battery Charging; The battery may contain explosive gases.; thin film of dielectric grease to the posts and cable connectors.

126 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...

Page 129 - Battery Installation

127 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...

Page 130 - Fuses; place. A spare 15 amp fuse is located in the fuse box.; Fuse Application

128 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...

Page 131 - Headlamp Adjustment

129 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 117)2. Verify suspension sag is 19-32mm (see pag...

Page 132 - Sidestand; Inspect Sidestand Pad; firmly attached to the sidestand.

130 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...

Page 133 - Sidestand Lubrication; Install the pivot bolt and tighten to specified torque.

131 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...

Page 134 - Road Test; safe and enjoyable vehicle performance.

132 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...

Page 136 - CLEANING; working order and appearance.; General Cleaning

134 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 ...

Page 137 - Washing and Drying the Motorcycle; into contact with electrical components or connectors.; reach with a cloth or a sponge.

135 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...

Page 138 - Dry these components thoroughly before using the motorcycle.; use on the type of surface you plan to clean.

136 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...

Page 139 - Waxing, Polishing and Applying Protectants; (Items Other Than Windshields and Leather Saddlebags); finish of painted surfaces.; motorcycle while riding, which may cause loss of control.

137 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...

Page 140 - Windshield Care; sponge clean by rinsing it frequently.

138 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...

Page 141 - Leather Saddlebag Care

139 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...

Page 142 - STORAGE; removing it from storage.; Storage Area Preparation; The storage surface should be free of oil and gasoline.; Clean and Protect the Motorcycle; Do not apply rubber protectant to the tire tread surfaces.

140 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;...

Page 143 - Fuel Stabilizer; the oil filter when you remove the motorcycle from storage.; oil you poured in the spark plug holes.

141 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...

Page 144 - Tire Inflation

142 STORAGE Tire Inflation Inflate the tires to normal pressure (see page 117). Battery Care 1. Remove the battery (see page 125).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...

Page 145 - Removal from Storage

143 STORAGE Removal from Storage 1. Remove the cover and unlock the front forks (if locked with accessory lock). 2. Check the tire pressure (page 117) and inflate the tires if necessary. 3. Reinstall the battery (see page 127).4. Wash and dry the entire motorcycle (see page 135). 5. Prior to startin...

Page 146 - WARRANTIES; Motorcycle Noise Regulation; Noise Emission Warranty

144 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...

Page 147 - Emissions Control System Warranty; Your Warranty Rights and Obligations

145 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...

Page 148 - Owner’s Warranty Responsibilities

146 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...

Page 151 - III. Limited Liability

149 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...

Page 152 - VICTORY Motorcycle Division, Polaris Sales Inc.

150 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...

Page 153 - VICTORY Motorcycle Warranty Policy; Limited Warranty

151 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...

Page 154 - Warranty Coverage And Exclusions:

152 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 ...

Page 156 - SPECIFICATIONS

154 SPECIFICATIONS Model Year 2004 VEGAS VEGAS ANSS Dimensions Overall Length 96.3 in (244.5 cm) 96.3 in (244.5 cm) Overall Width 38 in (97 cm) 38 in (97 cm) Overall Height 50.75 in (129 cm) 50.75 in (129 cm) Seat Height 26.5 in (67.3 cm) 26.5 in (67.3 cm) Wheelbase 66.5 in (169 cm) 66.5 in (169 cm)...

Page 160 - Fuel Specifications

158 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 ...

Page 161 - IDENTIFICATION NUMBERS; Record important numbers below.; Vehicle Identification Number:

159 IDENTIFICATION NUMBERS Record important numbers below. Vehicle Identification Number: ________________________________________ (Located on right side of steering head, see page 35) Engine Identification Number: ________________________________________ (Located on top of crankcase behind rear cyl...

Page 162 - INDEX

160 INDEX A Accelerating 71 . . . . . . . . . . . . . . . . . . . . Accessories 19 . . . . . . . . . . . . . . . . . . . . . Air Filter 86 . . . . . . . . . . . . . . . . . . . . . . . Axle, Front 99 . . . . . . . . . . . . . . . . . . . . . Axle, Rear 97 . . . . . . . . . . . . . . . . . . . . . . ...