Victory Kingpin 2004 Owner's manual

2004

Kingpin

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

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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

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2004 OWNER’S MANUAL

Kingpint

VICTORY Motorcycle Division, Polaris Industries Inc.

2100 Highway 55, Medina, Minnesota 55340-9800 Tele: (763) 417-8650 Fax: (763) 542 -0599

POLARIS, POLARIS THE WAY OUT and VICTORY MOTORCYCLES are registered trademarks of Polaris Industries Inc.

DUNLOP is a registered trademark of Dunlop Tire Corporation. LOCTITE is a registered trademark of LOCTITE Corporation.

D,397,976; D,398,065; D,407,169; D,409,551; D,416,831; D,436,561 with additional patents pending.

VEGAS and KINGPIN are trademarks of Polaris Industries Inc.

Features of VICTORY motorcycles are covered by U.S. Patent Nos.:

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 or damage your owner’s manual, you should purchase a replacement copy from an authorized VICTORY dealer. This manual should be considered part of the m otorcycle, and it should remain with the motorcycle when it’s sold.

If you have questions about the operation or maintenance of the motorcycle after you’ve read this manual, please contact an authorized VICTORY dealer. To locate the nearest authorized VICTORY dealer, call 1-800-POLARIS and provide the area code or zip code of your location. Visit www.polarisindustries.com for a listing of authorized VICTORY dealers by state, zip code or area code.

Your authorized VICTORY dealer will resolve all issues regarding your motorcycle. If you’re not satisfied with the performance of your VICTORY dealer, please contact the Polaris Consumer Service Department at 763-417-8650.

VICTORY motorcycles comply with all federal, state and local safety and emission regulations for the area of intended sale.

TABLE OF CONTENTS

FOREWORD 3.....................................................................

INTRODUCTION 5..................................................................

SAFETY 6.........................................................................

COMPONENT IDENTIFICATION 30..................................................

INSTRUMENTS, FEATURES AND CONTROLS 35.....................................

PRE-OPERATION CHECK 47.......................................................

OPERATION 60...................................................................

MAINTENANCE 74................................................................

MAINTENANCE RECORD 79.......................................................

CLEANING 131....................................................................

STORAGE 137....................................................................

WARRANTIES 141.................................................................

SPECIFICATIONS 151..............................................................

IDENTIFICATION NUMBERS 156....................................................

INDEX 157........................................................................

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 information found in the safety section beginning on page 6. Understand and follow the procedures in your owner’s manual to keep your VICTORY motorcycle in top condition on the road or in storage. Bring the manual with you when you ride. Following the precautions and procedures in the manual will add to your enjoyment and keep you riding safely.

WARNING

Failure to follow the safety precautions and operation and mainten ance procedures outlined in this manual may result in death or injury (to you or your passenger) or damage to the motorcycle.

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 safety alert symbol indicates a potential for personal i njury to you or others.

WARNING

The safety alert warning indicates a potential hazard that could result in serious injury or death.

Caution

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the motorcycle.

Caution

A caution indicates a situation that may result in damage to the motorcycle.

Notice A notice highlights important information you must pay attention to.

SAFETY

Safe Riding Practices

WARNING

Improper use of this motorcycle can result in serious in jury or death to you, your passenger and others. To minimize the risk of injury, read and understand the information contained in this section before operating the motorcycle. This section contains safety information specific to the VICTORY motorcycle, as well as information about general motorcycle safety. Anyone who uses the motorcycle (operators and passengers) must follow these safety precautions.

Motorcycling has inherent risks. You can minimize those risks, but you can’t eliminate t hem completely. Even if you’re an experienced motorcycle operator or passenger, read all of the information in this safety section before operating the motorcycle.

S Your ability to safely operate the motorcycle depends on your judgment and your use of safe riding habits. Take a

rider education course from the Motorcycle Safety Foundation or another qualified instructor. The course will help you develop or refresh your expertise in safe riding habits through instruction and riding. For information on Motorcycle Safety Foundation rider education courses in your area, call 1-800-446-9227 or visit their homepage at http://msf-usa.org.

S Read and understand all information in t his owner’s manual. It contains safety information specific to individual

components and operations.

S Pay close attentionto the motorcyclemaintenance requirements in this m anual.For additional information or

assista nce wi t h technical services speci fi ed in the manual o r required by mechanical circumstances, see the VICTORY Service Manual (Part Number 9918961) or your authorized VICTORY Dealer.

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, or the certification label on the steering head). Riding off-road, riding with more than one passenger, or carrying weight exceeding the maximum weight rating can make handling difficult, which could cause loss of control.

S In the first 500 miles, operate the motorcycle according to the break-in procedures described on page 61. Operat-

ing the motorcycle without following break-in procedures can result in serious engine damage.

S Some VICTORY motorcycles include saddlebags, a windshield, and a passenger backrest as standard equipment.

To maintain stability, be prepared to reduce the operating speed of motorcycles equipped with these accessories.

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 accident.

S Until you’re thoroughly familiar with the VICTORY motorcycle and all of its controls, practice riding where

there is little or no traffic. Practice riding at a moderate speed on varying road surfaces and under varying weather conditions.

S Know your skills and limits, and ride within them.

S Allow only licensed, experienced operators to ride your motorcycle, and then only after they have become familiar

with its controls and operation.

S Do not ride when you’re fatigued or under the influence of alcohol, prescription drugs, over-the-counter drugs or

any other drugs. Fatigue, alcohol and drugs can cause drowsiness, loss of coordination and loss of balance. They can also affect your awareness and judgment.

S If your motorcycle operates abnormally, correct the problem immediately (see the VICTORY Service Manual or

contact your authorized VICTORY dealer). If you continue to operate a motorcycle i n this condition, you are likely to aggravate the initial problem, increase the cost of repairs and threaten your safety.

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 motorists, and observe their behavior carefully, as they may not see or be aware of you.

S Be especially cautious at intersections, as these are the most likely places for an accident.

S To prevent loss of control while operating the motorcycle, keep your hands on the handlebars and your feet on the

footrests.

S Obey the speed limit and adjust your speed and riding technique based on road, weather and traffic conditions. As

you travel faster, the influence of all other conditions increases, which can affect the motorcycle’s stability and increase the possibility of losing control.

S Do not move or operate the motorcycle with the steering locked (with accessory lock), as the severely restricted

steering could result in loss of control.

S Reduce your speed when:

- The road has potholes or is otherwise rough or uneven.

- The road has sand, dirt, gravel or other loose substances on it.

- The road is wet, icy or oily.

- The road contains painted surfaces, manhole covers, metal grating, railway crossings or other slippery surfaces.

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 direction by a large vehicle that produces a wind blast in its wake.

S To maximize braking effectiveness, use the front and rear brakes together. Improper braking may cause loss

of control or may not slow the vehicle in time to avoid a collision. Be aware of the following braking facts and practices:

- The rear brake provides 40% of the motorcycle’s stopping power, at most.

- Consider road conditions before applying the brakes. When the road is wet or rough, or contains loose or other slippery substances, apply the brakes gradually.

- Bring the motorcycle to the upright position before applying the brakes, and avoid applying the brakes in a corner if at all possible. When the motorcycle is leaning through a corner, the amount of traction available for braking is reduced, increasing the possibility of the tires skidding when the brakes are applied.

S When approaching a curve, choose a speed and lean angle t hat allows you to pass through the curve in your own

lane without applying the brakes. Excessive speed, improper lean angle or braking in a curve can cause loss of control.

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 retracted, it could contact the road surface

and cause loss of control.

S Do not tow a trailer. Towing a trailer can make the motorcycle hard to handle, which could cause loss of control.

Carrying a Passenger

To carry a passenger safely, do the following:

S Direct the passenger to hold onto you or the seat strap with both hands and to keep both feet on the passenger

footrests. Do not carry a passenger who cannot place both feet firmly on the passenger footrests. A passenger who is not holding on properly, or who cannot reach the passenger footrests, can shift their body erratically, which can make the motorcycle hard to handle and cause loss of control.

S If necessary, adjust the rear shock absorber preload according to the instructions on page 92. Improper preload

adjustment can make your motorcycle hard to handle and can cause loss of control.

S Before riding, be sure your passenger knows safe riding procedures. Discuss any safety information unfamiliar to

your passenger. A passenger who is unaware of safe riding procedures may distract you or make movements that make the motorcycle hard to handle.

S Adjust your riding style to compensate for the differences in handling, acceleration and braking caused by the

additional weight of the passenger. Failure to do so can cause loss of control.

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 motorcycles, head injuries are the leading cause of motorcyclist

fatalities , and s tati s ti cs prove that a n approved helmet is the most effectiv e protection in preventing or reducing head injuries.

S Wear eye protection. Some state laws require that you wear eye protection. Eye protection reduces the chance that

your vision could be impaired by wind or by airborne particles and objects.

S You and your passenger should wear bright or light colored and/or reflective clothing to improve visibility to oth-

er motorists. A motorist’s failure to see or recognize a motorcycle is the leading cause of automobile/motor-

cycle accidents.

S Wear gloves, a jacket, heavy boots and long pants to prevent or reduce abrasions, lacerations or burns should the

motorcycle fall.

S Wear boots with low heels, as high heels can catch on pedals or footrests. The combination of boots and pants

should completely cover legs, ankles and feet, protecting skin from engine and exhaust system heat. The engine and exhaust system get hot soon after the engine is started and stay hot for about half an hour after the engine is turned off.

S Do not wear loose, flowing clothing or long boot laces, as they can catch on handlebars, levers or footrests, or

become entangled in the wheels, causing loss of control and serious injury.

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 motorcycle.

S The weight of the operator or passenger includes body weight, all apparel and objects in or on apparel.

Examples of calculating GVWR are provided on page 15.

Do not exceed the motorcycle’s gross vehicle weight rating. Exceeding the weight rating can reduce stability and handling and could cause loss of control.

Refer to t he specifications section of this manual (beginning on page 152) or the certification label on your motorcycle’s steering head for model-specific GVWR i nformation.

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 Weight 1060 lbs (481 kg)

Example 2: KINGPIN with Touring Package and cargo

Gross Vehicle Weight Rating 1170 lbs (531 kg)

Item Weight

KINGPIN - with full capacity of all fluids 685 lbs (311 kg)

Weight of Touring Package (Hard Bags & Brackets) 33 lbs (15 kg)

Cargo - saddlebags at capacity 14 lbs (6 kg)

Operator - with recommended riding apparel 220 lbs (100 kg)

Passenger - with recommended riding apparel 155 lbs (70 kg)

Total Weight 1107 lbs (502 kg)

NOTE: As shown in Example 2, the weight of any accessory items (touring package or individual items) in addition

to the cargo, must be added to the base weight of the KINGPIN. NEVER exceed GVWR. If you have any questions regarding safe loading of your VICTORY motorcycle, please consult an authorized VICTORY dealer.

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-

mize a change in the motorcycle’s center of gravity. Changing the center of gravity can cause loss of stability and handling and result in loss of control.

S Distribute weight evenly on both sides of the motorcycle. Maintain even weight distribution by checking accesso-

ries and cargo to make sure they’re securely attached to the motorcycle before riding and whenever you take a break from riding. Uneven weight distribution, or accessories or cargo that shift suddenly while you’re riding can make the motorcycle hard to handle and result in loss of control.

S Do not attach large or heavy cargo such as sleeping bags, duffel bags or tents to the handlebars, front fork area or

front fender . Cargo or accessories placed in these areas can cause instability (due to improper weight distribution or aerodynamic changes) and can cause loss of control. Such items can also block air flow to the engine and cause overheating that can damage the engine.

S Do not exceed the maximum cargo weight limit of any accessory (see accessory instructions and labels), and do

not attach cargo to an accessory not designed for that purpose, as these could result in an accessory failure that could cause loss of control.

S Never mount anything but Victory approved accessories to the highway bar.

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 or buffeting effects of wind, can make the motorcycle unstable and cause loss of control.

S Distribute weight evenly in each of the saddlebags. S Do not exceed the maximum cargo weight limit of the saddlebags. Hard bags (KINGPIN) or accessory leather

saddlebags are 7 lbs. (3.2 kg) each.

S Do not exceed the motorcycle’s gross vehicle weight rating. Exceeding the weight rating can reduce stability and

handling and cause loss of control.

Transporting the Motorcycle

If you must transport the motorcycle:

S Use a truck or trailer. Do not tow the motorcycle with another ve-

hicle, as towing will impair the motorcycle’s steering and handling, which can cause loss of control.

S Position and restrain the motorcycle so it remains upright on the

truck or trailer, as gasoline may leak out of the fuel tank if the motorcycle leans to one side. Gasoline is a fire hazard and it can also damage the motorcycle’ s finish.

S Place the transmission in first or second gear. S Do not restrain the motorcycle using the handlebars. Place tie-downs

around the fork tubes above the lower triple clamp. Secure the rear of the motorcycle with tiedowns around the swingarm or rear wheel, being careful to avoid the brake line, exhaust, and drive belt.

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 park near a flammable source such as a kerosene heater or an open flame, where hot components could ignite combustible materials.

Park the motorcycle on a firm, level surface. Sloped or soft surfaces may not support the motorcycle when it’s parked, and it may tip over. If you must park on a slope or soft surface, follow the precautions outlined on page 72.

Modifications

Modifying the motorcycle by removing any equipment or by adding equipment not approved by VICTORY may void your warranty. Such modifications may make the motorcycle unsafe to ride and could result in severe injury to operator or passengers, as well as damage to the motorcycle. Some modifications may also be illegal in some states. If in doubt, contact your authorized VICTORY Dealer.

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. Use the following guidelines when choosing and installing accessories:

S Do not install accessories that impair the stability, handling or operation of the motorcycle. B efore installing an

accessory, be sure that it does not:

- Reduce ground clearance when the motorcycle is either leaned or in a vertical position.

- Limit suspension or steering travel or your ability to operate controls.

- Displace you from your normal riding position.

- Obscure lights or reflectors.

S Bulky or large accessories can cause instability (due to the lifting or buffeting effects of wind) and loss of control.

S Do not install electrical accessories that exceed the capacity of the motorcycle’s electrical system. Never install

higher wattage light bulbs than those supplied as original equipment. An electrical failure could result and cause hazardous loss of engine power or lights or damage to the electrical system.

S If you want to add a windshield, backrest or luggage rack, choose one designed and approved by VICTORY

specifically for your model. Follow the instructions for proper installation and use. An improperly designed or installed windshield, backrest or luggage rack can reduce stability, causing loss of control.

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 t he engine. S Use a well-ventilated area. S Open the fuel cap slowly. S Do not spill gasoline on t he engine or the exhaust system. Immediately wipe, or rinse with water, gasoline spilled

on any part of the motorcycle or the surrounding area.

S Do not smoke while fueling. S Do not fuel in an area where there are sparks or open flame.

Gasoline and gasoline vapors are poisonous and can cause severe injury. Do not swallow gasoline, inhale gasoline vapors, or spill gasoline on yourself or your clothes. If you swallow gasoline, inhale more than a few breaths of gasoline vapor, or get gasoline in your eyes, see a physician immediately. If you spill gasoline on your skin, wash it off immediately with soap and water. If you spill gasoline on your clothes, change your clothes immediately.

Exhaust gases contain carbon monoxide, a colorless, odorless gas that can cause unconsciousness or severe injury. Observe the following precautions to avoid the effects of exhaust gases:

S Do not inhale exhaust gases. S Do not start or run the engine in an enclosed area.

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.

S Perform peri o di c maintenance according to the int erval s outlined in the Periodic Maintenance Interval tables

beginning on page 75. Operating the motorcycle without performing periodic maintenance can damage the motorcycle or result in bodily injury.

S Maintain proper tire pressure and tread condition and proper wheel and tire balance. Inspect tires regularly and

replace them if they’re worn or damaged. Use only an approved replacement tire and see the VICTORY Service Manual or your authorized VICTORY Dealer for tire replacement. Operating the motorcycle with improper tire pressure or tread condition, or improper wheel or tire balance, can make the motorcycle hard to handle and cause loss of control.

S Check proper steering head bearing adjustment. Regularly inspect the rear shock absorber and the front forks.

Check for fork oil or shock absorber fluid leaks. Operating the motorcycle with a loose, worn, or damaged steering system or front or rear suspension system can make the motorcycle hard to handle and cause loss of control. T o repair steering or suspension system wear or damage, see the VICTOR Y Service Manual or contact your authorized VICTORY Dealer.

SAFETY

Maintenance

S Keep the motorcycle clean. In addition to extending the service life and the original appearance of the motorcycle , a

complete and thorough cleaning can reveal items in need of repair. F or complete cleaning procedures, see page 131.

S Keep equipment required by federal, state, and local laws in place and in good working condition. Your license

plate must be clean, clearly visible in all conditions, and installed in a position specified by law.

S Each fastener used in the motorcycle meets our quality specifications for strength, finish and type. When replace-

ment fasteners are needed, use only genuine VICTORY parts, tightened to the proper torque. A fastener that does not meet original specifications could fail and result in damage to the motorcycle or injury to riders.

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 similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer or Polaris Industries.

To contact NHTSA, or obtain other information about motor vehicle safety, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393, visit the NHTSA website at www.nhtsa.dot.gov, or write to:

NHTSA US Department of Transportation 400 7th Street Southwest Washington, DC 20590