Victory Motorcycles Classic Cruiser 2002, Touring Cruiser 2002, Classic Cruiser 2004, Touring Cruiser 2004, Classic Cruiser 2003 Service Manual
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2002 - 2004 SERVICE MANUAL
Part Number 9918960
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 and right side of the motorcycle are from the operator’s
perspective when seated in a normal riding position.
Some procedures outlinedin this manual requirea sound knowledge of mechanical theory,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.
This manual includes procedures for maintenance, component identification and repair, along with service specifications
for Victory ClassicCruiser and TouringCruiser motorcycles.Comments or suggestions about this manual may be directed
to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina, Minnesota 55340.
2002 - 2004 Victory Standard, Deluxe, Classic, and Touring Cruiser Service Manual PN9918960.
Refer to page 1.6 for Owner’s Manual, Parts Book, and Microfiche part numbers.
E 2003 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
Maintenance
Frame/ Body/ Exhaust
Lubrication & Cooling
Fuel System / Fuel Injection
Engine Removal & Installation
Cylinder Head & Valves
Cylinder & Piston
Clutch, Primary , & Shift Linkage
Transmission & Crankshaft
Drive Line
Front Wheel & Suspension
Rear Wheel & Suspension
Tires
Brakes
Charging System
Ignition System & Battery
Electric Starter
Lighting & Instrumentation
UNDERSTANDING SAFETY LABELS & INSTRUCTIONS 1.1...............
DANGER, WARNINGS, & CAUTION SYMBOLS 1.1.......................
GENERAL SAFETY / SERVICE RULES 1.2..............................
VICTORY TOUCH UP PAINT AND REFINISHING KITS 1.3.................
VICTORY PAINT COLORS AND PAINT CODES 1.4.......................
VEHICLE IDENTIFICATION NUMBER (VIN) 1.5...........................
KEY IDENTIFICATION NUMBERS 1.5...................................
MODEL IDENTIFICATION NUMBER 1.5.................................
ENGINE NUMBER DECAL 1.5..........................................
BREAK-IN PROCEDURES 1.6..........................................
PUBLICATION PART NUMBERS 1.6.....................................
EMISSION CONTROL SYSTEMS 1.7....................................
EMISSION SOURCES 1.7..............................................
EXHAUST EMISSION CONTROL 1.7....................................
NOISE EMISSION CONTROL SYSTEM 1.7..............................
EVAPORATIVE EMISSION CONTROL CONTROL (CA MODELS) 1.7.......
CRANKCASE EMISSION CONTROL 1.7.................................
MULTI-FUNCTION DISPLAY (MFD) 1.8..................................
MFD FUNCTION FLOW CHART 1.10.....................................
SPECIAL SERVICE TOOLS 1.11.........................................
CABLE & HARNESS ROUTING 1.14......................................
TRADEMARKS
Victory acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shocks
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
UNDERSTANDING SAFETY LABELS & INSTRUCTIONS
DANGER, WARNINGS, & CAUTION SYMBOLS
This is the safety alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury. Your safety is involved!
Gasoline is extremely flammable and explosive under certain
conditions.
GENERAL
Indicates a potential hazard which could result in severe injury or
death.
Indicates a potential hazard whichmay result in minor personal
injury or damage to the motorcycle.
Indicates a situation that can result in damage to the motorcycle.
NOTE:
The word “NOTE:” in this manual will alert you to key information
or instructions.
The engine exhaust from this product
contains chemicals known to cause cancer,
birth defects or other reproductive harm.
Never run the engine in an enclosed area
without a properly functioning exhaust gas
evacuation system connected to the product.
Improper repairs or service can create
unsafe conditions that may cause severe
personal injury or death.
Modifications to this motorcycle not approved
by Victory may cause loss of performance,
excessive emissions, and make the machine
unsafe for use.
S Always stop the engine and refuel outdoors or in a
well ventilated area.
S Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
S Do not overfill the tank. Do not fill the tank neckabove
the fuel tank insert. Leave air space to allow for fuel
expansion.
S If you get gasoline in your eyes or if you swallow
gasoline, see your doctor immediately. Never try to
syphon gasoline using mouth suction.
S If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
S Never start the engine or let it run in an enclosedarea.
Engine exhaust fumes are poisonous and can cause
loss of consciousness or death in a short time.
The engine and exhaust components on this
product become very hot during operation
and remain so for a period of time after the
KEEP OUT OF REACH OF CHILDREN.
engine is stopped.
Brake fluid is poisonous.
Wear insulated protection for hands and
arms or wait until hot components have
cooled suf ficiently before working on the
product.
Brake fluid will damage plastic, painted and rubber parts. Protect
these surfaces whenever the brake system is being serviced.
Brake fluid is poisonous. Do not ingest or
allow brake fluid to contact eyes. Always
wear eye protection when working with
brake fluid.
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing.
1.1
GENERAL
SERVICE RULES
In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual
and familiarize themselves with the procedures before beginning. Photographs and illustrations have been
included with text as an aid. Notes, Cautions and Warnings have also been included for clarification of text and
safety concerns. Knowledge of mechanical theory, tool use and shop procedures are necessary to perform some
procedures in this manual safely and correctly.
Use only genuine Victory service parts.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act
as an abrasive and cause damage to precision parts. Clean the motorcycle before beginning service. Clean all
parts before installing.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or in the case of steering, driveline, and chassis components, can result in loss of control during
operation of the motorcycle, resulting in injury or death.
If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners in their
holes and hand tighten. Following the method and sequence indicated, tighten evenly to the specified torque value.
When removing nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn
before removing them to prevent distortion of that component.
If the condition of any gasket or o-ring is in question, replace it with a new one. Be sure the mating surfaces for
the gasket are clean and smooth to avoid leaks and maintain specified tolerances.
Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts,
therefore, they should always be replaced with new parts. When installing new retaining rings and clips, use care
not to expand or compress them beyond what is required for installation.
Because removal damages seals, always replace with new seals during a repair.
Victory lubricants and greases have been specially formulated to provide maximum performance and
protection when applied properly. In some applications, warranty coverage may be void if improper lubricants are
used.
Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly.
Deteriorating grease loses lubricity and may contain abrasive foreign matter.
WARNING
Working with Batteries
S When removing or installing batteries, care should be taken to avoid the possibility of explosion
resulting in serious burns. Remove battery from the motorcycle before charging. Keep battery away
from the source of any combustion (sparks, fire, etc..) when charging.
S Always disconnect the negative (black) cable first and reconnect it last.
S Battery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with
skin, eyes or clothing.
S IN THE EVENT OF CONTACT WITH SULFURIC ACID: External - Flush with water. Internal -Drink
large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call for
medical attention immediately.
S Eyes - Flush with water for 15 minutes and call for medical attention immediately.
1.2
GENERAL
VICTORY TOUCH-UP AND REFINISHING PAINT
Service Paint products are available in three different sizes and applications. Some paint colors require up to 3
components to create a color. Prices subject to change without notice. Dealer is responsible for freight on paint
and paint products.
.6 ounce bottle: (Order Multiple of 2) For brush touch--up of small nicks.
10 ounce aerosol can: (Order Multiple of 2)
Apply light even coats for best results. Recoat time is from 30-60 minutes or after 4 days of drying to prevent lifting.
Quarts: (Sold as each)
For repaint of properly prepared plastic components or metal substrates.
Paint is a high quality acrylic urethane manufactured by U.S. Paint.
Mix as indicated on back of paint can. Paint can be recoated after paint is tack free or has ”flashed off”.
Paint finish may be wet sanded and buffed after coating has cured.
Paint is available in a variety of sizes and styles for specific painting needs:
How to order:
Place your order via the dealer web site at : www.polarisdealers.com
Phone Customer Service: 1--800--330--9407
Fax your paint order to 1--866--245--7533 using the supplied paint order form.
Prices subject to change without notice.
Please have your dealer number, telephone number, and Polaris part # to give to the Customer Service Specialist,
or include on the order form. Additional charges may apply for phoned in orders.
Note: There will be a 25% service fee charged for all returns. Polaris dealer will be responsible for return freight.
VICTORY DETAIL AND FINISH RESTORER KITS
A Detail Kit (polish, wax, and dressing) and a Restore Kit (Polish, Swirl, and Scuff remover) is available from the
Victory parts department for painted surface protection and to remove minor surface imperfections.
Detail Kit: 2872195 Restore Kit: 2872192
1.3
GENERAL
VICTORY PAINT COLORS BY MODEL
NOTE: The 8th Position in the model number is a letter that designates the country / region:
C=Canada; D=49State; L=California; U=United Kingdom
The last letter is the color designator. Refer to the chart below for model / color. Paint ordering information is
available on the dealer web site.
MODEL YEAR 2002
Model Number Model Description / Color Model Number Model Description / Color
V02CB16CC,DC,LC,UC Std. Crsr. Cruiser Black
V02CB16CK,DK,LK,UK Std. Crsr. Solar Red / Stone White V02TB16CO, DO, LO, UO TC Solar Red / Vogue Silver
V02CB16CL,DL,LL,UL Std. Crsr. Speed Yellow / Crs Black V02TB16CP, DP, LP, UP TC Sonic Blue / Vogue Silver
V02CD16CC,DC,L C,UC Dlx. Crsr. Cruiser Black V02TD16CC, DC, LC, UC TC Dlx. Cruiser Black
V02CD16CK,DK,LK,UK Dlx. Crsr. Solar Red / Stone White V02TD16CO, DO, LO, UO TC Dlx. Solar Red / Vogue Silver
V02CD16CL,DL,LL,UL Dlx. Crsr. Speed Yellow / Crs Black V02TD16CP, DP , LP , UP TC Dlx. Sonic Blue / Vogue Silver
V02CD16CM, DM, LM ,UM Dlx. Crsr. Sonic Blue / Pearl White V02TD16CQ, DQ, LQ, UQ TC Dlx. Cruiser Black/V ogue Silver
V02CD16CN,DN,L N,UN Dlx. Crsr. Cobalt Green / Pearl White V02TD16CR, DR, LR, UR TC Dlx. Champagne / Pearl white
MODEL YEAR 2003
Model Number Model Description / Color Model Number Model Description / Color
V03C116 / V03C216 Classic Feature / Option V03T116 / V03T216 TC Feature / Option
V03CB16CA, DA, LA, UA Classic Cruiser Black V03TB16CA, DA, LA, UA TC Cruiser Black
V03CB16CB, DB, LB, UB Classic Sonic Blue V03TB16CB, DB, LB, UB TC Sonic Blue
V03CB16CC, DC, LC, UC Classic Solar Red V03TB16CC, DC, LC, UC, TC Solar Red
V03CB16CD, DD, LD, UD Classic Flame Yellow
MODEL YEAR 2004
Model Number Model Description / Color Model Number Model Description / Color
V04T118 Touring Feature / Option V04TB16CB, DB, LB Touring Sonic Blue
V04TB16CA, DA, LA Touring Cruiser Black V04TB16CC, DC, LC Touring Solar Red
V02TB16CC, DC, LC, UC TC Cruiser Black
VICTORY PAINT CODES
PAINT COLORS PAINT CODE PAINT COLORS PAINT CODE
Cruiser Black (PHAT) P-266
Indy Red P-293 Cobalt Green P-353
Steel Grey P-302 Vogue Silver P-354
Speed Y ellow P-323 Champagne P-355
Sparkle Grey
P-339
(Fork Legs, Triple Clamp)
Sonic Blue P-341 Flame Yellow P-388
Solar Red P-342 Retro Turquoise P-389
Stone White P-351 Daytona Orange P-393
Flame Tank (All Years) paint codes are made up of Indy Red, Stone White, Speed Yellow, and Daytona
Orange
1.4
Pearl White P-352
VEHICLE IDENTIFICATION NUMBER
GENERAL
SAE--assigned
World Manufacturing Identifier
MODEL NUMBER
Chassis:
C =Kingpin
T = Touring
G = Vegas
N = ANSS
Type:
B = Standard
*5VPCB16D032000000*
Engine Size:
1 = 1507 cc
Engine HP:
6 = 78-- 94
Chassis:
C = Kingpin
T = Touring
G = Vegas
N = ANSS
Victory
2 = 2002; 3 = 2003; 4 = 2004; etc.
V04TB16DC
Model Year:
Series:
C = Canada
D = Domestic (49 State)
L = California
U = United Kingdom
Plant Code
Check Digit Model Year:
2=2002, 3 = 2003, 4=2004, etc.
Engine HP:
6 = 78-- 94
Type:
B = Standard
D=Deluxe
Serial Number
Series:
C = Canada
D = Domestic (49 State)
L = California
U = United Kingdom
Color Indicator:
See Chart on page 1.4
IGNITION KEY IDENTIFICATION NUMBERS
The key identification number (1) is stamped on the key tag. If the
key and the identification number are lost or misplaced, the lock set
(ignition switch, seat lock (where applicable), and steering lock) must
be replaced.
Key blanks are available from service parts. Locksmiths familiar with
the motorcycle industry will be able to cut a replacement key with the
key I.D. number and a VIctory key blank.
Should the keys and key identification number become lost, the
ignition switch must be replaced.
VEHICLE IDENTIFICATION NUMBER (VIN)
The vehicle identification number (2) is stamped on the front of the
steering head.
MODEL IDENTIFICATION NUMBER
The model label (3) is located on the left side of the steering head.
ENGINE NUMBER DECAL
1
3
2
4
The engine label (4) is located on top of the crankcase behind the rear
cylinder. Thislabel identifies the engine model and serialnumber. The
engine serial number is also stampedon the crankcase just to the right
of the oil filter.
1.5
GENERAL
BREAK-IN PROCEDURES
There is never a more important period in the life of a new Victory motorcycle than the period between zero and
500 miles (805 km). A Victory motorcycle is manufactured using the best possible materials and manufacturing
techniques, but the final machining process is the break-in. During break-in period, many parts in the engine wear
and polish to correct operating clearances. During this time, the operator should:
S Avoid prolonged full throttle operation.
S Avoid operation which might result in excessive heating of the engine.
The general break-in guidelines are as follows:
BREAK-IN GUIDELINES
Miles/km Throttle
Position
0-90 miles 0-1/3 Avoid prolonged operation above 1/3 throttle. Stop engine and let it c ool following every hour
of operation. Vary speed of motorcycle. Do not operate machine at one set throttle position.
90-300 miles 0-1/2 Avoid prolonged operation above 1/2 throttle. Stop engine and let it cool following every hour
of operation. Vary speed of the motorcycle. Do not operate machine at one set throttle position.
300-500 miles 0-3/4 Avoid cruising speeds above 3/4 throttle.
500 miles Replace the engine oil and engine oil filter. Have Victory dealer perform 500 mile service on the ma-
chine. See chapter 2 for more information.
500 + Avoid prolonged full-throttle operation. Vary the engine speed occasionally. Follow the pre-ride inspec-
tion outlined in the owner’s manual.
Notes
PUBLICATION PART NUMBERS
The following chart lists the part numbers for Owner’s Manuals, parts books, and parts microfiche.
OTHER VICTORY PUBLICATIONS
Year / Model Publication Part Numbers U.S. and (Canada)
Owner’s Manual Parts Book Microfiche
2002 Standard Cruiser 9917169 (Can 9917170) 9917632 9917633
2002 Deluxe Cruiser 9917169 (Can 9917170) 9917630 9917631
2002 Touring Cruiser 9917171 (Can 9917172) 9917628 9917629
2002 Deluxe Touring Cruiser 9917171 (Can 9917172) 9917634 9917635
2003 Classic Cruiser 9918229 (Can 9918230) 9918364 9918365
2003 Touring Cruiser 9918229 (Can 9918230) 9918366 9918367
2004 Touring Cruiser 9918946 (Can 9918947) 9918952 9918953
1.6
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