Victory Motorcycles 2005-2006 Hammer, 2006 Vegas Jackpot, 2006 Ness Signature Series Vegas Jackpot Service Manual

2005-2006 HAMMER

2006 VEGAS JACKPOT

& NESS SIGNATURE SERIES VEGAS JACKPOT

SERVICE MANUAL

TM

TM

2005-2006 Hammert

2006 Vegas Jackpott

2006 Ness Signature Series Vegas Jackpott

SERVICE MANUAL

Part Number 9920340

Foreword

This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept
available for reference in the shop area. All references to left (LH) and right (RH) side of the motorcycle are from the
operator’s perspective when seated in a normal riding position.

Some procedures outlined in thismanual require a sound knowledge of mechanicaltheory, tool use, and shop procedures
in order to perform the work safely and correctly. Read the text and be familiar with the service procedures before starting
the work. Certain procedures will require the use of special tools. Use only the proper tools as specified. If you have any
doubt as to your ability to perform any of the procedures outlined in this service manual, contact an authorized Victory
dealer for service.

This manual includes procedures for maintenance, component identification and repair, along with service specifications
for the models listed above. Comments or suggestions about this manual may be directed to: Service Publications Dept.
@ Polaris Sales Inc. 2100 Hwy 55 Medina, Minnesota 55340. Victory dealers can also use the on-line feedback forum
located at:www.polarisdealers.com underNews, Forms & Links/Service & Warranty/Polaris ManualFeedback link and fill
out the information on the form.

E 2005 Polaris Industries. All information contained in this publication is based on the latest product information available at the time of
publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and /or procedures in this publication are intended
for reference use only. No liability can be accepted for omissions or inaccuracies in this publication. Any reprinting or reuse of the depictions
and/or procedures contained in this publication is expressly prohibited. Printed in U.S.A.

GENERAL

1

MAINTENANCE

GENERAL &

MAINTENANCE

FRAME/BODY/EXHAUST

LUBRICATION & COOLING

FUEL SYSTEM/FUEL INJECTION

ENGINE REMOVAL & INSTALLATION

CYLINDER HEAD & VALVES

ENGINE

CYLINDER & PISTON

CLUTCH, PRIMARY, & SHIFT

TRANSMISSION & CRANKSHAFT

2
3

4

5
6

7

8

9

10

DRIVE LINE

FRONT WHEEL & SUSPENSION

REAR WHEEL & SUSPENSION

CHASSIS

TIRES

BRAKES

CHARGING SYSTEM

IGNITION SYSTEM & BATTERY

ELECTRIC STARTER

ELECTRICAL

LIGHTING & INSTRUMENTATION

11
12
13

14
15

16
17

18
19

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

TRADEMARKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SERVICE RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

UNDERSTANDING SAFETY LABELS & INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .1.4

REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

VICTORY TOUCH-UP AND REFINISHING PAINT / DETAIL & FINISHING KITS . . . . .1.5

PAINTING TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5

PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

PAINT COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

VEHICLE IDENTIFICATION NUMBER (VIN) & MODEL NUMBER DESCRIPTIONS. . . 1.8

VIN NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

MODEL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

KEY IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

PUBLICATIONS & TECHNICAL LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

MATERIAL SAFETY DATA SHEET (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

BREAK-IN PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

EMISSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

EMISSION CONTROL SYSTEMS / EMISSION SOURCES . . . . . . . . . . . . . . . . . . . . .1.11

EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

NOISE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

EVAPORATIVE EMISSION CONTROL (CALIFORNIA MODELS) . . . . . . . . . . . . . . . .1.12

INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

TRIP ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

INDICATOR LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

GENERAL & PRECISION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15

TUNE UP & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15

ENGINE, CLUTCH, & TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16

STEERING & SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16

WHEEL & TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

FUEL SYSTEM & FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

TRANSPORTING AND SECURING THE MOTORCYCLE. . . . . . . . . . . . . . . . . . . . . 1.18

ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19

WIRE HARNESS - LEFT REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19

WIRE HARNESS - RIGHT REAR FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

WIRE HARNESS - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

WIRE HARNESS - UNDER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23

1

1.1