2005 2006 Polaris Victory Hammer, Vegas Jackpot, Ness Signature Series Vegas Jackpot Workshop Service Repair Manual

2003 - 2006 Vegas Vegas Eight Ball Kingpin Ness Signature Series Vegas Ness Signature Series Kingpin ™ ™ ® ™ ™

2003-2006 Vegas R Vegas Eight Ballt Kingpint Ness Signature Series Vegas R & Kingpint SERVICE MANUAL Part Number 9920337 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 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. 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 under News, Forms & Links/Service & Warranty/Polaris Manual Feedback link and fill out the information on the form. E 2006 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.

CHARGING SYSTEM 1 2 10 4 5 6 7 9 8 GENERAL FUEL SYSTEM/FUEL INJECTION MAINTENANCE LUBRICATION & COOLING ENGINE REMOVAL & INSTALLATION CLUTCH, PRIMARY, & SHIFT TRANSMISSION & CRANKSHAFT REAR WHEEL & SUSPENSION ELECTRIC STARTER TIRES ENGINE ELECTRICAL 3 14 15 16 17 18 19 CYLINDER & PISTON FRAME/BODY/EXHAUST CYLINDER HEAD & VALVES DRIVE LINE FRONT WHEEL & SUSPENSION BRAKES IGNITION SYSTEM & BATTERY LIGHTING & INSTRUMENTATION GENERAL & MAINTENANCE CHASSIS 11 12 13

GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 1.1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 VICTORY DETAIL AND FINISH RESTORER KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 PAINTING TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 PAINT COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 VIN NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 MODEL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 KEY IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 PUBLICATIONS & TECHNICAL LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 MATERIAL SAFETY DATA SHEET (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 BREAK IN PERIOD / BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 EMISSION SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 NOISE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 EVAPORATIVE EMISSION CONTROL (CALIFORNIA MODELS) . . . . . . . . . . . . . . . . 1.15 INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 SPEEDOMETER / TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 ODOMETER / TRIP ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 GENERAL & PRECISION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 TUNE UP & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 ENGINE, CLUTCH, & TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 STEERING & SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 WHEEL & TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 FUEL SYSTEM & FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 TRANSPORTING AND SECURING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . 1.21 ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 WIRE HARNESS - LEFT REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 WIRE HARNESS - RIGHT REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 WIRE HARNESS - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 WIRE HARNESS - UNDER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 WIRE HARNESS CONNECTOR LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26 TOP VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26 LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27 RIGHT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28

GENERAL INFORMATION 1.2 FUEL TANK VENT AND DRAIN HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 2003-2005 49 STATE, CANADA, UK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 2006 - ALL EXCEPT CALIFORNIA MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 CALIFORNIA MODELS (ALL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 MEASUREMENT CONVERSION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34

GENERAL INFORMATION 1.3 1 GENERAL INFORMATION 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 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 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. Notes, Cautions and Warnings have 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, including fasteners that require replacement if removed. Do NOT substitute fasteners or hardware. Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will 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, which may result in severe personal injury or death. If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners 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. Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. 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. 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. Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Victory hardware from an authorized Victory dealer. Working with batteries can be hazardous. Review all battery warnings and cautions. See “BATTERY SAFETY” on page 16.2.

GENERAL INFORMATION 1.4 SAFETY INFORMATION UNDERSTANDING SAFETY LABELS & INSTRUCTIONS READ AND BECOME FAMILIAR WITH ALL WARNING AND CAUTION SYSMBOLS AND STATEMENTS LISTED BELOW AND IN THE TEXT OF THIS MANUAL BEFORE YOU BEGIN WORK. 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 Indicates a potential hazard which may result in minor personal Indicates a situation that can result in damage to the motorcycle. The word “NOTE:”in this manual will alert you to key information or instructions. Gasoline is extremely flammable and explosive z Always stop the engine and refuel outdoors or in a z Do not smoke or allow open flames or sparks in or z Do not overfill the tank. Do not fill the tank neck above z If you get gasoline in your eyes or if you swallow z If you spill gasoline on your skin or clothing, z Never start the engine or let it run in an enclosed area. injury or death. injury or damage to the motorcycle. CAUTION NOTE: under certain conditions. well ventilated area. near the area where refueling is performed or where gasoline is stored. the fuel tank insert. Leave air space to allow for fuel expansion. gasoline, see your doctor immediately. Never try to syphon gasoline using mouth suction. immediately wash it off with soap and water and change clothing. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Improper repairs or service can create The engine and exhaust components on this The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. unsafe conditions that may cause severe personal injury or death. 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 Modifications to this motorcycle not approved Brake fluid is poisonous. KEEP OUT OF REACH OF CHILDREN. without a properly functioning exhaust gas evacuation system connected to the product. by Victory may cause loss of performance, excessive emissions, and make the machine unsafe for use. Wear insulated protection for hands and Brake fluid is poisonous. Do not ingest or Battery electrolyte is poisonous. It contains Brake fluid will damage plastic, painted and rubber parts. Protect arms or wait until hot components have cooled sufficiently before working on the product. allow brake fluid to contact eyes. Always wear eye protection when working with brake fluid. sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. CAUTION these surfaces whenever the brake system is being serviced.

GENERAL INFORMATION 1 1.5 REFINISHING 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. How to order: Authorized Victory Dealers only. Place your order via the dealer web site at : www.polarisdealers.com / News Forms & Links / Pure Polaris 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, and swirl / scuff remover) is available from the Vic- tory parts department for painted surface protection and to remove minor surface imperfections. Detail Kit: 2872195 (Includes Non-Abrasive Wash, Swirl Remover / Polish, Polywax Final Finish, Vinyl / Rubber Protector, Applicator and Cloth. Restore / Polish: 2872192 (12 oz. Aerosol) PAINTING TERMS The following terms describe the general operations referred to in the Paint Color Code notes on page 1.9-1.10. E-Coat (Factory Applied): This material is used as a rust protection. It is also used to form a bond between bare metal and the primer or base coat. Full-hide colors (such as black) do not require primer. Primer: Primer is necessary when applying some colors such as Flame Yellow, Sonic Blue, Solar Red, etc. The purpose of a primer coat is to prevent bleed-through or transparency in subsequent color coats. Base Coat: A color paint layer applied under another color or under the clear topcoat to improve color matching and consistency. Top Coat: Outermost layer of paint or clear coat.

GENERAL INFORMATION 1.6 PAINT COLORS BY MODEL NOTE: Refer to www.polarisdealers.com for more information. NOTE: The 9th letter of the model number designate the color. “P” in the 10th position indicates Premium model. Refer to page 1.9-1.10 for paint color code. Detailed paint ordering information is available on the dealer web site at News, Forms & Links / Pure Polaris / Paint Codes & Part Numbers. MODEL YEAR 2003 Model Number Model Description / Color V03G116 / V03G216 Vegas All Were Feature / Option (G116 or 216) Color Suffix: CA, DA, LA, UA = Cruiser Black; CB, DB, LB = Sonic Blue; CC, DC, LC = Solar Red; CD, DD, LD = Flame Yellow; CE, DE, LE, UE = Vogue Silver *The last letter of the model number is the color designator. Detailed paint ordering information is available on the dealer web site at News, Forms & Links / Pure Polaris / Paint Codes & Part Numbers MODEL YEAR 2004 Model Number Model Description / Color V04G116 / 216 Vegas Feature / Option V04GB16CA, DA, LA , UA Vegas Cruiser Black V04GB16CB, DB, LB, UB Vegas Sonic Blue V04GB16CC, DC, LC, UC Vegas Solar Red V04GB16CE, DE, LE, UE Vegas Vogue Silver V04GB16CG, DG, LG, UG Vegas Solar Red / Vogue Silver V04GB16CJ, DJ, LJ, UJ Vegas Cosmic Sunburst / Vogue Silver V04GB16CK, DK, LK, UK Vegas Black W/ Tribal Fade Flames V04GB16CL, DL, LL, UL Vegas Sonic Blue W/ Tribal Fade Flames V04NC16 CN / DN / LN Ness Vegas Black Cherry Fade V04C116 / 216 Kingpin Feature / Option V04CB16CA, DA, LA , UA Kingpin Cruiser Black V04CB16CB, DB, LB, UB Kingpin Sonic Blue V04CB16CC, DC, LC, UC Kingpin Solar Red V04CB16CD, DD, LD, UD Kingpin Black / Bronze Mist V04CB16CF, DF, LF, UF Kingpin Bronze Mist / Pearl White V04CB16CK, DK, LK, UK Kingpin Black W/ Tribal Fade Flames V04CB16CL, DL, LL, UL Kingpin Sonic Blue W/ Tribal Fade Flames V04CB16CM, DM, LM, UM Kingpin Purple Thunder * The 8th letter of the model number designates the series: C (Canada), D (49 State), L (California), U (United Kingdom) See page 1.11. The 9th letter of the model number designates the color. “P” in the 10th position indicates Premium model. Detailed paint ordering information is available on the dealer web site at News, Forms & Links / Pure Polaris / Paint Codes & Part Numbers. Refer to www.polarisdealers.com for more information.

2005 2006 Polaris Victory Hammer, Vegas Jackpot, Ness Signature Series Vegas Jackpot Workshop Service Repair Manual

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