2002-2004 Victory Polaris Classic Cruiser/Touring Cruiser

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 outlined in this manual require a 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 Classic Cruiser and Touring Cruiser 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 Frame/ Body/ Exhaust Maintenance 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 ......................................

GENERAL 1.1 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! Indicates a potential hazard which could result in severe injury or death. Indicates a potential hazard which may result in minor personal injury or damage to the motorcycle. NOTE: The word “NOTE:” in this manual will alert you to key information or instructions. Indicates a situation that can result in damage to the motorcycle. Gasoline is extremely flammable and explosive under certain conditions. 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 neck above 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 enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Improper repairs or service can create unsafe conditions that may cause severe personal injury or death. The engine and exhaust components on this product become very hot during operation and remain so for a period of time after the engine is stopped. Never run the engine in an enclosed area without a properly functioning exhaust gas evacuation system connected to the product. Modifications to this motorcycle not approved by Victory may cause loss of performance, excessive emissions, and make the machine unsafe for use. Wear insulated protection for hands and arms or wait until hot components have cooled sufficiently before working on the product. Brake fluid is poisonous. KEEP OUT OF REACH OF CHILDREN. 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. Brake fluid will damage plastic, painted and rubber parts. Protect these surfaces whenever the brake system is being serviced.

GENERAL 1.2 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.

GENERAL 1.3 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

GENERAL 1.4 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 V02TB16CC, DC, LC, UC TC 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,LC,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/Vogue Silver V02CD16CN,DN,LN,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 VICTORY PAINT CODES PAINT COLORS PAINT CODE PAINT COLORS PAINT CODE Cruiser Black (PHAT) P-266 Pearl White P-352 Indy Red P-293 Cobalt Green P-353 Steel Grey P-302 Vogue Silver P-354 Speed Yellow P-323 Champagne P-355 Sparkle Grey (Fork Legs, Triple Clamp) P-339 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

SAE -assigned World Manufacturing Identifier Chassis: C =Kingpin T = Touring G = Vegas N = ANSS Type: B = Standard Engine Size: 1 = 1507 cc Engine HP: 6 = 78--94 Series: C = Canada D = Domestic (49 State) L= California U = United Kingdom Check Digit Model Year: 2=2002, 3 = 2003, 4=2004, etc. Plant Code Serial Number *5VPCB16D032000000* GENERAL 1.5 VEHICLE IDENTIFICATION NUMBER MODEL NUMBER Chassis: C = Kingpin T = Touring G = Vegas N = ANSS Color Indicator: See Chart on page 1.4 Engine HP: 6 = 78--94 Series: C = Canada D = Domestic (49 State) L= California U = United Kingdom Model Year: 2 = 2002; 3 = 2003; 4 = 2004; etc. V04TB16DC Victory Type: B = Standard D = Deluxe 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 The engine label (4) is located on top of the crankcase behind the rear cylinder. This label identifies the engine model and serial number. The engine serial number is also stamped on the crankcase just to the right of the oil filter. 1 2 3 4

GENERAL 1.6 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 Notes 0-90 miles 0-1/3 Avoid prolonged operation above 1/3 throttle. Stop engine and let it cool 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 posi- tion. 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. 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