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V92TC V92TC DELUXE - Save Big on Victory Motorcycle Service

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1. 56 Operation 57 Engine Break in Period 57 Fueling and Fill Height 59 Starting the Engine 60 Shifting Gears 62 Accelerating 65 Braking rt p lana 66 Stopping the Engine 67 PAKO 67 Maintenance 69 Initial Maintenance 70 Periodic Maintenance Intervals 70 Periodic Maintenance Interval Table 71 Engine Oil eee ees 74 Change Engine Oil and Oil Filter 74 Check Engine Oil Level 75 Inspect Air Filter 76 Inspect Drive Sprocket and Sprocket N t 77 Drive Belt ror 77 Check Drive Belt Condition 77 Table of Contents Check Drive Belt Tension Adjust Drive Belt Tension Align Rear Wheel Rear Suspension Adjust Rear Shock Absorber Inspect Swing Arm and Rear Axle Front Suspension and Steering Check Front Forks Replace Front Fork Oil Inspect Steering and Front Axle Fuel System cies us core Check Fuel Hose Rail and Connections Check Crankcase Ventilation Hose and Connections i ibi ee
2. 43 Pre Operation Check 45 Check Electrical Equipment 45 Instrument Cluster 45 Headlamp eren 46 Taillight ERO 46 Turn Signals Running Lights 46 Emergency Flashers 46 che RR M 46 Engine Stop Run Switch 47 Check Engine Oil Level 47 pec Os wee een 48 Check Fuel Level 48 Check Fuel Hose Rail and Connections 48 Check Evaporative Emission Control System California model only TMCS Check Tire Pressure Tire Pressure Table Check Tire Condition Check Tread Depth Brakes luc Xi ew x e Race Check Front Brake Lever Movement Check Front Brake Fluid Level Check Rear Brake Pedal Freeplay and Movement Check Rear Brake Fluid Level Check Hoses and Connections Check Brake Pads Check Throttle Control Grip and Cables llle RII rrr Check Clutch Check Fast Idle Lever Check Front Suspension Check Steering Check Rear Suspension Check Drive Belt Check Sidestand Table of Contents Check Fasteners
3. Sidestand page 111 Fasteners page 113 Road Test page 113 1 1 1 1 1 1 P 1 1 1 1 L 1 L U l i v r v r L y Operation Codes I Inspect tighten clean adjust correct or replace if necessary L Lubricate with proper lubricant R Replace Rebuild P Perform Replace at specified interval or annually Replace at specified interval or every 2 years 73 Maintenance Engine Oil Change Engine Oil and Oil Filter This procedure involves using a small automotive style oil filter wrench 1 2 3 74 Start and run the engine until it reaches normal operating temperature Stop the engine Securely support the motorcycle on the sidestand Place an oil drain pan under the drain plug and oil filter center rear of the engine Remove the drain plug and seal allowing the oil to drain into the pan Use an oil filter wrench to loosen the filter slowly Allow oil in the filter to drain before removing the filter Remove the oil filter Use a new seal and reinstall the drain plug Torque 25 ft lbs 34 Nm Clean any residue or debris from the oil filter mounting plate and threads Make sure the new oil filter gasket is properly seated in the oil filter and apply a thin f
4. cables exposed connectors Connecting the negative cable first can produce an electric shock that could result in damage or injury Connecting the battery cables to the wrong terminals can severely damage the electrical system 5 Reinstall the battery hold down strap 6 Reinstall the left side cover 107 Maintenance Electrical Equipment Replace Fuses Caution Use only recommended amperage fuses or you can damage the electrical system 1 2 3 4 Remove the operator s seat and the right side cover Release the tabs on each side of the fuse box cover and remove the cover Remove the damaged fuse from the fuse box and seat the new fuse firmly in its place Reinstall the fuse box cover with the double cutout toward the front of the motorcycle The fuse box decal should be readable from the right side of the motorcycle 5 Reinstall the side cover and the operator s seat Fuse Application Fuse Size Ignition Coil 15 amp Horn Brake Headlamp 20 amp Flashers 15 amp Powertrain Control Module PCM 20 amp Fuel Pump 10 amp 1 Fuse Box 108 Maintenance Adjust Headlamp The headlamp should shine straight ahead of the motorcycle The top of the headlamp High beam should be just below the center of the lamp at a distance of 25 feet 7 62 m 1 Check and adjust the tire pressure and rear shock absorber 25 7 62 Center of Headlamp
5. Front Forks page 85 Front Turn Signal Running Light page 38 Headlamp page 38 Air Filter page 76 Spark Plug 2 page 101 Ignition Switch page 30 7 Side Cover page 43 8 Battery under side cover page 105 9 Seat one piece page 104 10 Rear Turn Signal page 38 11 Taillight page 46 12 Rear Brake Caliper page 97 13 Horn page 38 Deluxe Touring Cruiser Left Side Shown 14 Passenger s Foot Rest 15 Oil Filter page 74 16 Sidestand page 43 17 Operator s Foot Rest 18 Gear Shift Lever page 41 19 Front Brake Caliper page 97 Motorcycle Description Deluxe Touring Cruiser Left Side Shown 1 Auxiliary Lights page 110 2 Auxiliary Lights Switch page 42 3 4 Exhaust Muffler 2 page 103 Lockable Hard Saddlebags page 42 25 Motorcycle Description 26 Seat Strap Drive Belt under guard page 77 Rear Shock Absorber under seat page 82 Side Cover page 43 Engine Oil Fill Cap Dipstick page 75 Headlamp page 38 Steering Lock page 29 ec 2 t17 0s 1504 03 12 Deluxe Touring Cruiser Right Side Shown 8 Front Turn Signal Running Light page 38 9 Front Fork page 85 10 O0il Cooler 11 Rear Brake Pedal page 41 12 Operator s Foot Rest 13 Engine Oil Drail Plug under engine page 74 14 Drive Sprocket under cover page 77 15 Rear Brake Fluid Reservoir under
6. 2 Turn the handlebars from stop to stop The action should be smooth but not loose or interfered with by wires hoses or control cables 3 Point the front wheel straight ahead Grasp the front forks near the front axle and attempt to move the front wheel front to back If there is front to back movement at the steering head the steering head bearings should be inspected lubricated and adjusted see the Victory Service Manual or an authorized Victory dealer BCC The steering head bearings require periodic lubrication even if there is no front to back movement at the steering head when checked see the Victory Service Manual or an authorized Victory dealer 4 Turn the handlebars all the way to the right or left Grasp the front tire and attempt to move the front wheel side to side If there is movement at the front axle inspect the wheel bearings and front axle see the Victory Service Manual or an authorized Victory dealer 5 Slowly rotate the front wheel If the wheel does not rotate smoothly inspect the wheel bearings front brake rotors and calipers and front axle see the Victory Service Manual or an authorized Victory dealer 86 Maintenance Fuel System Check Fuel Hose Rail and Connections Inspect the fuel hoses for cracks or damage Inspect the hose connection at the fuel tank and at the fuel rail for dampness or stains from leaking or dried fuel Check Crankcase Ventilation Hose and Connections Remove the operat
7. 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 statistics prove that an approved helmet is the most effective protection in preventing or reducing head injuries 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 You and your passenger should wear bright or light colored and or reflective clothing to improve your visibility to other motorists A motorist s failure to see or recognize a motorcycle is the leading cause of automobile motorcycle accidents Wear gloves and a jacket to prevent or reduce abrasions lacerations or burns that you can suffer if you fall Safety Precautions Protective Apparel continued Wear heavy boots and pants to prevent or reduce abrasions lacerations or burns that you can suffer if you fall Wear boots with low heels because boots with high heels can catch on pedals or footrests The combination of your boots and pants should completely cover your legs ankles and feet protecting you 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 Do not wear loose flowing clothing or long boot laces as they
8. Squeeze the front brake lever toward the handlebar and release it It should move freely and smoothly and should return to its T mn rest position quickly when released You should feel a firm y resistance in the lever within the first 3 4 inch 19 mm of lever travel K If the brake lever travels too far before beginning to engage the brake see the Victory Service Manual or contact an authorized Victory dealer for service 92 Maintenance Lubricate Front Brake Lever 1 2 3 4 5 Remove right mirror brake lever pivot nut and pin Remove any old grease and dirt from the brake lever and lever housing Lubricate the brake lever and lever pivot pin with Victory All Purpose Grease or equivalent Reinstall the brake lever lever pivot pin and nut and right mirror Torque 12 ft lbs 16 Nm Check front brake lever movement Check Front Brake Fluid Level 1 2 To check the front brake fluid level rest the motorcycle on the sidestand and on level ground Turn the handlebars until the front brake fluid reservoir is level View the brake fluid through the sight glass The fluid should be clear and at a level in or above the sight glass Add brake fluid if necessary Add Front Brake Fluid 1 Straddle the motorcycle and bring it to a vertical position Turn the handlebars until the reservoir is horizontal Wipe the area around the reservoir cover with a clean cloth Wipe the brake fluid container with a cl
9. You can minimize those risks but you can t eliminate them completely Take the time to read and understand the following information to help minimize risk and maximize pleasure when operating the motorcycle Even if you are an experienced motorcycle operator or passenger read this section of the Owner s Manual before operating the motorcycle Your ability to safely operate the motorcycle depends on your judgment and 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 Read and understand the rest of the Owner s Manual The Manual contains safety information specific to individual components and operations throughout 3 Safety Precautions Pay close attention to the motorcycle maintenance requirements in this Manual For additional information or assistance regarding technical service specified in the Owner s Manual or required by mechanical circumstances see the Victory Service Manual or your authorized Victory Dealer Safe Riding Design Characteristics The following design characteristics affect how you should ride the Victory motorcycle The motorcycle is designed for on road use with one ride
10. adjusting the shock absorber preload The distance measured while the motorcycle is elevated will not change and needs only be measured once After the measurement and the locations from where the measurement is taken are recorded steps 1 4 you will only need to perform steps 5 8 to correctly adjust the rear shock absorber Have an assistant help you complete the following procedure 1 Center of Rear Axle 1 Elevate the rear of the motorcycle until the rear wheel 2 Bottom of Rear Fender is about 1 inch 2 5 cm off of the ground Use an appropriate motorcycle lift or a block of wood or steel Measurement step 2 placed securely under the frame 2 Measure the distance from the center of the rear axle to Upper Location MISES the bottom of the rear fender directly above the axle On some models it may be easier to measure from the top of the drive belt guard to a convenient spot on the Lower Location step 2 rear fender along the pinstriping for example Both locations must be directly above the rear axle 82 Maintenance Record the measurement and the locations from where the measurement is taken in the space provided Remove the motorcycle lift apparatus and return the motorcycle to the ground Load the motorcycle with all the things you intend to carry cargo and accessories Sit in the operator s seat with your riding gear on and if you plan on carrying a passenger have them sit
11. damage or serious injury could result 113 Maintenance Notes 114 Cleaning and Storage This section explains how to properly clean the various parts of your Victory motorcycle and how to store it to keep it in good working order and appearance Cleaning Clean your motorcycle regularly to protect it from corrosion and to keep it looking new As you clean your motorcycle you perform a complete and thorough visual inspection that may reveal components in need of repair Clean the motorcycle if it is dusty or muddy or if it has picked up foreign material such as road salt insects oil tar or tree sap If you ride in an area with salty or polluted air wash your motorcycle frequently Proper cleaning requires washing and drying the motorcycle and then applying wax polish and protectants to extend the service life and appearance of various components During cleaning you might use products that are potentially hazardous such as polishing compounds When using any of these products follow the instructions and warnings on the product packaging Some foreign materials like insects oil tar and tree sap can damage the motorcycle s fit and finish and you should remove these materials as soon as possible If normal washing does not remove these materials you may need to use a special cleaner Choose a cleaner designed for use on the type of surface you need to clean 115 Cleaning and Storage Washing and Drying Before wa
12. 2 Straddle the motorcycle in an upright position and sit in the operator s seat 3 Set the ignition switch to the On position and set the headlamp to High beam Check the headlamp for correct W a es 4 To adjust the headlamp remove the headlamp bezel to expose the adjusting screws Turn the desired adjusting screw clockwise one revolution and turn the screw directly across the headlamp counterclockwise one revolution Repeat if necessary one revolution at a time 5 Reinstall the headlamp bezel 1 Headlamp Adjusting Screws 109 Maintenance Adjust Auxiliary Lights Each lamp should shine straight ahead or slightly to the right of the motorcycle The top of each lamp beam should be just below the center of the lamp at a distance of 25 feet 7 62 m 1 Check and adjust the tire pressure and rear shock absorber 25 feet 7 62 m 2 Straddle the motorcycle in an upright position and sit in the operator s seat 3 Set the ignition switch to the On position and turn the auxiliary lights on Check the auxiliary lights for correct aim 4 To adjust the lights remove the front running light turn signal bracket to expose the auxiliary light nut Loosen the nut and adjust the auxiliary light 5 Tighten the auxiliary light nut and recheck the light for correct aim 6 Reinstall the front running light turn signal bracket 1 Running Light Turn Signal Bracket 110 Maintenance Re
13. Elite II MT90 B16 71H MT90 B16 71H use with inner tube Rear Wheel Type Size Dunlop D417 160 80 B16 75H 160 80 B16 75H use with inner tube Lights and Fuses 138 Specifications Fuel Specifications Use only unleaded gasoline 92 pump octane minimum DO NOT USE GASOLINE CONTAINING METHANOL Using gasoline methanol blends can result in poor starting and drivability and may damage critical fuel system components Gasoline containing up to 15 Methyl Tertiary Butyl Ether MTBE can be used Gasoline containing up to 10 Ethanol can be used Gasoline that has been Reformulated or Oxygenated can be used Engine Oil Specifications Use only Victory Brand Semi Synthetic 20W 40 Motor Oil or equivalent Do not combine mineral base and synthetic oil in the crankcase at the same time as this can cause serious engine damage 139 Specifications Identification Numbers for Your Motorcycle Vehicle Identification Number Engine Identification Number Ignition Key Number Model Number 140 Index A Accelerating 65 Accessories Loading 12 Selecting and installing 15 Air filter Location 24 Maintenance intervals 71 Maintenance procedure 76 Aligning rear wheel 80 Applying protectants 118 Auxiliary lights Adjustment 110 Location 25 Maintenance intervals 73 Switch Function 42 Location 25 B Battery Charging 106 Cleaning terminals 107 Description 105 Instal
14. If the sprocket nut is loose remove the sprocket nut retainer screws and the retainer Remove the sprocket nut Replace with a new sprocket nut if necessary Clean the output shaft threads and the sprocket nut threads Apply a few drops of Loctite Thread Locker 262 or equivalent to the output shaft threads Apply the rear brake and tighten the drive sprocket nut Torque 100 ft Ibs 136 Nm 8 Install the nut retainer and the retainer screws Torque 115 in Ibs 13 Nm BEC The nut retainer can be installed in many positions and on either side If you cannot align the mount ing holes tighten the sprocket nut slightly and install the nut retainer SIS Un oe DB 9 Check rear wheel alignment see page 80 and drive belt tension see page 78 Drive Belt Check Drive Belt Condition Replace the drive belt if it is cracked or has broken teeth or frayed edges No matter its condition the drive belt should be replaced at periodic intervals see the Victory Service Manual or an authorized Victory dealer 77 Maintenance Check Drive Belt Tension This procedure involves using the belt tension gauge part no PV 43532 which is designed specifically for measuring drive belt tension Before beginning this procedure Make sure the drive belt is dry and at room temperature Make sure the rear suspension is properly adjusted see 1 Belt Tension Gauge Adjust Rear Shock Absorber page 82 O Ring 1 Place the transmission in Neutra
15. above that in the table of recommended shift points Downshifting abruptly on wet rough loose or slippery surfaces can cause the motorcycle to skid When downshifting while passing over such surfaces release the clutch lever very gradually Downshifting in a curve may cause the rear wheel to lose traction Downshift before you enter a curve Recommended Shift Points The following table shows the appropriate speed at which to shift up and shift down to each gear M CET Upshift Speed eT a Gear Downshift Speed 1st to 2nd 15 mph 24 km h 5th to 4th 35 mph 56 km h 2nd to 3rd 25 mph 40 km h 4th to 3rd 25 mph 40 km h 3rd to 4th 35 mph 56 km h 3rd to 2nd 15 mph 24 km h 4th to 5th 45 mph 72 km h 2nd to 1st 10 mph 16 km h 64 Operation Accelerating To accelerate open the throttle roll the throttle control grip toward you For even acceleration open the throttle with a smooth continuous motion When you reach the recommended speed for upshifting shift up one gear according to the instructions in Shifting Gears page 62 The more quickly you open the throttle the more quickly the motorcycle accelerates amp WARNING Abrupt acceleration can cause your body to shift suddenly toward the rear of the motorcycle Accelerating abruptly on wet rough loose or slippery surfaces may cause the rear wheel to lose traction When accelerating on such surfaces whether you are at a stop
16. and increases the tire air pressure For an accurate reading check the tire pressure before you ride Adjust tire pressure as required for the total weight of your intended load Tire Pressure Table V92TC Touring Cruiser Up to 200 Ibs 91 kg load 200 449 Ibs 91 204 kg load FRONT Dunlop 491 Elite Il MT90 B16 71H 34 psi 235 kpa 40 psi 275 kpa REAR Dunlop D417 160 80 B16 75H 36 psi 250 kpa 41 psi 280 kpa V92TC Deluxe Touring Cruiser inner tubes required Up to 200 Ibs 91 kg load 200 441 Ibs 91 200 kg load FRONT Dunlop 491 Elite Il MT90 B16 71H 34 psi 235 kpa 40 psi 275 kpa REAR Dunlop D417 160 80 B16 75H 36 psi 250 kpa 41 psi 280 kpa 49 Pre Operation Check Check Tire Condition Inspect the tire sidewalls road contact surface and tread base for cuts punctures and cracking Replace damaged tires immediately see your Victory Service Manual or an authorized Victory dealer Check Tread Depth Raised areas at the base of the tread known as wear bars act as easily visible tread depth indicators When the road contact surface has worn to the top of the wear bars replace the tire For more precise measurement use a depth gauge or an accurate ruler to measure the depth of the center tire tread Replace the tire if the tread depth is less than 1 16 inch 1 6 mm Brakes Check Front Brake Lever Movement Squeeze the fr
17. at its place of business dur ing customary business hours This warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the Victory dealer VICTORY SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES LOSS OR DAMAGE WHETHER DIRECT INCIDENTAL CONSEQUEN TIAL OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE VICTORY MOTORCYCLE FOR ANY PURPOSE SOMESTATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU B NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY VICTORY EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IM PLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WAR RANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENTS OF WARRANTY AREEXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIM ITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU C No dealer is authorized to modify this Victory Limited Emission Control System Warranty Warranties IV Legal Rights THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE V This Warranty Is In Addition To The Victory Limited Motorcycle Warranty VI Additional Information Any r
18. brise 7079506 Highway bar is not designed to protect you from injury in a collision 7079798 20 A WARNING USE ONLY CORRECT SERIES TIRE ON THIS RIM MOUNT USING TIRE LUBRICANT DO NOT EXCEED MAXIMUM RECOMMENDED INFLATION PRESSURE TO SEAT BEAD OTHERWISE TIRE TUBE OR RIM A FAILURE COULD RESULT WHICH MAY CAUSE PERSONAL 7078699 Deluxe Touring Cruiser Left Side Shown fk WARNING To prevent serious injury or death when using saddlebags Never ride above 80 mph 120 kph with saddlebags Doing so could cause you to lose control This maximum safe speed may be less See Owner s Manual for more information Do not exceed maximum load limit of 10 Ibs 4 54 kg in each saddlebag Distribute weight evenly Total weight of rider passenger accessories and cargo must not exceed the Gross Vehicle Weight Rating in Owner s Manual and on Tire Information Label Afin d viter de graves blessures ou la mort lorsque vous utilisez des sacoches de selle Ne jamais rouler plus de 120 km h 80 mih avec des sacoches de selle install es on pourrait ainsi perdre le contr le du v hicule Cette vitesse s curitaire maximale peut tre moindre Consultez votre Manuel d utilisation pour obtenir de plus amples renseignements Ne pas d passer la charge maximale de 4 54 kg 10 Ib dans chaque sacoche de selle Repartir le poids uniform ment Le poids total du conducteur du passager des accessoires et du
19. can catch on components like handlebars levers or footrests or get caught in the wheels causing you to lose control of the motorcycle Gross Vehicle Weight Rating GVWR Gross vehicle weight is the total weight of the motorcycle the operator and the passenger The weight of the motorcycle includes the motorcycle and all its fluids any accessories and their contents and any additional cargo on the motorcycle The weight of the operator or passenger includes body weight all apparel and objects in or on apparel Do not exceed the motorcycle s gross vehicle weight rating Exceeding the weight rating can reduce stability and handling and could cause you to lose control of the motorcycle For the gross vehicle weight rating of your specific Victory model see Specifications or the certification label on the steering head 10 Safety Precautions Example 1 V92TC Touring Cruiser with no cargo Gross Vehicle Weight Rating 1210 Ibs 549 kg Item Weight Touring Cruiser with full capacity of all fluids 759 Ibs 344 kg Operator with recommended riding apparel 220 Ibs 100 kg Passenger with recommended riding apparel 155 Ibs 70 kg Total Weight 1134 Ibs 514 kg Example 2 V92TC Deluxe Touring Cruiser with cargo Gross Vehicle Weight Rating 1210 Ibs 549 kg Item Weight Deluxe Touring Cruiser with full capacity of all fluids 770 lbs 349 kg Cargo saddlebags at capacity 30 Ibs 13 6 kg Oper
20. chargement ne doit pas d passer le poids nominal brut du v hicule indiqu e dans le Manuel d utilisation et sur l tiquette de renseignements sur les pneus de la motocyclette 7o Safety Precautions Location of Safety and Vehicle Information Labels continued TIRE INFORMATION Cold Tire Pressures Up to 200 Ibs 91 kg Load Up to Maximum Load Capacity Maximum Load Capacity Front Rear Front Rear 441 Ibs 200 kg 34 psi 235 36 psi G85 ips 40 psi 275 41 psi 26 ipa Tire Brand Type Tire Size Minimum Recommended Tire Center Tread Depth Front Rear Front Rear Front Rear Dunlop 491 Elite Il Dunlop D417 MT90 B16 71H 160 80 B16 75H 1 6 mm 2 32 1 6 mm 2 32 TIRES REQUIRE TUBES READ OWNER S MANUAL 7079793 under seat des PATENT NOTICE Mtd by Victory Motorcycle Division Polaris Industries Inc under one or more of the following patents Other patents pending U S Patents D 397 976 0 407 169 D 416 831 0 398 065 0 409 551 D 436 561 under side cover HEADLAMP PCM RELAY RELAY RELAIS RELAIS DE PCM PHARE FUEL PUMP RELAIS DE POMPE CARBURANT on left crankcase half Engine Identification Number Label Deluxe Touring Cruiser Right Side Shown Safety Precautions Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury o
21. emission related assemblies Where a warrantable condition exists Victory will repair your motorcycle at no cost to you including diagnosis parts and labor 126 Warranties Manufacturer s Warranty Coverage Class III motorcycles 280 cc and larger for a period of use of five 5 years or 30 000 kilometers 18 641 miles whichever first occurs If an emission related part on your motorcycle is defective the part will be repaired or replaced by Victory This is your emission control system DEFECTS WARRANTY Owner s Warranty Responsibilities As the motorcycle owner you are responsible for the performance of the required maintenance listed in your owner s manual Victory recommends that you retain all receipts covering maintenance on your motorcycle but Victory cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your motorcycle to a Victory dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the motorcycle owner you should be aware that Victory may deny your warranty coverage if your motorcycle or part has failed due to abuse neglect improper maintenance or unapproved modifications If you have any questions regarding your warranty rights and responsibilities you should contact Victory Motorcycle Division Polaris Sales Inc Box 47
22. for service Adjust Rear Brake Pedal Freeplay 1 Loosen the brake linkage rod locknuts 2 Turn the linkage rod in or out as necessary 3 Tighten the linkage rod locknuts 4 Check the brake pedal freeplay 95 Maintenance Check Rear Brake Fluid Level 1 To check the rear brake fluid level remove the right side cover Straddle the motorcycle and bring it to a vertical position View the brake fluid through the reservoir The fluid should be clear and at a level between MIN and MAX Add brake fluid if necessary Add Rear Brake Fluid 1 Rear Brake Fluid Reservoir 1 we WN 2 MIN Fluid Level Bring the motorcycle to a vertical position with an 3 MAX Fluid Lever appropriate motorcycle lift or a block of wood or steel placed securely under the frame Remove the right side cover Wipe the area around the reservoir cover with a clean cloth Wipe the brake fluid container with a clean cloth Remove the reservoir cover and gasket Brake fluid attacks painted surfaces and plastic parts Always clean spilled brake fluid immediately with plenty of water and a mild detergent 96 Maintenance A WARNING Do not operate the rear brake while its reservoir cover is removed Fluid could overflow from the reservoir and cause air to enter the fluid system Air in the brake fluid system could cause the brakes to malfunction Use only DOT 4 brake fluid from a sealed clean container Using the wrong brake
23. measure the depth of the center tire tread Replace the tire if the tread depth is less than 1 16 inch 1 6 mm A Check Wheel Spokes 1 Tread Depth Gauge Inspect both wheels for loose bent broken or missing spokes To identify loose spokes grasp each spoke and try to move it side to side or up and down All spokes should be equally tight and have the same amount of flex Tighten loose spokes or replace bent broken or missing spokes see an authorized Victory dealer amp WARNING Spokes adjusted or replaced improperly could distort the wheel making the motorcycle difficult to handle and cause you to lose control of the motorcycle 100 Maintenance Check or Replace Spark Plugs The spark plugs must be removed from the engine to inspect them Spark plugs with bright white deposits sooty black deposits or with damaged insulators or electrodes can indicate engine problems If these conditions exist or if the condition of one plug is markedly different from the other see the Victory Service Manual or an authorized Victory dealer for assistance 1 Make sure the engine is at room temperature and remove the operator s seat Remove the fuel tank 1 Insulator 3 Disconnect the spark plug wire by pulling upward on 2 Electrode Tip the spark plug boot 3 Electrode Bridge 4 To prevent any debris from entering the engine through the spark plug hole use pressurized air to blow clean the area around each spark plug be
24. not need to replace the oil filter at this time but you must replace the oil filter when you remove the motorcycle from storage Carbon deposits normally suspended in engine oil that is in service settle on internal engine components during storage Settled carbon deposits can cause engine damage 2 Using pressurized air blow any debris from the area around each spark plug WARNING Wear face protection when using pressurized air 3 Remove the spark plugs see Check or Replace Spark Plugs page 101 Pour one tablespoon of clean motor oil into each spark plug hole 121 Cleaning and Storage 4 5 Connect the spark plugs to the spark plug wires and ground the spark plugs to the engine With the main switch in the On position the stop run switch set to Run and the transmission in neutral press the electric starter button to crank the engine a few times This procedure inhibits corrosion by coating the cylinder walls with the oil you poured in the spark plug holes Set the main switch to the Off position and reinstall the spark plugs Inflate Tires Inflate the tires to normal pressure Remove Clean and Store Battery 1 2 3 4 3i Remove the battery see Remove Battery page 106 To clean oxidation from the battery posts and cable connectors use a wire brush Wash the posts and cable connectors with a solution of 1 part baking soda to 16 parts water Rinse with clean water and wipe dry Apply a
25. on the passenger seat with their riding gear on Have your assistant bounce the rear suspension a few times by pushing down on the rear fender slowly and releasing Make sure the suspension moves freely without binding Without moving the motorcycle have your assistant measure the distance from the center of the rear axle to the bottom of the rear fender directly above the axle This measurement must be taken from the same locations recorded in step 2 Subtract the second measurement step 7 from the first measurement recorded in step 2 The difference is called sag and should be 3 4 to 1 1 4 inch 19 to 32 mm Adjust the shock absorber preload and recheck the sag if necessary 1 Preload Adjustment Collar 83 Maintenance Inspect Swing Arm and Rear Axle 84 1 Remove the swing arm pivot covers and tighten the swing arm pivot nut Torque 85 ft Ibs 115 Nm Reinstall the pivot nut covers Sit in the operator s seat and slowly bounce the rear suspension a few Make sure the suspension moves freely without binding Elevate the rear of the motorcycle until the rear wheel is off of the ground Use an appropriate motorcycle lift or a block of wood or steel placed securely under the frame Grasp the rear tire and attempt to move the rear wheel side to side If there is movement at the rear axle inspect the wheel bearings and rear axle see the Victory Service Manual or an authorized Victory dealer I
26. procedure to install the side cover Sidestand The sidestand is located on the left side of the motorcycle 4 WARNING Correctly retract the sidestand before operating the motorcycle The sidestand could come into contact with the ground and cause you to lose control of the motorcycle To extend the sidestand swing it out from the end until it is fully extended Lean the motorcycle toward the sidestand until the sidestand firmly supports the motorcycle To retract the sidestand lean the motorcycle away from the sidestand until the motorcycle is fully upright Swing the sidestand back into its fully retracted position 43 Instruments and Controls Notes 44 Pre Operation Check To keep your Victory motorcycle in good working order make the checks described in this section before each ride This is especially important before you make a long trip or when you remove the motorcycle from storage You must be familiar with the Victory motorcycle instruments and controls to make these checks You can find additional service information in the Maintenance section of the Owner s Manual in the Victory Service Manual or from an authorized Victory dealer During the pre operation check you might use products that are potentially hazardous such as oil or brake fluid When using any of these products follow the instructions and warnings on the product packaging 4 WARNING Failure to perform these checks before you ride may resul
27. side cover page 96 16 Passenger s Foot Rest 17 Fuses under side cover page 108 18 Evaporative Canister Calif Models under seat page 87 Motorcycle Description Vehicle Identification Number The vehicle identification number VIN is stamped into the front of the steering head and also appears on the certification label You will need the vehicle identification number to title register license or insure the motorcycle or to order replacement parts Chassis Type Series C Curiser B Standard Canada Touring D Deluxe D Domestic 49 State L California SAE assigned World Manufacturing Identifier x U United Kingdom _ Serial Number _ 5VPTB16D022000000 _ UK Model Only UK Model Only Engine Size Plant Code 1 1507 cc Engine HP Check Digit Model Year 6 78 94 2 2002 Engine Identification Number The engine identification number is a combination of the engine model and serial numbers The engine identification number is located on top of the crankcase behind the rear cylinder The engine serial number is stamped into the rear of the crankcase just to the right of the oil filter You may need the engine identification number to title register license or insure the motorcycle or to order replacement parts 27 Motorcycle Description Ignition Key Number The ignition key identification number is stamped into the shaft of each key With the ignition key number an
28. the battery Make sure ventilation is adequate when charging or using the battery in an enclosed space During charging if the battery gets very hot to the touch stop charging and let the battery cool down before continuing 106 Maintenance 1 clean oxidation from the battery posts and cable connectors use a wire brush Wash the posts and cable connectors with a solution of 1 part baking soda to 16 parts water Rinse with clean water and wipe dry Apply a thin film of dielectric grease to the posts and cable connectors 2 Following the charger manufacturer s instructions use a battery charger designed for use with 12 volt batteries The charger should have a maximum charging rate of 1 8 amps Charge the battery for approximately 10 hours at a rate of 1 8 amps If you use a taper or trickle charger it will take longer to charge the battery 3 After charging the battery use a voltmeter to check the condition of the battery Allow battery to sit 1 2 hours before checking the charge The charge should be a minimum of 12 5 volts Repeat the charging cycle if the charge is less than the minimum Replace the battery if it fails to reach a 12 5 volt charge after 2 complete charging cycles Install Battery 1 Before installing the battery make sure it is fully charged and clean 2 Slide the battery into position in the battery tray 3 Connect the positive battery cables covered with a red boot 4 Connect the negative
29. the oil level 7 P If necessary add or remove oil to bring the level into al the area on the dipstick above the ADD mark and below the FULL mark see Engine Oil Specifications page 139 Repeat steps 1 2 each time 1 ADD Mark 2 FULL Mark you adjust the oil level 47 Pre Operation Check WARNING Do not operate the motorcycle with the oil level above the FULL mark or below the ADD mark Operating the engine with too much or too little oil can cause serious engine damage or engine seizure resulting in you losing control of the motorcycle Fuel Check Fuel Level 1 Straddle the motorcycle on level ground and bring it to a vertical position 2 Turn the ignition switch to the On position and press the multi function display MFD Mode button until the fuel gauge appears in the MFD 3 Note the fuel level 4 Estimate your next fuel stop and plan accordingly Check Fuel Hose Rail and Connections Inspect the fuel hoses for cracks or damage Inspect the hose connection at the fuel tank and at the fuel rail for dampness or stains from leaking or dried fuel Check Evaporative Emission Control System California model only Visually inspect all evaporative emission control system hoses and connections Make sure all connections are tight Also inspect the evaporative canister to make sure it has not been damaged 48 Tires Check Tire Pressure Pre Operation Check Normal riding warms the tires
30. the shift arm and the linkage rod must be maintained to insure correct shift linkage operation 98 Tires Check Tire Pressure Maintenance Normal riding warms the tires and increases the tire air pressure For an accurate reading check the tire pressure before you ride Adjust tire pressure as required for the total weight of your intended load Tire Pressure Table V92TC Touring Cruiser Up to 200 Ibs 91 kg load 200 449 Ibs 91 204 kg load FRONT Dunlop 491 Elite Il MT90 B16 71H 34 psi 235 kpa 40 psi 275 kpa REAR Dunlop D417 160 80 B16 75H 36 psi 250 kpa 41 psi 280 kpa V92TC Deluxe Touring Cruiser inner tubes required Up to 200 Ibs 91 kg load 200 441 Ibs 91 200 kg load FRONT Dunlop 491 Elite Il MT90 B16 71H 34 psi 235 kpa 40 psi 275 kpa REAR Dunlop D417 160 80 B16 75H 36 psi 250 kpa 41 psi 280 kpa 99 Maintenance Check Tire Condition Inspect the tire sidewalls road contact surface and tread base for cuts punctures and cracking Replace damaged tires immediately see your Victory Service Manual or an authorized Victory dealer Check Tread Depth Raised areas at the base of the tread known as wear bars act as easily visible tread depth indicators When the road contact surface has worn to the top of the wear bars replace the tire For more precise measurement use a depth gauge or an accurate ruler to
31. thin film of dielectric grease to the posts and cable connectors Clean the outside of the battery with a solution of mild detergent and warm water Store the battery in a dry location that maintains a temperature of 32 to 90 F 0 to 32 C While in storage fully charge the battery once a month see Charge Battery page 106 Park and Cover the Motorcycle Park the motorcycle in its storage location and lock the steering Cover the motorcycle with a durable breathable material or with a high quality motorcycle cover designed for storage Covering the motorcycle helps protect it from dust and other airborne materials The cover must be of a breathable material to prevent moisture from building up on the motorcycle 122 Cleaning and Storage Maintaining During Storage Check and maintain normal tire pressure and battery voltage during storage Removing from Storage 1 2 3 4 5 Remove the cover and unlock the front forks Check the tire pressure and inflate the tires if necessary Reinstall the battery see Install Battery page 107 Wash and dry the entire motorcycle see Washing and Drying page 116 Prior to starting the engine change the engine oil and filter see Change Engine Oil and Oil Filter page 74 beginning with step 2 During storage temperature and humidity changes can cause condensation to form in the crankcase and mix with engine oil Running the engine with oil that contains condensatio
32. to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VICTORY MOTORCYCLE IS REGISTERED WITH VICTORY MOTORCYCLES DIVISION OF POLARIS SALES INC Initial dealer preparation and set up of your Victory Motorcycle is very important in ensuring trouble free operation Purchasing a motorcycle in the crate or without proper dealer set up will void your warranty coverage 132 Warranties Warranty Coverage And Exclusions Limitations Of Warranties And Remedies The warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any Victory Motorcycle that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or Victory Motorcycle due to fire explosions or any other cause beyond Victory
33. when the emergency flashers are active 32 Instruments and Controls If a turn signal bulb has failed or if there is a short circuit in the turn signal system the turn signal indicator flashes at more than twice the normal rate Headlamp High Beam Indicator zb illuminates when the headlamp switch is set to high beam see page 38 Multi Function Display MFD Use the MFD to view the odometer the trip odometer the clock the fuel gauge the voltmeter the instrument cluster light dimmer the headlamp high beam indicator light dimmer and the check engine indicator The MED operates only when the ignition switch is in the On position To select the desired function press the MFD Mode button page 40 To adjust a particular function press the MFD Set button page 39 Odometer The odometer is the default mode of the MFD after starting the engine The odometer shows total miles traveled To toggle the odometer and trip odometer reading between miles and kilometers and the fuel gauge reading between gallons and liters the ignition switch must be in the On position with the MFD in odometer mode Press and hold the MFD Set button for 3 seconds To change to the next MFD function press the MFD Mode button Trip Odometer TRIP appears as part of the display when in trip odometer mode The trip odometer shows total miles traveled since the trip odometer was reset You can use the trip odometer to calculate your miles per gallon and es
34. you wash Let the detergent do the cleaning not the pressure you apply Excessive washing pressure may cause dirt sand or other foreign materials on the windshield to scratch it Soak the cloth or sponge in the detergent and water solution frequently to provide plenty of soapy water for washing and keep the cloth or sponge clean by rinsing it frequently Minor scratches may be removed with a quality plastic polishing compound Follow the manufacturer s instructions when using plastic polishing compounds Insects oil tar and tree sap may also damage the motorcycle s finish If normal washing does not remove these materials you may need to use a special cleaner Choose a cleaner designed for use on clear plastic and follow the manufacturer s instructions when using special cleaners Do not use glass water and soil repellents or alcohol based cleaners as these products can damage the windshield Repairing Painted Surface Damage After cleaning the motorcycle inspect it for damage to the painted surfaces If you discover chips or scratches in the paint apply genuine Victory touch up paint as soon as possible to prevent corrosion 119 Cleaning and Storage Storage If you will not operate the motorcycle for several months such as during the winter store the motorcycle to prevent damage to the fuel system and the battery and to protect components from corrosion or deterioration During storage you might use products that are pot
35. 1 L Front Brake Lever page 92 1 1 L 1 L 1 L 1 L 1 L Rear Brake Pedal page 95 1 1 1 1 1 1 1 1 1 1 1 Brake Fluid page 93 amp 96 1 1 1 1 1 1 1 1 1 1 1 R 1 1 1 1 1 1 1 Operation Codes I Inspect tighten clean adjust correct or replace if necessary L Lubricate with proper lubricant R Replace Rebuild P Perform Replace at specified interval or annually Replace at specified interval or every 2 years 72 Maintenance Periodic Maintenance Interval Table continued DOMETER READING MILES KILOMETERS Component see operation codes below 500 800 7 500 12 000 10 000 16 000 12 500 20 000 15 000 24 000 17 500 28 000 22 500 36 000 37 500 60 000 42 500 68 000 Brake Pads page 97 2 500 4 000 27 500 44 000 32 500 52 000 47 500 76 000 Gear Shift Pedal page 98 Tires page 99 Wheel Spokes page 100 Spark Plugs page 101 5000 8 000 20 000 32 000 7 7 7 7 25 000 40 000 30 000 48 000 35 000 56 000 40 000 64 000 45 000 72 000 7 7 50 000 80 000 Engine Compression page 103 Exhaust System page 103 Battery page 105 Headlamp page 109 Auxiliary Lights page 110
36. 12 Spark plug 102 Swing arm pivot nut 84 Transmission specifications 136 Transporting the motorcycle 14 Trip odometer MFD 33 Turn signals Checking operation 46 Front location 24 Indicator light 32 Rear location 24 Switch Function 38 Location 38 V Vehicle identification number VIN 27 Vehicle information labels 19 23 VIN See Vehicle identification number Voltmeter MFD 35 W Warranties 125 134 Wear bars tires 100 Weight specifications 135 Wheel Alignment rear 80 Specifications 138 Wheel bearings Checking front 86 Checking rear 84 Maintenance intervals front 71 Maintenance intervals rear 71 Wheel spokes Maintenance intervals 73 Windshield Cleaning 119 Index 151 PeLARIS The Way Out Part No 9917171 PRINTED IN THE USA
37. 6 75H Tire 16 3 5 Rim at 36 psi Q50 Cold THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE vaa THIS 2002 VICTORY VMD42T1507 MOTORCYCLE WITH EXHAUST ASM NO 1260913 MEETS USEPA NOISE EMISSION REQUIREMENTS OF 80 dBA AT 2750 RPM BY THE FEDERAL TEST PROCEDURE MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED FEDERAL NOISE STANDARDS ARE PROHIBITED BY FEDERAL LAW SEE OWNER S MANUAL VICTORY MOTORCYCLE DIVISION Polaris Industros In _ 2100 HWY 55 ORE ACES HAMEL MN 55340 9800 Deluxe Touring Cruiser Left Side Shown Safety Precautions Y MOTORCYCLE DMSION Polaris Industries n WY 55 56240 0000 STEM SFI NITION TIMING PERMANENTLY FACTORY SET E MIXTURE EFI CONTRO y ANCE HYDRAUI NGK CA7EB IK PLUG GAP 0 032 D GASOLINE ONLY 92 FORMS TO USEPA REGULATIONS APPI VEHICLE EMISSION CONTROL INFORMATION and EVAPORATIVE HOSE ROUTING CALIFORNIA fo OTORCYCLE DMSION Polaris Industries 85940 9000 MISSION CONTROL SFI SPECIF PERMANENTLY FACTORY SET SPARK PLUG NGK CA7EB SPARK PLUG GAP 0 032 FUEL UNLEADED GASOLINE ONLY 92 PUMP OCTANE OR HIGHER 20W 40 EVAP FAMILY 2VMCEOO22V92 EVAPORATIVE SYSTEM HOSE ROUTING DIAGRAM HICLE CONFORMS TO USEPA AND CALIFORNI APPLICABLE TO 2002 MODEL YEAR NEW MOTORCY CERTIFIED TO 1 4 HC G KM ENGINE FAMILY EXHAUST California models only 19 Safety Pre
38. 61 with additional patents pending Foreword Thank you for choosing a Victory Motorcycle The Owner s Manual contains information on the following Victory Motorcycles V92TC Touring Cruiser V92TC Deluxe Touring Cruiser All photographs and illustrations used are generalizations and your specific model may be slightly different than what is shown If you misplace or damage the Owner s Manual you should purchase a replacement copy from an authorized Victory dealer The manual should be considered part of the motorcycle and remain with the motorcycle when it is sold If after reading the Owner s Manual you have questions about the operation or maintenance of the motorcycle contact an authorized Victory dealer To locate an authorized Victory dealer near you 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 Foreword Your authorized Victory dealer will resolve all issues regarding the motorcycle If you are unsatisfied with the performance of your Victory dealer contact Polaris Customer Service at 763 417 8650 Victory motorcycles comply with all federal state and local safety and emission regulations for the area of intended sale Have a safe and enjoyable ride Table of Contents Introduction 1 Read the Owner s Manual 1 Symbols and Terms Used
39. 700 Hamel Minnesota 55340 9960 or the California Air Resources Board P O Box 8001 9528 Telstar Avenue El Monte CA 91734 8001 Victory Motorcycle Division Polaris Sales Inc Limited Warranty on Emission Control System 127 Warranties Victory Motorcycle Division Polaris Sales Inc hereinafter Victory warrants that each new 2002 and later Victory Motorcycle that includes as standard equipment a headlight taillight and stoplight and is street legal A 15 designed built and equipped so as to conform at the time of initial retail purchases with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and B is free from defects in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for a period of use depending on the engine displacement of 12 000 kilometers 7 456 miles if the motorcycle s engine displacement is less than 170 cubic centimeters of 18 000 kilometers 11 185 miles if the motorcycle s engine displacement is equal or greater than 170 cubic centimeters but less than 280 cubic centimeters or of 30 000 kilometers 18 641 miles if the motorcycle s engine displacement is 280 cubic centimeters or greater or 5 five years from the date of initial retail delivery whichever occurs first I Coverage Warranty d
40. 87 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Operation Codes I Inspect tighten clean adjust correct or replace if necessary L Lubricate with proper lubricant R Replace Rebuild P Perform Replace at specified interval or annually Replace at specified interval or every 2 years 71 Maintenance Periodic Maintenance Interval Table continued ODOMETER READING in MILES KILOMETERS al S S El 85 S o o o S S S S S S S gt Sle 8 3 2 29 5 2 3 SF 9 9 Ss S S ey j Z 5 S oj e q c S q o wo q e S g S 8 S 2 2 5 sj amp Component operation codes 2 8 8 3 S amp 8 8 5 085289 8 3 9 8 below Bl al 2 amp S BS B SB FS SI 3 Crankcase Ventilation Sys tem page 87 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Evaporative Emission Con trol System Calif Only 1 1 1 1 1 1 1 1 I l 1 87 Fuel Filter page 88 R R Fast Idle Lever page 88 1 L 1 L l L 1 L 1 L Throttle page 89 1 1 1 L 1 L 1 1 L 1 1 IIL Clutch Lever page 90 1 1 L l L 1 L l L 1 L Control Cables page 92 1 1 L 1 L 1 L 1 L
41. A toggle switch located underneath the left side of the upper triple clamp controls both auxiliary lights The auxiliary lights operate only when the headlight is set to Low Beam The auxiliary lights extinguish automatically when the headlight is set to High Beam You can operate the motorcycle with the auxiliary light switch on or off Saddlebags Saddlebags are included on some Victory models For loading and operating speed information regarding models with saddlebags see Safety Precautions page 13 Lockable hard saddlebags are included with some Victory models Use the Ignition Key to lock or unlock the saddlebag Each saddlebag has a net for small cargo The load carrying capacity for lockable hard saddlebags is 10 165 4 5 kg each To open the saddlebag depress the lock button to release the cover latch and open the cover outward away from the motorcycle To close the saddlebag press down firmly near the lock button until the cover latch engages 1 Lockable Hard Saddlebags 42 Instruments and Controls Side Covers The motorcycle is equipped with 2 removable side covers Remove the left side cover to access the battery and remove the right side cover to access the fuses and the rear brake fluid reservoir To remove either side cover remove the operator s seat see page 104 and pull the lower corners of the side cover out and away from the motorcycle Lift the side cover up and off the motorcycle Reverse this
42. MIN and MAX Add brake fluid if necessary see page 96 E 1 R Brake Fluid R i Check Hoses and Connections SATE aw Inspect all brake hoses and connections for dampness or stains SUME IE Paver from leaking or dried fluid Tighten any leaking connections and replace components as necessary Check Brake Pads Look into the front brake caliper s from underneath and into the rear brake caliper from behind you should see at least 1 16 inch 1 6 mm of friction material on each of the brake pads If in doubt measure remaining friction material Replace brake pads having less than the specified amount of friction material at their thinnest point 1 Front Brake Pad 2 Rear Brake Pad Friction Material Friction Material 52 Pre Operation Check Check Throttle Control Grip and Cables 1 Rotate the throttle control grip It should rotate smoothly from its rest position to its completely open position and 1 tee back again It should return to its rest position quickly when released 2 Throttle freeplay the amount of throttle control grip movement from the rest position to the point of cable resistance should be 1 8 1 4 inch 3 6 mm 3 Adjust throttle cable freeplay if necessary see page 89 Check Clutch 1 Squeeze the clutch lever toward the handlebar and release it It should move freely and smoothly and should return to its rest position quickly when released 2 Clutch freeplay the amount of clutch
43. Motorcycle Division Polaris Sales Inc control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the Victory Motorcycle The exclusive remedy for breach of this warranty shall be at Victory Motorcycle Division Polaris Sales Inc exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY VICTORY MOTORCYCLES DIVISION OF POLARIS SALES INC SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 133 Warranties ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD VICTORY MOTORCYCLES DIVISION OF POLARIS SALES INC FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY OTHER THAN EMISSIONS AND EXCISE WARRANTIES Some states do not allow limitations on how long an implied warranty lasts so the above limitati
44. Purpose Grease or equivalent Maintenance 10 Reconnect the clutch cable and reinstall the clutch lever lever pivot screw and nut Torque 40 in Ibs 5 Nm 11 Adjust clutch freeplay Adjust Clutch Freeplay 1 Remove the operator s seat 2 Remove the front and rear fuel tank screws r 9 3 Raise the rear of the fuel tank high enough to expose the clutch cable Support the rear of the fuel tank with a block of wood 4 Slide the rubber cover off the cable adjuster and loosen the adjuster jam nut 5 Turn the cable adjuster in or out until the clutch freeplay is 0 04 0 08 inch 1 2 mm 6 Tighten the adjuster jam nut and reinstall the rubber 1 eum ENT e Adjuster cover 2 Adjuster Jam Nut 3 Rubber Cover 7 Reinstall and tighten the front and rear fuel tank screws Torque 20 ft Ibs 27 Nm 8 Reinstall the operator s seat 91 Maintenance Lubricate Control Cables The following cables used on the motorcycle require periodic lubrication for smooth operation and longevity Throttle Cables Clutch Cable Fast Idle Lever Cable 1 Loosen the adjuster of the cable to be lubricated and disconnect one end of the cable 2 Lubricate the cable and the inside of the cable housing with Victory Cable Lube or a commercially available cable lubricant 3 Lubricate the cable end with Victory All Purpose Grease or equivalent 4 Reconnect the cable and adjust as necessary Brakes Check Front Brake Lever Movement
45. al for a safe and comfortable ride Check the rear shock absorber movement and preload to insure the motorcycle has the correct amount of suspension travel and ground clearance see page 82 amp WARNING Inadequate ground clearance could allow components to come into contact with the ground causing you to lose control of the motorcycle Check Drive Belt The drive belt should fit tightly Replace the drive belt if it is cracked or has broken teeth or frayed edges consult your Victory Service Manual or an authorized Victory dealer 55 Pre Operation Check Check Sidestand Straddle the motorcycle and bring it to a vertical position Move the sidestand to its stored up position then to its fully extended down position and back again It should move smoothly and quietly When the sidestand is in its stored position the sidestand return spring should hold the sidestand tightly against the motorcycle Check the condition of the sidestand rubber pad and make sure it is firmly attached to the sidestand Check Fasteners 1 Sidestand 2 Rubber Pad Visually inspect the entire motorcycle chassis and engine for loose damaged or missing fasteners Tighten loose fasteners to the proper torque see the Specifications section of the Owner s Manual or the Victory Service Manual Replace stripped damaged or broken fasteners with genuine Victory fasteners of equal size and strength immediately 56 Operation This sect
46. apy water for washing A toothbrush or bottlebrush can help you wash places that are difficult to reach with a cloth or a sponge 116 Cleaning and Storage Use as little water as possible when washing near the air cleaner or the exhaust pipe openings An excessively wet air cleaner or water in the exhaust pipes may cause the engine to start and run poorly Dry these components thoroughly before using the motorcycle 5 6 Clean the front fork tubes thoroughly to reduce fork seal wear and leakage If insects oil tar tree sap or other foreign material is difficult to remove by applying gentle pressure using the warm water and mild detergent mixture you may need to use a special cleaner See Cleaning page 115 Rinse the motorcycle with water running at low pressure Remove the rubber bands and plastic bags from the exhaust pipes and wipe the motorcycle dry with a soft cloth or chamois After washing the motorcycle start the engine and let it idle for a few minutes Make sure the brakes are functioning properly before riding amp WARNING Excessively wet brake pads or discs may diminish braking effectiveness Dry these components thoroughly before using the motorcycle 117 Cleaning and Storage Waxing Polishing and Applying Protectants Items Other Than Windshields After washing and drying the motorcycle you can help extend the life and appearance of its components by waxing painted surfaces polishing chrom
47. are potentially hazardous such as oil or brake fluid When using any of these products follow the instructions and warnings on the product packaging For information on major repairs see the Victory Service Manual Major repairs typically require the technical skills and specially designed tools available from your authorized Victory dealer Your Victory dealer has the equipment and training required to properly perform emission system maintenance and repairs 69 Maintenance Initial Maintenance Perform the initial maintenance after you ve ridden your new motorcycle 500 miles 800 kilometers This maintenance is one of the most important services your motorcycle requires and should be performed by an authorized Victory dealer Initial maintenance includes servicing all adjustments tightening all fasteners and changing engine oil Performing this maintenance at the required mileage point helps the engine maintain top performance for its entire service life Periodic Maintenance Intervals Use the following table to determine how often you should perform maintenance on various components For additional information on maintenance operations for each component listed in the table refer to the instructions in this section If you regularly ride your motorcycle at high or low speed for extended periods of time or in dusty or other adverse conditions perform the required maintenance more frequently to help keep your motorcycle in safe
48. ator with recommended riding apparel 220 Ibs 100 kg Passenger with recommended riding apparel 155 Ibs 70 kg Total Weight 1175 Ibs 533 kg 11 Safety Precautions Loading Use the following guidelines when attaching cargo or accessories to the motorcycle Where applicable these guidelines refer to accessories and their contents Keep cargo and accessory weight to a minimum and keep it as close to the motorcycle as possible to minimize a change in the motorcycle s center of gravity Changing the center of gravity can lessen stability and handling and could cause you to lose control of the motorcycle Distribute weight evenly on both sides of the motorcycle Maintain even weight distribution by checking accessories and cargo to make sure they are securely attached to the motorcycle before riding and whenever you take a break while riding Uneven weight distribution or accessories or cargo that shift suddenly while you are riding can make the motorcycle hard to handle and cause you to lose control of the motorcycle Do not attach large or heavy cargo such as sleeping bags duffle bags or tents to the handlebars front fork area or front fender If you add accessories to the handlebars or the front fork area they must be as small and as lightweight as possible Cargo or accessories placed in any of these areas can cause instability due to improper weight distribution or aerodynamic changes and can cause you to lose control o
49. c Nil Specifications page 139 Repeat steps 1 2 each time you adjust the oil level 1 ADD Mark 2 FULL Mark 75 Maintenance A WARNING Do not operate the motorcycle with the oil level above the FULL mark or below the ADD mark Operating the engine with too much or too little oil can cause serious engine damage or engine seizure resulting in you losing control of the motorcycle Inspect Air Filter The standard Victory air filter element is a dry paper design and does not require the use of air filter oil BC Inspect the air filter often if riding in unusually wet or dusty conditions 1 Remove the air filter access cover and the air filter element 2 To remove debris from the element use low pressure air and blow from the rear forward amp WARNING i 1 Air Filter Access Cover Wear face protection when using pressurized air 2 Air Filter Element 3 Apply a small amount of lubricant to the edge of the air filter element frame and reinstall the element and access cover Do not overtighten the access cover screws 76 Maintenance Inspect Drive Sprocket and Sprocket Nut 1 Remove the drive sprocket cover BCC On some models it may be necessary to remove portions of the exhaust system to access all of the drive sprocket cover screws see the Victory Service Manual or an authorized Victory dealer 2 Inspect drive sprocket and sprocket nut for wear or damage Make sure the sprocket nut is tight
50. cautions Location of Safety and Vehicle Information Labels continued ion seems unsafe immediately remove all and cargo Contact your dealer to m and remount the accessories Windshields provide wind pr riding comfort but will not protect you with another vehicle the road birds or any other object Do not ride with loose or damaged windshield or mounting hardware Regularly check the hardware for tightness Replace windshield if scratches cannot A CAUTION Brake fluid and alcohol will permanently damage the lastic windshield Do not clean the windshield with glass cleaners or rain protective products CLEANING Victory Owner s Manual for complete instructions on the proper care of your windshield T accessoires et la charge transport e Communiquer avec votre concessionnaire pour r gler le probl me et faire r installer les Le pare brise prot ge contre le vent et am liore le confort du pilote mais n offre aucune protection en cas de collision avec un autre v hicule de chute la roi impact avec un oiseau ou tout autre objet nduire avec des pi ces de fixati r s ou endommag d que les rayures nuisent ATTENTION Tout contact avec du liquide de frein ou de l alcool des dommages permanents au pare bris des produits nettoyants pour ou des produits de protection contre la pl plastiqui n installation du pare ictory pour les consignes jtaillges sur l entretien du pare
51. ce from the base of the alignment tool to the center of the rear axle The right side measurement and the left side measurement must be identical Maintenance To adjust the rear wheel alignment remove and discard the rear axle cotter pin and loosen the rear axle castle nut Loosen the rear axle adjuster jam nuts Turn the axle adjuster on the side with the longer measurement counterclockwise one flat 1 6 revolution Turn the axle adjuster on the side with the shorter measurement clockwise one flat 1 6 revolution Recheck rear wheel alignment as outlined in steps 2 5 Readjust if necessary BC Whenever you turn the rear axle adjusters push the rear wheel forward to keep the axle spacers seated against the axle adjusters 8 9 10 11 12 Reinstall the swing arm pivot caps Check and adjust drive belt tension see page 78 Hold the axle adjusters in position and tighten the adjuster jam nuts Torque 12 ft Ibs 16 Nm Tighten the rear axle nut Torque 65 ft Ibs 88 Nm Recheck drive belt tension and install a new rear axle cotter pin 4 WARNING Do not reuse a cotter pin because it may fail causing the wheel to loosen and you to lose control of the motorcycle 13 Pump rear brake several times to reset brake pad distance 81 Maintenance Rear Suspension Adjust Rear Shock Absorber This procedure involves using the shock absorber preload wrench part no PV 43507 which is designed specifically for
52. ck 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 you to lose control of the motorcycle To repair steering or suspension system wear or damage see the Victory Service Manual or contact your authorized Victory Dealer 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 For complete cleaning procedures see Cleaning page 115 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 Each fastener used in the motorcycle meets our quality specifications for strength finish and type If you need a replacement fastener use only a genuine Victory fastener tightened to the proper torque A fastener that does not meet original specifications could fail and damage the motorcycle or injure you or others Location of Safety and Vehicle Information Labels helm clothing s Manual is missing acement Month Year Mtd By VICTORY MOTORCYCLE DIVISION Polaris Industries Inc GWA r2 bs 649 K9 MOTORCYCLE GAWRF 417 ibs 189 Kg with MT9O B16 71H Tire 16 x3 Rim at 34 psi 235 Kpa Cold 793108 960 Kg with 160 80 B1
53. cle Carrying a Passenger To carry a passenger safely do the following 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 you to lose control of the motorcycle If necessary adjust the rear shock absorber preload according to the instructions in Rear Shock Absorber Adjustment page 82 Improper preload adjustment can make your motorcycle hard to handle and cause you to lose control of the motorcycle Before you ride 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 and cause you to lose control of the motorcycle Safety Precautions Carrying a Passenger continued 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 you to lose control of the motorcycle Protective Apparel To decrease the risk of injury and increase riding comfort wear the following Wear a Department of Transportation
54. cs 4 Dimensions 135 Dimmer switch See Headlamp high low beam switch Dipstick Function 75 Location 75 Drain plug oil location 74 Drive belt Adjusting tension 79 Checking condition 77 Checking tension 78 Location 26 Maintenance intervals 71 Drive sprocket Inspecting 77 Location 26 Maintenance intervals 71 Dry weight 135 Index E Electric starter button Function 40 Location 39 Emergency flashers Checking operation 46 Switch Function 40 Location 39 Emission system California models Canister location 26 Maintenance intervals 72 Maintenance procedure 87 System label 19 Engine Compression check 103 Identification number 27 Specifications 136 Starting 60 Stopping 67 Engine oil See Oil engine Engine stop run switch Checking operation 47 Function 39 Location 39 143 Index Evaporative emission control system See Emission control system Exhaust gases safety 16 Exhaust system Checking 103 Location 25 Maintenance intervals 73 F Fast idle lever Adjusting freeplay 88 Checking movement 88 Function 38 Location 38 Maintenance intervals 72 Fluid capacities 135 Footrest Operator s location 24 Passenger s location 24 Front brake See Brakes Front fork Oil replacement 85 144 Front forks Checking 85 Location 24 Maintenance intervals 71 Oil replacement intervals 71 Front tire See Tires Front turn signals See Turn signals Front wheel See Whee
55. d On Position In the On position all electrical circuits are energized and the ignition key cannot be removed The headlamp running lights taillight and instrument lights illuminate With the engine stop run switch set to the Run position see page 39 you can start 3 3 1 Off 3 P Park the engine You can also activate the emergency flashers turn 2 On sang signals and all other electrical features Before starting the engine read the instructions for starting the engine on page 60 30 P Park Position Instruments and Controls In the Park position the taillight and running lights illuminate the emergency flashers can be activated and the ignition key can be removed You must push the ignition key into the switch while selecting the Park position Instrument Cluster The instrument cluster includes the speedometer the tachometer the indicator lights and the multi function display Speedometer The speedometer reports current motorcycle speed in miles per hour or kilometers per hour Tachometer The tachometer reports current engine speed in revolutions per minute RPM A red line on the gauge indicates maximum safe engine RPM amp WARNING Do not operate the engine over 5600 RPM Excessive RPM could cause engine damage or failure that could result in you losing control of the motorcycle LS ES Speedometer Tachometer Low Oil Pressure Indicator Low Fuel Indicato
56. d proof of ownership an authorized Victory dealer can assist you in obtaining a replacement key have your dealer reference Voice of Victory April May 2001 BETTE For easy reference record all vehicle numbers in the space provided on page 140 28 Instruments and Controls Ignition Key The ignition key operates the steering lock the ignition switch and the saddlebag lock on models equipped with hard saddlebags Steering Lock The motorcycle is equipped with a steering lock to deter others from moving or using the motorcycle The steering lock is on the right side of the steering head To lock the steering turn the handlebars fully to the left open the lock cover insert the key and turn it clockwise To unlock the steering move the handlebars to the left or right slightly and turn the key counterclockwise Always remove the key after locking or unlocking the steering amp WARNING Moving or operating the motorcycle with the steering locked severely restricts steering and can cause you to 1 Steering Lock drop or lose control of the motorcycle 29 Instruments and Controls Ignition Switch The ignition switch energizes the ignition the lighting system and all electrical switches and buttons Off Position In the Off position all electrical circuits are inactive and the ignition key can be removed Turn the ignition switch to the Off position and remove the ignition key when leaving the motorcycle unattende
57. e Capacity 135 Changing 74 Checking 75 Maintenance intervals 71 Specifications 139 Operation 57 68 Operator s seat See Seat s 147 Index P Parking 67 Passenger s seat See Seat s Passengers 8 Periodic maintenance interval table 7 1 Periodic maintenance intervals 70 Pre operation check 45 56 Product modifications 15 Protective apparel 9 R Rear brake See Brakes Rear shock absorber See Rear suspension Rear suspension Adjustment 82 Inspecting 84 Checking ride height 82 Maintenance intervals 71 Shock absorber location 26 Rear tire See Tires Rear turn signals See Turn signals Rear wheel See Wheels Rear wheel alignment 80 148 Recommended shift points 64 Regular service intervals 70 Regular service intervals table 71 Reporting safety defects 22 Riding 57 68 Road test After maintenance 113 After storage 123 Running lights Checking operation 46 Location 24 S Saddle See Seat s Saddlebags Loading 13 Location 25 Remove and install 111 Safe riding practices 5 9 Safety labels 19 23 Safety precautions 3 24 Seat Location 24 Seat s VO2TC Remove and install 104 Service 69 114 Service interval table 71 Service intervals 70 Shift points 64 Shifting gears 62 65 Downshifting 63 Recommended shift points 64 Upshifting 63 Shock absorber See Rear suspension Side cover Left side location 24 Right side location 26 Sidestand Functi
58. e ignition starter and fuel pump circuits To complete the C circuits allowing the engine to start and run press the lower portion of the engine stop run switch Run position To interrupt the circuits press the upper portion of the switch Stop position The engine should not start or run when the switch is in the Stop position Use the engine stop run switch to turn the engine off under normal or emergency conditions Engine Stop Run Switch Emergency Flasher Switch Starter Button Throttle Control Grip Multi Function Display Mode Button 39 Instruments and Controls Emergency Flasher Switch A The emergency flasher switch activates and cancels the emergency flashers When the emergency flashers are active all of the turn signals flash To activate the emergency flashers slide the switch to the left to cancel the flashers slide the switch to the right Starter Button 5 To engage the engine starter motor press the right side of the starter button The starter button works only when the engine stop run switch is in the Run position and the transmission is in Neutral or the clutch is disengaged For complete engine starting procedures see Starting the Engine page 60 Front Brake Lever To apply the front brake pull the front brake lever toward the handlebar For braking procedures in various riding conditions see Braking page 66 Throttle Control Grip The
59. e rear axle adjuster jam nuts Turn both rear axle adjusters an equal amount until the drive belt tension is correct see Check Drive Belt Tension page 78 making sure the adjusters are firmly seated against the axle spacers Tighten the adjuster jam nuts Torque 12 ft Ibs 16 Nm Tighten the rear axle castle nut Torque 65 ft Ibs 88 Nm Recheck drive belt tension and install a new rear axle cotter pin 79 Maintenance WARNING Do not reuse a cotter pin because it may fail allowing the wheel to loosen and you to lose control of the motorcycle 6 Pump rear brake several times to reset brake pad distance Align Rear Wheel This procedure involves using the rear wheel alignment tool part no PV 43528 which is designed specifically for aligning the rear wheel Do not rely on the rear axle reference marks for wheel alignment WARNING A skewed rear axle can damage the drive belt causing it to fail and you to lose control of the motorcycle 1 Bring the motorcycle to a vertical position with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame 2 Remove the swing arm pivot caps and install the rear wheel alignment tool on the right side of the motorcycle 3 Measure and record the distance from the tip of the alignment tool to the center of the rear axle 4 Install the rear wheel alignment tool on the left side of the motorcycle 5 Measure and record the distan
60. e surfaces and applying a protectant to exposed rubber vinyl and plastic parts Avoid cleaning waxing compounds as they may contain abrasives that may damage the finish of painted parts For chrome surfaces use either a window cleaning solution or a polish specifically designed for chrome Follow manufacturer s instructions for proper application and use of wax polish or protectants After washing and drying the motorcycle to help extend the life and appearance of its components Wax painted surfaces Avoid cleaning waxing compounds as they may contain abrasives that may damage the finish of painted surfaces Polish chrome surfaces Use either a window cleaning solution or a polish specifically designed for chrome Apply a protectant to exposed rubber vinyl and plastic components A WARNING Do not use a protectant on the seats footboard inserts or handgrips that leaves a slippery coating after it dries If these surfaces are slippery you may have difficulty holding your position on the motorcycle while riding which may cause you to lose control of the motorcycle Follow manufacturer s instructions and safety precautions on wax polish and protectant labels to prevent injury or damage 118 Cleaning and Storage Windshield Care A windshield is included with some Victory models Wash the windshield using a soft cloth or sponge soaked in a solution of mild detergent and warm water applying minimal pressure as
61. ean cloth Remove the reservoir cover and gasket 93 Maintenance Brake fluid attacks painted surfaces and plastic parts Always clean spilled brake fluid immediately with plenty of water and a mild detergent 4 WARNING Do not operate the front brake while its reservoir cover is removed Fluid could overflow from the reservoir and cause air to enter the fluid system Air in the brake fluid system could cause the brakes to malfunction Use only DOT 4 brake fluid from a sealed clean container Using the wrong brake fluid or allowing contaminants into the brake fluid system can damage the system seals resulting in the brakes malfunctioning 5 Carefully add enough brake fluid to bring the level just above the sight glass 6 Reinstall the reservoir gasket and cover 94 Maintenance Check Rear Brake Pedal Freeplay and Movement Rear brake pedal freeplay the amount of brake pedal movement from the rest position to the point of contacting the master cylinder should be 3 16 5 16 inch 5 8 mm Adjust pedal freeplay as necessary see page 95 Press and release the rear brake pedal It should move freely and smoothly and should return to its rest position quickly when you release it You should feel a firm resistance in the pedal within the first 3 4 inch 19 mm of pedal travel If the brake pedal travels too far before beginning to engage the brake see the Victory Service Manual or contact an authorized Victory dealer
62. efects shall be remedied during customary business hours at any authorized Victory motorcycle dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board Any part or parts replaced under this warranty shall become the property of Victory In the State of California only emission related warranted parts are specifically defined by the state s Emission Warranty Parts List These warranted parts are carburetor and internal parts intake manifold fuel tank fuel injection system spark advance mechanism crankcase breather air cutoff valves fuel tank cap for evaporative emission controlled vehicles oil filler cap pressure control valve fuel vapor separator canister igniters breaker governors ignition coils ignition wires ignition points condensers and spark plugs if 128 Warranties failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related parts may vary from model to model certain models may not contain all of these parts and certain models may contain functionally equivalent parts In the State of California only Emission Control System emergency repairs as provided for in the California Administrative Code may be performed by other than an authorized Victory dealer An emergency situation occurs wh
63. en an authorized Victory dealers is not reasonably available a part is not available within 30 days or a repair is not complete within 30 days Any replacement part can be used in an emergency repair Victory will reimburse the owner for expenses including diagnosis not to exceed Victory s suggested retail price for all warranted parts replaced and labor charges based on Victory s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate The owner may be required to keep receipts and failed parts in order to receive compensation Il Limitations This Emission Control System warranty shall not cover any of the following A Repair or replacement required as a result of 1 accident 2 misuse 3 repairs improperly performed or replacements improperly installed 4 use of replacement parts or accessories not conforming to Victory specifications which adversely affect performance and or 5 use in competitive racing or related events 129 Warranties B Inspections replacement of parts and other services and adjustments necessary for required maintenance C Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readi ly determined Limited Liability 130 A The liability of Victory under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized Victory motorcycle dealer
64. entially hazardous such as fuel stabilizer When using any of these products follow the instructions and warnings on the product packaging This section includes instructions for preparing the motorcycle for storage maintaining it during storage and removing it from storage Preparing for Storage Choose an adequate storage location Choose a dry well ventilated storage location inside a garage or other structure if possible The location should have a firm flat surface and allow enough space for the motorcycle To best preserve tire condition The storage area should have a relatively constant and moderate temperature The motorcycle should not be near a radiator or other heat source or any type of electric motor The storage surface should be free of oil and gasoline Clean and Protect the Motorcycle To prepare the motorcycle for storage begin by cleaning it see Cleaning page 115 Wax painted surfaces and polish chromed surfaces Apply protectant to exposed rubber vinyl and plastic parts 120 Cleaning and Storage Stabilize Fuel 1 Using a mixture of fuel and the amount of gasoline stabilizer recommended by the stabilizer manufacturer fill the fuel tank only to the top of the filler insert 2 Start and run the engine for 15 minutes to pass the stabilized fuel through entire fuel injection system Protect Engine Components 1 Change the engine oil see Change Engine Oil and Oil Filter page 74 You do
65. eplace Spark Plugs 101 Protectants Items Other Than Check Engine Compression 103 Windshields E 118 Check Exhaust System 103 Windshield Care pall dent wah tae de e s 119 Remove and Install Seat 104 Repairing Painted Surface Damage 119 Battery wei ce eee eee eee ee 105 Storage E NET CE AN by n Preparing for Storage 120 Remove Battery 106 Clean and Protect the Motorcycle 120 Charge Batleny arysirna ive Stabilize 121 Install Battery DA ADU EC 107 Protect Engine Components 121 Electrical Equipment 108 Inflate Tires 122 Replace Fuses 108 Remove Clean and Store Battery 122 Adjust Headlamp 109 Park and Cover the Motorcycle 122 Adjust Auxiliary Lights 110 Maintaining During Storage 123 Remove and Install Saddlebags 111 Removing from Storage 123 Sidestarid 111 Lubricate Sidestand 111 Warranties 125 Inspect Sidestand 112 Motorcycle Noise Regulation 125 Check Fasteners 113 Noise Emission Warranty 126 Road Test oi ln ek mee 113 Emissions Control System Warranty 126 Your Warranty R
66. eplacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However Victory is not liable for these parts The owner is responsible for the perfor mance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins on the date the motorcycle is delivered to an ultimate purchaser Victory Motorcycle Division Polaris Sales Inc P O Box 47700 Hamel MN 55340 9960 ATTN Warranty Department 131 Warranties Victory Motorcycle Warranty Policy Limited Warranty Victory Motorcycle Division Polaris Sales Inc P O Box 47700 Hamel Minnesota 55340 9960 gives a ONE YEAR LIMITED WARRANTY on all components of the Victory Motorcycle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Victory Motorcycle dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Victory Motorcycle Division Polaris Sales Inc within ten days Upon receipt of this registration Victory Motorcycle Division Polaris Sales Inc will record the registration for warranty No verification of registration will be sent
67. ers Do not operate the motorcycle for extended periods of time at throttle positions above 3 4 throttle At 500 miles 800 kilometers Perform initial maintenance as described in the Maintenance section of the Owner 5 Manual This maintenance is one of the most important services your motorcycle requires and should be performed by an authorized Victory dealer Initial maintenance includes servicing all adjustments tightening all fasteners and changing engine oil Performing this maintenance at the required mileage point helps the engine maintain top performance for its entire service life If engine trouble should occur during the engine break in period consult the Maintenance section of the Owner s Manual the Victory Service Manual or an authorized Victory dealer immediately 58 Operation Fueling and Fill Height Fuel the motorcycle with the sidestand down and on level ground Use only the recommended fuel see Fuel Specifications page 139 Fill the fuel tank to a level just below the bottom of the fuel filler insert A WARNING Do not allow gasoline to come into contact with a hot engine or exhaust system This could cause a fire Immediately wipe or rinse with water gasoline spilled on any part of the motorcycle or the surrounding area Do not fill the fuel tank above the fuel filler insert Overfilling the fuel tank may cause fuel to overflow when it expands Fuel may leak from an improperly seated or tightened
68. f control while operating the motorcycle keep your hands on the handlebars and your feet on the footrests 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 lessen the motorcycle s stability and increase the possibility of your losing control of the motorcycle Do not move or operate the motorcycle with the steering locked as steering is severely restricted and you could drop or lose control of the motorcycle If in doubt 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 Precautions Safe Riding Practices continued If in doubt reduce your speed when The weather is windy raining 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 To maximize braking effectiveness use the front and rear brakes together Be aware of the following braking facts and practices The rear brake provides 4046 of the moto
69. f the motorcycle Such items can also block airflow to the engine and could cause overheating that can damage the engine 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 either of these could result in an accessory failure that could cause you to lose control of the motorcycle Except for highway footrests do not attach anything else to the highway bar 12 Safety Precautions Saddlebags Saddlebags are included with some Victory models Use the following guidelines when operating a motorcycle with saddlebags installed Never ride a motorcycle with saddlebags above 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 can make the motorcycle unstable due to the lifting or buffeting effects of wind and can cause you to lose control of the motorcycle Distribute weight evenly in each of the saddlebags Do not exceed the maximum cargo weight limit of the saddlebags Lockable hard saddlebags 10 165 4 5 kg each Do not exceed the motorcycle s gross vehicle weight rating Exceeding the weight rating can reduce stability and handling and could cause you to lose control of the motorcycle 13 Safety Precautions Parking For complete parking procedures see Parking page 67 When leaving the motorcycle una
70. f there is movement at the front of the swing arm check the swing arm pivot nut torque If movement is still present inspect the swing arm pivot bushings see the Victory Service Manual or an authorized Victory dealer With the transmission in neutral slowly rotate the rear wheel If the wheel does not rotate smoothly inspect the wheel bearings rear brake rotor and caliper and rear axle see the Victory Service Manual or an authorized Victory dealer Maintenance Front Suspension and Steering Check Front Forks 1 To check the front suspension straddle the motorcycle and bring it to a vertical position 2 Apply the front brake and push down hard on the handlebars several times The front suspension should operate smoothly and quietly 3 Place the motorcycle on the sidestand and inspect the front forks Make sure there is no fork oil present on the fork tube or around the fork seal Replace Front Fork Oil Front fork oil condition and level is associated with front suspension performance and internal component wear For fork oil replacement procedures and special tools required see the Victory Service Manual or contact an authorized Victory dealer peo 1 Front Fork Tube 2 Fork Seal 85 Maintenance Inspect Steering and Front Axle 1 Elevate the front of the motorcycle until the front wheel is off of the ground Use an appropriate motorcycle lift or a block of wood or steel placed securely under the frame
71. fluid or allowing contaminants into the brake fluid system can damage the system seals resulting in the brakes malfunctioning 6 Carefully add enough brake fluid to bring the level between MIN and MAX 7 Reinstall the reservoir gasket and cover 8 Reinstall the side cover Check Brake Pads Look into the front brake caliper s from underneath and into the rear brake caliper from behind you should see at least 1 16 inch 1 6 mm of friction material on each of the brake pads If in doubt measure remaining friction material Replace brake pads having less than the specified amount of friction material at their thinnest point If the brake pads require replacement see the Victory Service 1 Front Brake Pad 2 Rear Brake Pad Manual or an authorized Victory dealer for assistance Friction Material Friction Material 97 Maintenance Check Brake Hoses and Connections Inspect all brake hoses and connections for dampness or stains from leaking or dried fluid Tighten any leaking connections and replace components as necessary Gear Shift Pedal Adjust Gear Shift Pedal Height 1 Loosen the gear shift linkage rod locknuts 1 Gear Shift Linkage Rod Locknut 2 Linkage Rod 2 Turn the linkage rod in or out as necessary 3 Tighten the linkage rod locknuts 4 Check the gear shift pedal height Do not remove and reposition the shift arm on the shift shaft to adjust gear shift pedal height A 90 5 angle between
72. fore removing it 4 WARNING Wear face protection when using pressurized air 101 Maintenance 102 5 Remove the spark plug from the cylinder head with a spark plug socket Both spark plugs should have the same light or medium tan color deposits on the insulator around the electrode tip The spark plug electrode tip and bridge 0 032 inch 0 8 mm should have sharp square edges If spark plugs are in good condition and are not due for replacement you can clean them with a stiff bristle brush set the gap and reinstall them Replace spark plugs NGK CR7EB or equivalent at the recommended intervals Always replace spark plugs in pairs Set the electrode gap with a spark plug gauge Gap 0 032 inch 0 8 mm Clean the mating surface on the cylinder head and install the spark plug with a spark plug socket Torque 8 ft Ibs 11 Nm Reconnect both spark plug wires Reinstall and tighten the front and rear fuel tank screws Torque 20 ft lbs 27 Nm 10 Reinstall the operator s seat Maintenance Check Engine Compression An accurate periodic engine compression check documents engine wear and condition For engine compression check procedures and special tools required see the Victory Service Manual or contact an authorized Victory dealer Check Exhaust System Check the exhaust system for stains from leaking exhaust gasses Replace exhaust gaskets if necessary see the Victory Service Man
73. fuel cap Tighten the fuel cap until you hear one or more distinct clicks Be certain the fuel cap is properly seated and tightened before starting the engine Fuel can damage painted surfaces and plastic parts Wipe spilled fuel immediately from the motorcycle using a clean dry soft cloth BCE f the motorcycle has run completely out of fuel cycle the fuel pump 4 5 times to prime the system before starting the engine To cycle the fuel pump set the ignition switch to the On position and toggle the engine stop run switch from the Stop position to the Run position 4 5 times 59 Operation Starting the Engine The Victory motorcycle has a starter interlock system The engine can be started only when the transmission is in neutral or when the transmission is in gear and the clutch is disengaged Follow these steps to start the motorcycle 1 2 60 Unlock the steering lock see page 29 Perform the Pre Operation Check beginning on page 45 If you are carrying cargo inspect cargo restraints for tightness Insert the ignition key into the ignition switch and turn the switch to the On position see Ignition Switch page 30 Mount the motorcycle and bring it to an upright position Engage the front brake and place the sidestand in the stored up position If the neutral indicator is not illuminated shift the transmission to neutral see Shifting Gears page 62 If the engine is cold has not been run in a few h
74. g 1210 Ibs 549 kg Capacities Engine Oil 6 Qt 5 7 Ltr 6 Qt 5 7 Ltr Fuel 5 US Gal 19 Ltr 5 US Gal 19 Ltr 135 Specifications Model Year 2002 v92TC V921C Touring Cruiser Deluxe Touring Cruiser Engine Model Number MCVT1507D 2002 Configuration 50 V Twin Displacement 92 cu in 1507 cc Cooling System Air amp Oil Compression Ratio 9 2 1 4 Valves per Cylinder Bore and Stroke 97 x 102 mm 97 x 102 mm Spark Plug Gap NGK CR7EB NGK CR7EB 032 in 0 8 mm 032 in 0 8 mm Drive System Constant Mesh Constant Mesh 136 Specifications Touring Cruiser Deluxe Touring Cruiser ad Clutch Type Wet Multi Disk Wet Multi Disk Diaphragm Spring Diaphragm Spring Drive Belt Deflection 3 8 inch 9 5 mm 3 8 inch 9 5 mm Chassis Front Suspension Type Travel Telescopic Telescopic 5 1 in 13 cm 5 1 in 13 cm Rear Suspension Type Travel Single Shock Single Shock 4 in 10 cm 4 in 10 cm Front Brakes Dual 300 x 5 mm Disc with 4 Piston Fixed Dual 300 x 5 mm Disc with 4 Piston Fixed Caliper Caliper Rear Brakes Single 300 x 6 mm Disc with 2 Piston Single 300 x 6 mm Disc with 2 Piston Floating Caliper Floating Caliper 137 Specifications Model Year 2002 v92TC V921C Touring Cruiser Deluxe Touring Cruiser Wheels and Tires Front Wheel Type Size Cast 5 Spoke Laced 40 Spoke 16x3 in 16x3 in Rear Wheel Type Size Cast 5 Spoke Laced 40 Spoke 16x3 in 16x3 5in Front Tire Type Size Dunlop 491 Elite II Dunlop 491
75. halt pavement can become soft in hot weather The sidestand can sink into soft asphalt until the motorcycle falls over When parking on asphalt in hot weather use a sidestand footrest under the foot of the sidestand to prevent the sidestand from sinking into the asphalt WARNING A hot engine or hot exhaust pipes can be hazardous The engine and exhaust pipes are hot for some time after the engine is stopped Touching the engine or exhaust pipes while hot can cause serious burns Allowing flammable materials to contact a hot engine or exhaust pipes may cause a fire Park the motorcycle where people will not touch the engine or exhaust pipes and where it is not near flammable materials 68 Maintenance This section includes information for maintaining your Victory motorcycle It also includes recommended periodic maintenance intervals Periodic maintenance means performing the regular service required to keep your motorcycle in top working condition Regular service increases motorcycle durability safety and dependability and provides greater riding pleasure Also see Safety Precautions Maintenance page 17 Before you begin any maintenance procedure read the instructions for the entire procedure in this section of the Owner s Manual Choose a flat firm surface for servicing the motorcycle Make sure you have the time tools and expertise to complete a procedure properly During maintenance you might use products that
76. he low beam press the lower portion of the switch To activate the momentary passing beam press and hold the lower portion of the switch Turn Signal Switch M c The turn signal switch activates and cancels the turn signals To activate the left turn signals push the switch to the 1 Fast Idle Lever 2 Headlamp High Low Beam Switch 3 4 5 Turn Signal Switch Horn Button Mutti Function Display Set Button left to activate the right turn signals push the switch to the right To cancel the turn signals push the switch in toward the handlebar The turn signals cancel automatically at speeds above 6 miles per hour 9 6 kilometers per hour Horn Button xe To sound the horn press the horn button 38 Clutch Lever Instruments and Controls To disengage the clutch pull the clutch lever toward the handlebar To engage the clutch gradually release the clutch lever For smooth clutch operation pull the lever quickly and release it gradually Notice The motorcycle is equipped with a clutch interlock switch that prevents the engine from starting when the transmission is in gear and the clutch is engaged see page 62 Multi Function Display MFD Set Button Use the MFD Set button in conjunction with the MFD Mode button to control the features of the multi function display see page 33 Right Side Handlebar Controls Engine Stop Run Switch The engine stop run switch completes or interrupts th
77. ights and Obligations 126 Manufacturer s Warranty Coverage 127 Cleaning and Storage 115 Owner s Warranty Responsibilities 127 Cleaning 115 Coverage 128 Washing and Drying 116 Il Limitations 0 0000 129 Table of Contents Ill Limited Liability IV Legal Rights V This Warranty Is In Addition To The Victory Limited Motorcycle Warranty VI Additional Information Victory Motorcycle Warranty Policy Limited Warranty Registration Warranty Coverage And Exclusions Specifications Fuel Specifications Engine Oil Specifications Identification Numbers for Your Motorcycle viii sese 131 S 183 Introduction Read the Owner s Manual The Owner s Manual contains information that is essential to safe riding and proper maintenance of all 2002 Victory motorcycles 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 Precautions section Understand and follow the procedures in the Owner s Manual to keep your Victory motorcycle in top condition on the road or in storage If possible bring the manual with you when you ride Failure to follow the safety precautions and operati
78. ilm of clean engine oil to the gasket Screw the new filter on until the gasket contacts the filter mounting plate Tighten the filter by hand an additional 1 2 to 3 4 turn Fill the crankcase through the oil fill cap with 6 quarts 5 7 liters of the proper grade and viscosity oil see Engine Oil Specifications page 139 1 Oil Filter 2 Drain Plug under engine Maintenance 10 Reinstall the oil fill cap and then start and run the engine until it reaches normal operating temperature After an oil change the low oil pressure indicator remains illuminated longer than usual before going out Revving the engine while the low oil pressure indicator is illuminated can damage the engine 11 Stop the engine and make sure there are no leaks around the drain plug and oil filter Check the oil level and adjust if needed BC Recycle used oil and oil filters in accordance with local regulations Check Engine Oil Level 1 With the engine at normal operating temperature straddle the motorcycle on level ground and bring it to a vertical position Remove the oil fill cap and wipe the dipstick clean Reinstall the dipstick and turn the cap 25 clockwise until it seats 1 Oil Fill Cap Dipstick 2 Remove the dipstick again and note the oil level 3 If necessary add or remove oil to bring the level into 9 the area on the dipstick above the ADD mark and Gh below the FULL mark see Engine Oil
79. in the Owner s IREDAeREE CERES 2 Safety Precautions 3 Safe Riding 4 Design Characteristics 4 Safe Riding Practices 5 Carrying a Passenger 8 Protective Apparel 9 Gross Vehicle Weight Rating GVWR 10 Loading 12 Saddlebags 13 Parking 14 Transporting 14 Product Modifications 15 Selecting and Installing Accessories 15 Gasoline and Exhaust Gases 16 Maintenance 17 Location of Safety and Vehicle Information Labels 19 Reporting Safety Defects 22 Motorcycle Description 23 Vehicle Identification Number 27 Engine Identification Number 27 Ignition Key Number 28 Instruments and Controls 29 Ignition 29 Steering Lock 29 Ignition Switch 30 Off Position 30 On Position 30 P Park Position 31 Instrument Cluster 31 Speedometer 31 Tachometer 31 Indicator LightS 32 Low Oil Pres
80. indshield backrest or luggage rack choose one designed and approved by Victory specifically for your model and follow the instructions for proper installation and use An improperly designed or installed windshield backrest or luggage rack can reduce stability causing you to lose control of the motorcycle Gasoline and Exhaust Gases For complete fueling procedures see Fueling and Fill Height page 59 Gasoline is highly flammable and can be explosive in certain conditions Observe the following precautions when you refuel or service the fuel system Turn off the engine Use a well ventilated area Remove the fuel cap slowly Do not spill gasoline on the engine or the exhaust system Immediately wipe or rinse with water gasoline spilled on any part of the motorcycle or the surrounding area Do not smoke while fueling Do not fuel in an area where there are sparks or open flame 16 Safety Precautions Gasoline and Exhaust Gases continued 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 carbo
81. ion describes how to operate the Victory motorcycle for best performance and longevity including Engine Break in Period Fueling And Fill Height Starting The Engine Shifting Gears Accelerating Braking Stopping The Engine Parking For safe operation and riding see Safety Precautions beginning on page 3 Engine Break in Period During the first 500 miles 800 kilometers critical engine parts require special wear in procedures so they seat and mate properly Read understand and use the following rules for operating the motorcycle during the first 500 miles 800 kilometers to ensure your engine s long term performance and durability Do not put unnecessary load on the engine during the first 500 miles 800 kilometers Avoid prolonged full throttle operation or any condition that creates excessive engine heat 57 Operation Engine Break in Period continued 0 90 miles 0 145 kilometers Do not operate the motorcycle for extended periods of time at throttle positions above 1 3 throttle Vary the engine speed of the motorcycle Do not operate the motorcycle for extended periods of time at any one set throttle position 90 300 miles 145 483 kilometers Do not operate the motorcycle for extended periods of time at throttle positions above 1 2 throttle Vary the engine speed of the motorcycle Do not operate the motorcycle for extended periods of time at any one set throttle position 300 500 miles 483 800 kilomet
82. ized Victory dealer Fast Idle Lever Check Fast Idle Lever and Cable 1 Mowve the fast idle lever It should move smoothly from its rest position to its completely open position and back again 2 Fast idle lever freeplay the amount of lever movement from the rest position to the point of cable resistance should be 1 8 1 4 inch 3 6 mm 3 Adjust fast idle lever freeplay if necessary Adjust Fast Idle Lever Freeplay 1 Remove the operator s seat 2 Remove the fuel tank 88 Maintenance 3 Loosen the fast idle cable adjuster jam nut 4 Turn the cable adjuster in or out until the fast idle lever freeplay is 1 8 1 4 inch 3 6 mm 5 Tighten the adjuster jam nut and reinstall the fuel tank and operator s seat Throttle Check Throttle Control Grip and Cable 1 3 Rotate the throttle control grip It should rotate smoothly from its rest position to its completely open position and back again It should return to its rest position quickly when released Throttle freeplay the amount of throttle control grip movement from the rest position to the point of cable resistance should be 1 8 1 4 inch 3 6 mm Adjust throttle freeplay if necessary 1 8 1 4 inch Adjust Throttle Freeplay 1 2 3 Slide the rubber covers off both cable adjusters and loosen both adjuster jam nuts Turn both cable adjusters into the cable as far as possible Turn the cable adjuster on the throttle opening cable ou
83. l and lift the rear 4 Plunger wheel off the ground with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame 2 Position the small O ring on the belt tension gauge directly over the 10 Ibs mark on the plunger as E shown 3 Place a tape measure or rule next to the drive belt as f shown E 4 Place the base of the tension gauge bracket squarely EI against the lower strand of the drive belt halfway J between the front and rear drive sprockets Use the By Y Tu tape measure or ruler and record the position of the E base of the tension gauge bracket This position 1 Drive Belt 3 Rule represents zero force 2 Belt Tension Gauge 78 7 Maintenance Push the plunger upward until the small O ring touches the tension gauge body Make sure the tension gauge is seated squarely against the drive belt and record the position of the base of the tension gauge bracket This position represents 10 lbs force Calculate the difference between the zero force position and the 70 lbs force position you recorded V92TC Touring Cruiser and Deluxe Touring Cruiser 3 8 inch 9 5 mm Adjust belt tension as necessary Adjust Drive Belt Tension BCE Before adjusting drive belt tension be sure the rear axle is properly aligned see Align Rear Wheel page 80 1 Remove and discard the rear axle cotter pin Loosen the rear axle castle nut and th
84. lever movement from the rest position to the point of cable resistance should be between 0 04 0 08 inch 1 2 mm Measure the thickness of the gap between the clutch lever and the lever 1 Clutch Lever housing 2 Lever Housing 3 Gap 3 Adjust clutch lever freeplay if necessary see page 91 53 Pre Operation Check Check Fast Idle Lever 1 Move the fast idle lever It should move smoothly from its rest position to its completely open position and back again 2 Fast idle lever freeplay the amount of lever movement from the rest position to the point of cable resistance should be 1 8 1 4 inch 3 6 mm 3 Adjust fast idle lever freeplay if necessary see page 88 Check Front Suspension 1 To check the front suspension straddle the motorcycle and bring it to a vertical position 2 Apply the front brake and push down hard on the handlebars several times The front suspension should operate smoothly and quietly 3 Place the motorcycle on the sidestand and inspect the front forks Make sure there is no fork oil present on the fork tube or around the fork seal _ 1 Front Fork Tube 2 Fork Seal 54 Pre Operation Check Check Steering Straddle the motorcycle and bring it to a vertical position Turn the handlebars from stop to stop The action should be smooth but not loose or interfered with by wires hoses or control cables Check Rear Suspension Proper rear suspension adjustment is essenti
85. ling 107 Location 24 Maintenance intervals 73 Removing 106 Battery cables Installing 107 Removing 106 Brake caliper location Front 24 Rear 24 Brake fluid Adding to front 93 Adding to rear 96 Checking front 93 Checking rear 96 Maintenance intervals 72 Brake fluid reservoir location Front 23 Rear 26 Brake hoses and connections 98 141 Index Brake lever front Checking movement 92 Function 40 Location 23 Lubricating 93 Maintenance intervals 72 Brake pads Checking 97 Maintenance intervals 73 Replacement 97 Brake pedal rear Adjusting freeplay 95 Checking movement 95 Function 41 Location 26 Maintenance intervals 72 Braking 66 Break in Maintenance at 500 miles 800 km 70 Operation during first 500 miles 800 km 57 Bulbs See Lights C Capacities fluids 135 142 Cargo 12 Chassis specifications 137 Check engine indicator MFD 36 Cleaning 115 121 Battery terminals 122 Washing and drying 116 118 Waxing polishing and applying protectants 118 Windshield 119 Clock MFD 34 Clothing See Protective apparel Clutch cable Adjusting freeplay 91 Location 23 Maintenance intervals 72 Maintenance procedure 92 Clutch lever Adjust freeplay 91 Checking freeplay 90 Function and use 39 Location 23 Maintenance interval 72 Maintenance procedure 90 Component locations 23 27 Controls and instruments 29 44 Crankcase ventilation hose 87 D Design characteristi
86. ls Fuel Capacity 135 Fill height 59 Fueling procedures 59 Specifications 139 Stabilize for storage 121 Stabilizing for storage 121 Fuel cap Function and use 41 Location 23 Fuel filter Maintenance intervals 72 Replacement 88 Fuel gauge MFD 35 Fuel system Checking crankcase ventilation hose and connec tions 87 Checking hoses and connections 87 Fuel tank removal and installation 87 Maintenance intervals 71 Fuses Location 26 Replacement 108 Specifications 138 G Gasoline See Fuel Gear ratios 137 Gear shift lever Location 24 Gear shift pattern 62 Gear shift pedal Adjustment 98 Function 41 Maintenance intervals 73 Gross Vehicle Weight Rating GVRW Description 10 Examples 11 Specifications 135 Index H Hazardous materials handling 69 Headlamp Adjustment 109 Checking operation 46 High beam indicator light 33 High low beam switch Function 38 Location 38 Location 24 Maintenance intervals 73 Headlamp high beam indicator dimmer MFD 35 Horn Checking operation 46 Location 24 Horn button Function 38 Location 38 Identification numbers Engine 27 Ignition key 28 Vehicle 27 145 Index Ignition key Function 29 Identification number 28 Ignition switch Function 30 Location 24 Off position 30 On position 30 Park position 31 Indicator lights Headlamp high beam indicator Function 33 Location 32 Low fuel indicator Function 32 Location 32 Low oil p
87. ment Cluster Light Dimmer DIM appears as part of the display when in instrument cluster light dimmer mode To change the intensity of the instrument cluster light press the MFD Set button to select from six 6 intensity levels The engine does not need to be running to change the light intensity To change to the next MFD function press the MFD Mode button Headlamp High Beam Indicator Light Dimmer HB appears as part of the display when in headlamp high beam indicator light dimmer mode To change the intensity of the headlamp high beam indicator light press the MFD Set button to select from four 4 intensity levels The engine does not need to be running to change the indicator intensity To change to the next MFD function press the MFD Mode button Fuel Gauge The fuel gauge shows the amount of fuel in the fuel tank The fuel gauge range is from LOW 0 8 gallons 3 03 liters to FULL 5 gallons 18 9 liters To change to the next MFD function press the MFD Mode button Voltmeter When the engine is not running BAT and the battery voltage appear When the engine is running ALT and the charging system voltage appear To return to the odometer function press the MFD Mode button 35 Instruments and Controls Check Engine Indicator The check engine indicator will flash CH ENG any time the the ignition switch is in the On position and the Engine Control Module sensors report abnormal sensor or engi
88. motorcycle unsafe to ride and could severely injure you or others or damage the motorcycle Some modifications may be illegal in some states If in doubt contact your authorized Victory Dealer Selecting and Installing Accessories Because Victory cannot test and make specific recommendations concerning every accessory or combination of accessories sold you are responsible for determining that your motorcycle can be safely operated with accessories you install or additional weight you carry Use the following guidelines when choosing and mounting accessories Do not install accessories that impair the stability handling or operation of the motorcycle Before 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 Bulky or large accessories can make the motorcycle unstable due to the lifting or buffeting effects of wind and can cause you to lose control of the motorcycle 15 Safety Precautions Selecting and Installing Accessories continued Do not install electrical accessories that exceed the capacity of the motorcycle s electrical system An electrical failure could result and cause hazardous loss of engine power or lights or damage to the electrical system If you want to add a w
89. move and Install Saddlebags Remove the lower saddlebag mounting screw located outside and underneath the saddlebag Remove the two 2 upper saddlebag mounting screws located inside the saddlebag Disconnect the wiring harness and remove the saddlebag To reinstall the saddlebag reconnect the wire harness and install all spacers and fasteners in their original location Torque 18 ft Ibs 25 Nm Sidestand Straddle the motorcycle and bring it to a vertical position Move the sidestand to its stored up position then to its fully extended down position and back again It should move smoothly and quietly When the sidestand is in its stored position the sidestand return spring should hold the sidestand tightly against the motorcycle DOES If the sidestand is bent it should be replaced immediately Do not try to straighten a bent sidestand The sidestand will be weakened and may not be able to support the motorcycle Lubricate Sidestand 1 Bring the motorcycle to a vertical position with an appropriate motorcycle lift or a block of wood or steel placed securely under the frame 111 Maintenance 2 Move the sidestand to its stored up position and remove the sidestand return spring WARNING Wear face protection The sidestand return spring is under tension and can injure your eyes and face when released Remove the sidestand pivot bolt Remove any old grease and dirt from the sidestand frame and pivot bolt Lubrica
90. n can cause engine damage 6 Wax polish or apply protectant to the appropriate motorcycle components see Waxing Polishing and Applying Protectants page 118 Perform the pre operation check described in Pre Operation Check page 45 Test ride the motorcycle before returning it to regular use see Road Test page 113 123 Cleaning and Storage Notes 124 Warranties Motorcycle Noise Regulation Tampering with noise control systems is prohibited Federal law prohibits the following acts or causing thereof The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal or puncturing of any part of the intake system Lack of proper maintenance Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer This product should be checked for repair or replacement if the motorcycle noise has increa
91. n monoxide a colorless odorless gas that can cause unconsciousness or severe injury Observe the following precautions to avoid the effects of exhaust gases Do not breathe exhaust gases Do not start or run the engine in a closed area Maintenance Maintain the motorcycle according to the following requirements e Before you ride each time complete a pre operation check as described in the Pre Operation Check section Operating the motorcycle without completing the pre operation check can cause damage to the motorcycle or result in an accident Perform periodic maintenance according to the intervals specified in Periodic Maintenance Intervals beginning on page 70 Operating the motorcycle without performing periodic maintenance can damage the motorcycle or injure you or others Maintain proper tire inflation pressure and tread condition and proper wheel and tire balance Inspect tires regularly and replace them if they are worn or damaged Use only an approved replacement tire and 17 Safety Precautions 18 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 you to lose control of the motorcycle Check proper steering head bearing adjustment Regularly inspect the rear shock absorber and the front forks Check for fork oil or sho
92. nd remove the ignition key A WARNING Stopping the engine while the motorcycle is in motion and the transmission is engaged may damage the engine and the transmission or cause the rear wheel to lose traction In either case you may lose control of the motorcycle If the motorcycle is in motion and the engine stops on its own guide the motorcycle to a safe location off the road and away from traffic Parking When parking the motorcycle choose a flat firm surface Bring the motorcycle to a complete stop and with the transmission in neutral stop the engine Fully extend the sidestand turn the handlebars to the left and lean the motorcycle to the left until the sidestand firmly supports the motorcycle Lock the steering lock and take the key with you WARNING Moving or operating the motorcycle with the forks locked severely restricts steering and can cause you to drop or lose control of the motorcycle 67 Operation Parking continued If you must park on a slope point the motorcycle toward the top of the slope Put the transmission in gear and park the motorcycle so that it is stable when it rests on the sidestand If you must park on a soft surface use a sidestand plate under the foot of the sidestand to provide a firm surface The sidestand footrest must be strong enough and large enough to support the motorcycle s weight without sinking into the parking surface Many motorcyclists carry a sidestand plate Asp
93. ne operation The check engine indicator will continue to flash as long as the fault condition exists If the check engine indicator flashes repeatedly while the engine is running a serious engine problem may exist Contact an authorized Victory dealer as soon as possible 36 Instruments and Controls DEFAULT ODOMETER TRIP ODOMETER CLOCK T SET 3 Sec SET 3 Sec SET 3 Sec Y Y FLASHING FLASHING FLASHING METRIC RESET TRIP HOURS DIGIT TEN MINUTE DIGIT MINUTES DIGET ENGLISH ODOMETER T T T SET SET SET INCREASE INCREASE INCREASE VALUE VALUE VALUE ALTERNATOR _ TM BACK LIGHTING HIGH BEAM DIMMER FUEL BATTERY SET SET CHANGE CHANGE DIMMER VALUE DIMMER VALUE Multi Function Display MFD Functions 37 Instruments and Controls Left Side Handlebar Controls Fast Idle Lever The fast idle lever increases the engine idle speed when starting cold engine see page 60 To engage the fast idle lever move the lever toward the rear of the motorcycle until the lever stops Headlamp High Low Beam Switch The headlamp high low beam switch toggles the headlamp between high beam low beam and momentary passing beam To activate the high beam press the upper portion of the switch to activate t
94. on 43 Location 24 Lubrication 111 Maintenance intervals 73 Pad inspection 112 Spark plugs Gap 102 Inspecting 101 Installing 102 Location 24 Maintenance intervals 73 Removing 101 Specifications 136 Specifications 135 141 Index Speedometer Function 31 Location 31 Spokes Checking or replacing 100 Maintenance intervals 73 Starter button Function 40 Location 39 Starting the engine 60 Steering See Front forks Steering lock Function 29 Location 26 Stopping the engine 67 Storage 120 125 Maintenance during storage 123 Preparing for storage 120 123 Removing from storage 123 Suspension adjustment See Rear suspension 149 Index T Tachometer Function 31 Location 31 Taillight Checking operation 46 Location 24 Throttle cable Maintenance intervals 72 Maintenance procedure 92 Throttle cables Location 23 Throttle control grip Adjusting freeplay 89 Checking movement 89 Function 40 Location 23 Maintenance intervals 72 Tire pressure 99 Tires Air pressure 99 Check condition 100 Check tread depth 100 Maintenance intervals 73 Specifications 138 150 Torque specifications Brake lever pivot nut 93 Clutch lever pivot screw 91 Drive sprocket nut 77 Drive sprocket nut retainer 77 Exhaust system 103 Fuel tank mounting screws 88 Oil drain plug 74 Rear axle adjuster jam nut 79 Rear axle nut 79 Saddlebag mounting screws hard 111 Sidestand pivot bolt 1
95. on and maintenance procedures may result in death or injury to you or your passenger or damage to your motorcycle Following the precautions and procedures in this manual will add to your enjoyment and keep you riding safely Introduction Symbols and Terms Used in the Owner s Manual The following signal words and symbols appear in the Owner 5 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 Owner 5 Manual AN The safety alert symbol indicates a potential for personal injury to you or others amp WARNING Indicates a potential hazard that could result in serious injury or death Indicates a potential hazard that may result in minor personal injury or damage to the motorcycle Indicates a situation that may result in damage to the motorcycle BCC Highlights important information that we don t want you to overlook Safety Precautions 4 WARNING Improper use of this motorcycle can result in serious injury or death To minimize the risk of injury to you your passenger and others read and understand the information contained in this section before operating the motorcycle This section contains safety information specific to the Polaris Victory 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
96. on may not apply to you if inconsistent with controlling state law How To Obtain Warranty Service If your Victory Motorcycle requires warranty service you must take it to a Victory Motorcycle Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Victory Motorcycles division of Polaris Sales Inc suggests that you use your original selling dealer however you may use any Victory Motorcycle Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Victory Motorcycles division of Polaris Sales Inc This warranty also gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 134 Specifications Model Year 2002 v92TC V921C Touring Cruiser Deluxe Touring Cruiser Overall Length 98 in 249 cm Overall Width 42 in 107 cm Overall Height 60 8 154 cm Seat Height 28 3 in 72 cm Weelbase 65 5 in 166 cm Ground Clearance 5 in 13 cm 5 in 13 cm Dry Weight 720 Ibs 326 6 kg 727 105 329 8 kg Wet Weight 759 Ibs 344 3 kg 770 Ibs 349 3 kg Gross Vehicle Weight Rating GVWR 1210 Ibs 549 k
97. ont brake lever toward the handlebar and release it It should move freely and smoothly and should return to its rest 3 4 inch position quickly when released You should feel a firm resistance 19 mm in the lever within the first 3 4 inch 19 mm of lever travel y 50 Pre Operation Check Check Front Brake Fluid Level 1 check the front brake fluid level rest the motorcycle on the sidestand and on level ground Turn the handlebars until the front brake fluid reservoir is level 2 View the brake fluid through the sight glass The fluid should be clear and at a level in or above the sight glass Add brake fluid if necessary see page 93 Check Rear Brake Pedal Freeplay and Movement Rear brake pedal freeplay the amount of brake pedal movement from the rest position to the point of contacting the master cylinder should be 3 16 5 16 inch 5 8 mm Adjust pedal freeplay as necessary see page 95 Press and release the rear brake pedal It should move freely and smoothly and should return to its rest position quickly when you release it You should feel a firm resistance in the pedal within the first 3 4 inch 19 mm of pedal travel 51 Pre Operation Check Check Rear Brake Fluid Level 1 To check the rear brake fluid level remove the right side cover Straddle the motorcycle and bring it to a vertical position 2 View the brake fluid through the reservoir The fluid should be clear and at a level between
98. operating condition Notice Use the space provided at the back of this manual to record information about maintenance per formed on your motorcycle 70 Maintenance Periodic Maintenance Interval Table ODOMETER READING in MILES KILOMETERS al S 65 El oc S S S S S S c S S S Sila 3 3 3 9 9 9 9 9 9 S 3 3 3 9 98 S oj e a c S o A oj ol a o S g s a amp 2 2 s s 5 amp eye Component uw o o o o operation codes 3 S 3 S amp 8 8 8 098 508 8 3 8 8 8 below Bl 8 A amp A 8 8 5 9 FS F F 8 Engine Oil page 74 RR RR R R R R IR JRR RR R R R I R JRJ JR R R Engine Oil Filler 74 R RR Air Fllter page 76 I R 1 R I R I I R 1 R I R I I 1 R Drive Sprocket and I Sprocket Nut page 77 Drive Belt page 77 1 1 1 1 1 1 1 1 1 1 1 1 1 Rear Wheel Alignment page 80 1 1 1 1 1 1 1 1 Rear Shock Absorber page 82 1 1 1 R 1 R 1 R 1 Swing Arm and Rear Axle page 84 1 1 1 1 1 1 1 1 Front Fork Oil page 85 l 1 1 R 1 l R 1 1 R 1 Front Forks and Front Axle page 86 1 1 1 1 1 1 1 1 Fuel System page
99. or already in motion open the throttle gradually 65 Operation Braking To slow the motorcycle with the brakes close the throttle and apply the front and rear brakes evenly As the motorcycle slows either disengage the clutch or downshift each time your speed reaches a downshift point Applying slightly more front brake than rear brake generally gives you the best braking performance Do not apply the brakes so forcefully or quickly that either wheel stops rotating Leave sufficient distance so you can apply the brakes gradually if you need to stop amp WARNING Do not apply either brake so strongly that the wheel stops rotating This may cause you to lose control of the motorcycle Braking hard on wet rough loose or slippery surfaces can cause the motorcycle to skid and you could lose control of the motorcycle Apply the brakes lightly on such surfaces e Braking while in a curve can cause you to lose control of the motorcycle Bring the motorcycle to the upright position before applying the brakes and avoid applying the brakes in a corner if at all possible 66 Operation Stopping the Engine Before stopping the engine bring the motorcycle to a complete stop either in neutral or with the clutch disengaged Once the motorcycle is at a complete stop if it is not already in neutral shift into neutral To stop the engine set the engine stop run switch to the Stop position turn the ignition switch to the Off position a
100. ors seat and fuel tank Inspect the crankcase ventilation hose for cracks or damage Inspect the hose connection at the air cleaner and at the crankcase for dampness or stains from leaking Evaporative Emission Control System California models only Visually inspect all evaporative emission control system hoses and connections Make sure all connections are tight Also inspect the evaporative canister to make sure it has not been damaged Fuel Tank 1 To remove the fuel tank remove the operator s seat 2 Remove the front and rear fuel tank mounting screws 3 Unplug the fuel level sensor and fuel pump wire harness 4 Wrap a clean rag around the fuel rail bleed valve and relieve the fuel line pressure by depressing the center of the bleed valve Fuel can damage painted surfaces and plastic parts Wipe spilled fuel immediately from the motorcycle using a clean dry soft cloth 87 Maintenance Disconnect the fuel line Disconnect the tank vent line To reinstall the fuel tank reconnect all fuel lines and wire harness tA Reinstall the fuel tank mounting screws Torque 20 ft Ibs 27 Nm 9 Reinstall the operator s seat Replace Fuel Filter The fuel filter is attached to the electric fuel pump located inside the fuel tank Fuel filter condition is associated with engine performance and fuel economy For fuel filter replacement procedures and special tools required see the Victory Service Manual or contact an author
101. ours move the fast idle lever toward the rear of the motorcycle until the lever stops Set the engine stop run switch to the Run position You should hear the fuel pump momentarily as it pressurizes the fuel system Operation Starting the Engine continued 7 Leaving the throttle closed press and hold the starter button until the engine starts If the engine does not start within a few seconds after you press the starter button release the button and wait several seconds Then press and hold the starter button again Hold the starter button for as short a time as possible to minimize battery drain and do not push the starter button for more than 10 seconds at any one time If either the check engine indicator or the low oil pressure indicator does not go out after the engine starts stop the engine See either Check Engine Indicator page 36 or Low Oil Pressure Indicator page 32 8 As soon as the engine warms enough to idle smoothly move the fast idle lever toward the front of the motorcycle until the lever stops Allow the engine to idle for about 1 minute after a cold start or 30 seconds after a warm start Do not rev the engine or put the transmission in gear immediately after starting the engine This allows the oil to reach all areas requiring lubrication before the engine is put under load 61 Operation Shifting Gears amp WARNING The clutch must be fully disengaged clutch lever pulled completely in to
102. r 80 100 UN 5 6 T 8 120 80 Neutral Indicator Turn Signal Indicators Headlamp High Beam Indicator Multi Function Display MFD 31 Instruments and Controls Indicator Lights Low Oil Pressure Indicator illuminates when engine oil pressure drops below safe operating pressure If this indicator illuminates while the engine is running turn the engine off immediately and check the oil level Add oil if necessary If the oil level is correct and the indicator remains illuminated after the engine is restarted turn the engine off immediately The low oil pressure indicator also illuminates when the ignition switch is in the On position and the engine is not running This demonstrates that the indicator is functioning properly Low Fuel Indicator illuminates when approximately 0 8 gallons 3 03 liters of fuel remains The low fuel indicator also illuminates momentarily when the ignition switch is in the On position and the engine is not running This demonstrates that the indicator is functioning properly Neutral Indicator illuminates when the transmission is in neutral The neutral indicator also illuminates momentarily when the ignition switch is in the On position and the engine is not running This demonstrates that the indicator is functioning properly Turn Signal Indicators flashes when the left turn signals are active flashes when the right turn signals are active Both turn signal indicators flash
103. r and one passenger Do not exceed the gross vehicle weight rating see Specifications 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 you to lose control of the motorcycle n the first 500 miles operate the motorcycle according to the break in procedures described in Engine Break in on page 57 Operating the motorcycle without following break in procedures can result in serious engine damage Some Victory motorcycles include saddlebags auxiliary lights a windshield a passenger backrest and a highway bar as standard equipment Under certain conditions it may be necessary to reduce the operating speed of motorcycles with this equipment Safety Precautions Safe Riding Practices Follow these general safe riding practices Before you ride make sure you can operate the motorcycle safely and properly by following the recommendations given at the beginning of the Safety Precautions section on page 3 Each time you ride make the checks described in the Pre Operation Check section Operating the motorcycle without completing the pre operation check can cause damage to the motorcycle or result in an accident Until you are thoroughly familiar with the Victory motorcycle and all of its controls practice riding where there is little or no traffic Practice riding at moderate
104. r 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 22 Motorcycle Description Use the following information to identify and locate the major components of the Victory motorcycle Information on vehicle and engine identification numbers model number and the ignition key number is also provided Ea E uM C For All Models Standard Cruiser Operator s View Shown 1 Clutch Cable page 90 7 Front Brake Lever 40 2 Instrument Cluster page 31 8 Right Handlebar Controls page 39 3 Fuel Cap page 41 9 Throttle Cables page 89 4 Front Brake Fluid Reservoir page 98 10 Left Handlebar Controls page 38 5 Right Mirror 11 Clutch Lever page 39 6 Throttle Control Grip page 40 12 Left Mirror 23 Motorcycle Description 24
105. rcycle s stopping power at most Consider road conditions before applying the brakes when the road is wet 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 you apply the brakes Improper braking may cause you to lose control of the motorcycle or may not slow you in time to avoid a collision As you approach a curve choose a speed and a lean angle that allow 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 you to lose control of the motorcycle Safety Precautions Safe Riding Practices continued Ground clearance is reduced when you lean the motorcycle Do not allow components to contact the road surface when leaning the motorcycle in a curve as this could cause you to lose control of the motorcycle Retract the sidestand fully before riding If the sidestand is not fully retracted while you are riding it could contact the road surface and cause you to lose control of the motorcycle Do not tow a trailer Towing a trailer can make the motorcycle hard to handle and cause you to lose control of the motorcy
106. rd you As the clutch begins to engage the motorcycle begins to move forward To shift to the next higher gear accelerate smoothly and easily to the recommended shift point see Recommended Shift Points page 64 With a quick motion simultaneously close the throttle completely and disengage the clutch Raise the shift pedal with your toe or depress it with your heel until you feel it stop at the next gear Simultaneously moving both the clutch lever and the throttle with a smooth gentle motion gradually release the clutch lever and open the throttle Within the recommended speed ranges see Recommended Shift Points page 64 you can downshift shift to a lower gear to slow the motorcycle or to increase the available power You may want to downshift when climbing a hill or passing Downshifting also helps to decrease your speed when combined with closing the throttle To shift to a lower gear simultaneously pull in the clutch lever and close the throttle Shift into the next lower gear by depressing the shift pedal with your toe Simultaneously release the clutch lever and open the throttle 63 Operation Shifting Gears continued WARNING Downshifting at a speed in excess of the recommended downshift point may severely damage the transmission or cause the rear wheel to lose traction It could also result in engine damage from running at excessive rpm Reduce speed before downshifting and do not downshift at a speed
107. re a Evaporative Emission Control System California models only Fuel Tank rep ee eR onere eS Replace Fuel Filter Fast Idle Lever Check Fast Idle Lever and Cable Adjust Fast Idle Lever Freeplay Throttle iis ccd leeren Check Throttle Control Grip and Cable vi Adjust Throttle Freeplay 89 rive RET ES 90 Check Clutch Lever and Cable 90 Lubricate Clutch Lever 90 Adjust Clutch Freeplay 91 Lubricate Control Cables 92 Brakes csi reu 92 Check Front Brake Lever Movement 92 Lubricate Front Brake Lever 93 Check Front Brake Fluid Level 93 Add Front Brake Fluid 93 Check Rear Brake Pedal Freeplay and Movement 95 Adjust Rear Brake Pedal Freeplay 95 Check Rear Brake Fluid Level 96 Add Rear Brake Fluid 96 Check Brake Pads 97 Check Brake Hoses and Connections 98 Gear Shift Pedal 98 Adjust Gear Shift Pedal Height 98 99 Check Tire Pressure 99 Tire Pressure Table 99 Check Tire Condition 100 Check Tread Depth 100 Table of Contents Check Wheel Spokes 100 Waxing Polishing and Applying Check or R
108. ressure indicator Function 32 Location 32 Neutral indicator Function 32 Location 32 Turn signal indicators Function 32 Location 32 146 Information labels 19 23 Instrument cluster Description 31 Location 23 Instrument cluster light dimmer MFD 35 Instruments and controls 29 44 Introduction 1 3 K Kickstand See Sidestand L Light bulb specifications 138 Lights Adjusting auxiliary lights 110 Adjusting headlamp 109 Bulb specifications 138 Low fuel indicator Function 32 Location 31 Low oil pressure indicator Function 32 Location 31 Maintenance 69 114 Maintenance interval table 71 Maintenance intervals 70 MFD See Multi Function Display MFD Modifications See Product modifications Motorcycle description 23 28 Mufflers exhaust location 25 Multi Function Display MFD Check engine indicator function 36 Clock function 34 Fuel gauge function 35 Function 33 38 Headlamp high beam indicator light dimmer func tion 35 Instrument cluster light dimmer function 35 Location 32 Mode button Function 40 Location 39 Odometer function 33 Set button Function 39 Location 38 Index Trip odometer function 33 Voltmeter function 35 Neutral indicator Function 32 Location 31 O Odometer MFD 33 Oil drain plug location 74 Oil fill cap dipstick location 75 Oil filter Changing 74 Location 24 Maintenance intervals 71 Oil level checking 75 Oil engin
109. sed significantly through use Otherwise the owner may become subject to penalties under state and local ordinances 125 Warranties Noise Emission Warranty Victory Motorcycle Division warrants that this exhaust system at the time of sale meets all applicable U S EPA Federal noise standards This warranty extends to the first person who buys this exhaust system for purposes other than resale and to all subsequent buyers Warranty claims should be directed to an authorized Victory dealer or Victory Motorcycle Division Polaris Sales Inc Box 47700 Hamel MN 55340 9960 Emissions Control System Warranty Victory Motorcycles Polaris Sales Inc Emission Control System Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Victory Motorcycle Division Polaris Sales Inc hereinafter Victory are pleased to explain the emission control system warranty on your 2002 or later Victory motorcycle In California new motor vehicles must be designed built and equipped to meet the state s stringent anti smog standards Victory must warrant the emission control system on your motorcycle for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your motorcycle Your emission control system may include parts such as the fuel injection system the ignition system catalytic converter and engine computer Also included may be hoses belts connectors and other
110. shing the motorcycle make sure the exhaust pipes are not hot Cover each exhaust pipe opening with a plastic bag and attach the bag to the pipe with a strong rubber band To prevent contamination from water check that the spark plugs spark plug wire caps oil fill cap and fuel caps are properly seated 1 Park the motorcycle in the shade to prevent water spotting 2 The engine cases are painted If you choose to use a degreaser follow the degreaser manufacturer s instructions 3 Rinse off as much dirt and mud as possible with water running at low pressure Do not use high water pressure or high pressure sprayers such as those found at coin operated car washes Excessive water pressure may allow water to seep into and deteriorate such components as wheel bearings brake caliper assemblies brake master cylinders and transmission seals Electrical components may be damaged by contact with water Do not spray or allow water to come into contact with electrical components or connectors 4 Wash the entire motorcycle using a soft cloth or sponge soaked in a solution of mild detergent and warm water applying minimal pressure as you wash Let the detergent do the cleaning not the pressure you apply Excessive washing pressure may cause dirt sand or other foreign materials on the motorcycle to scratch the finish Keep the cloth or sponge clean by rinsing it frequently and soak it in the detergent and water solution to provide plenty of so
111. speed on varying road surfaces and under varying weather conditions Know your skills and limits and ride within them Allow only licensed experienced operators to ride your motorcycle and then only after they have become familiar with its controls and operation Do not ride when you are 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 loss of balance and can affect your awareness and judgment f your motorcycle operates abnormally correct the problem immediately see the Victory Service Manual or contact your authorized Victory Dealer If you continue to operate the motorcycle in this condition you are likely to aggravate the initial problem increase the cost of repairs and threaten your safety Safety Precautions Safe Riding Practices continued 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 are visible to other motorists and observe their behavior carefully as they may not see or be aware of you Be especially cautious at an intersection as this is the most likely place for an accident Remember that you are more vulnerable to injury on a motorcycle than in an enclosed vehicle To prevent loss o
112. sure Indicator 32 Low Fuel Indicator 32 Neutral Indicator 32 Turn Signal Indicators 32 Table of Contents Headlamp High Beam Indicator Multi Function Display MFD Trip Odometer ero dr Instrument Cluster Light Dimmer Headlamp High Beam Indicator Light Dirmtnet acte ert Fuel Gauge Voltmeter Check Engine Indicator Left Side Handlebar Controls Fast Idle Lever Headlamp High Low Beam Switch Turn Signal Switch Horn Button Clutch Lever Multi Function Display MFD Set BURNOM a mte ae EAA Baad Right Side Handlebar Controls Engine Stop Run Switch Emergency Flasher Switch Starter Button Front Brake Lever Throttle Control Grip 40 Multi Function Display MFD Mode Button ioo cube 40 Gear Shift Pedal 41 Rear Brake Pedal 41 2 2 ese 41 Auxiliary Light Switch 42 Saddlebags 42 Side Covers 43 Sidestand
113. t in serious injury or damage Adjust components designed for normal wear adjustment and repair or replace worn or damaged components as necessary Check Electrical Equipment To perform a pre operation check on the electrical equipment set the ignition switch to the On position Set the ignition switch to the Off position once you have completed the electrical equipment portion of the pre operation check Instrument Cluster The low fuel indicator and the neutral indicator should illuminate momentarily The multi function display MFD should be in odometer mode The low oil pressure indicator should illuminate If the transmission is in neutral the neutral indicator should remain illuminated 45 Pre Operation Check Pressing the MFD Mode button should advance the MFD through the various functions see page 33 Headlamp Check the headlamp to see that it is on Set the headlamp switch to the high beam position The headlamp brightness should increase and the headlamp high beam indicator in the instrument cluster should illuminate Taillight With the ignition switch in the On position the taillight and the license plate light should illuminate Apply slight pressure to the front brake lever taillight brightness should increase Apply slight pressure to the rear brake pedal taillight brightness should increase Turn Signals Running Lights The two amber front running lights should illuminate US and Canadian models only Move the
114. t until the throttle freeplay is between 1 8 1 4 inch 3 6 mm Hold the throttle control grip at the fully closed position and turn the cable adjuster on the throttle closing cable out until resistance is felt Tighten the adjuster jam nuts on both cables and reinstall both rubber covers 89 Maintenance Clutch Check Clutch Lever and Cable 1 3 Squeeze the clutch lever toward the handlebar and release it It should move freely and smoothly and should return to its rest position quickly when released aN Clutch freeplay the amount of clutch lever movement m pu from the rest position to the point of cable resistance should be between 0 04 0 08 inch 1 2 mm Measure the gap between the clutch lever and the lever housing 1 Clutch Lever 2 Lever Housing Adjust clutch freeplay if necessary see page 91 3 Gap Lubricate Clutch Lever 1 2 3 SANNA 90 Remove the operator s seat Remove the front and rear fuel tank screws Raise the rear of the fuel tank high enough to expose the clutch cable Support the rear of the fuel tank with a block of wood Slide the rubber cover off the cable adjuster and loosen the adjuster jam nut Turn the cable adjuster all the way in Disconnect the clutch cable from the clutch lever Remove clutch lever pivot nut and screw Remove any old grease and dirt from the clutch lever and lever housing Lubricate the clutch lever and lever pivot screw with Victory All
115. te the sidestand and pivot bolt with Victory All Purpose Grease or equivalent Nn PW Reinstall the sidestand pivot bolt Torque 35 ft Ibs 47 Nm 7 Move the sidestand to its stored up position and reinstall the sidestand return spring Inspect Sidestand Pad 1 Check the condition of the sidestand rubber pad and make sure it is firmly attached to the sidestand 2 Inspect the sidestand rubber pad for wear Replace the rubber pad if it is worn above the wear limit see the Victory Service Manual or an authorized Victory dealer 1 Sidestand 2 Rubber Pad 112 Maintenance Check Fasteners Visually inspect the entire motorcycle chassis and engine for loose damaged or missing fasteners Tighten loose fasteners to the proper torque see the Specifications section of the Owner 5 Manual or the Victory Service Manual Replace stripped damaged or broken fasteners with genuine Victory fasteners of equal size and strength immediately Road Test Before returning the motorcycle to regular use road test it in a safe environment Pay special attention to the proper fit and operation of all serviced components Make any corrections or additional adjustments as necessary to ensure safe and enjoyable vehicle performance A WARNING Improperly installed or adjusted components can make the motorcycle unstable or hard to handle Improperly installed electrical components can cause engine or electrical system failure In either case
116. throttle control grip controls the engine speed To increase engine speed twist the throttle control grip toward you to decrease engine speed twist the grip away from you When you release the grip it returns to the idle speed position Multi Function Display MFD Mode Button Use the MFD Mode button in conjunction with the MFD Set button to control the features of the multi function display see page 33 40 Instruments and Controls Gear Shift Pedal The gear shift pedal is located on the left side of the motorcycle To shift to a lower gear press down on the front of the gear shift pedal To shift to a higher gear press down on the rear or lift up on the front of the gear shift pedal For proper gear shifting procedure see Shifting Gears page 62 Rear Brake Pedal The rear brake pedal is on the right side of the motorcycle To engage the rear brake press down on the rear brake pedal For braking procedures in various riding conditions see Braking page 66 Fuel Cap The fuel cap is right hand threaded turn clockwise to tighten turn counterclockwise to loosen When tightening the fuel cap continue turning the cap until a clicking sound is heard indicating proper tightness Continue turning the fuel cap clockwise to align the Victory logo if desired 1 Rear Brake Pedal For fueling procedure see Fueling and Fill Height page 59 41 Instruments and Controls Auxiliary Light Switch
117. timate the number of miles you can travel on a tank of fuel 33 Instruments and Controls To reset the trip odometer the ignition switch must be in the On position with the MFD in trip odometer mode Press and hold the MFD Set button for 3 seconds To change to the next MFD function press the MFD Mode button Clock A clock icon appears as part of the display when in clock mode When the clock is operating normally the colon between the hour and minutes flashes To set the clock the ignition switch must be in the On position with the MFD in clock mode 1 2 3 4 5 6 7 Press and hold Set button for 3 seconds when in clock mode The hour digits should flash Press the MFD Set button to select the desired hour Press the MFD Mode button to accept the new hour setting The ten minute digit should flash Press the MFD Set button to select the desired ten minute Press the MFD Mode button to accept the new ten minute setting The minute digit should flash Press the MFD Set button to select the desired minute Press the MFD Mode button to accept the new minute setting The clock should return to normal operation and the colon should flash To change to the next MFD function press the MFD Mode button BEC The multi function display clock will not function if the battery voltage drops below 11 5 volts The clock will reset to 12 00 if the battery is disconnected 34 Instruments and Controls Instru
118. ttended turn the engine off engage the steering lock and take the ignition key with you The engine and exhaust system are very hot after the engine has been running Therefore park the motorcycle where people are not likely to touch the 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 as the motorcycle could catch fire Park the motorcycle on a firm level surface if possible Sloped or soft surfaces may not support the motorcycle when it is parked and it may fall over If you must park on a sloped or soft surface reduce the chances of the motorcycle falling over by following the procedures described in Parking page 67 Transporting If you must transport the motorcycle do the following Use a truck or trailer Do not tow the motorcycle with another vehicle as towing will impair the motorcycle s steering and handling which can cause you to lose control of the motorcycle Position and restrain the motorcycle so it is kept upright on the truck or trailer as gasoline may leak out of the fuel tank if the motorcycle leans over Gasoline is a fire hazard and it can also damage the motorcycle s finish 14 Safety Precautions Product Modifications Modifying the motorcycle by removing any equipment or adding equipment not approved by Victory may void your warranty Such modifications may also make the
119. turn signal switch to the left The front and rear left turn signals and the left turn signal indicator in the instrument cluster should flash Push the switch in toward the housing The turn signals and turn signal indicator should stop flashing Repeat the procedure for the right turn signals Emergency Flashers Slide the emergency flasher switch to the left All four turn signals and both turn signal indicators in the instrument cluster should flash Slide the switch to the right The turn signals and turn signal indicators should stop flashing Horn Press the horn button The horn should sound loudly 46 Pre Operation Check Engine Stop Run Switch Be sure the engine stop run switch stops the engine or prevents the engine from starting when set to the Stop position BETTTTEH lf you regularly use this switch to shut off the engine you are already checking its operation each time you use the motorcycle Check Engine Oil Level A dipstick attached to the oil fill cap registers the engine oil level 1 With the transmission in neutral start and run the engine for several minutes Shut the engine off and wait for 3 5 minutes Straddle the motorcycle on level ground and bring it to a vertical position Remove the oil fill cap and wipe the dipstick clean Reinstall the dipstick and turn the cap 1 Oil Fill Cap Dipstick clockwise until it seats Remove the dipstick again and note
120. ual or an authorized Victory dealer Check all exhaust system fasteners 1 Tighten exhaust header flange nuts Torque 12 ft lbs 16 Nm V92C Standard and Deluxe Cruiser Exhaust System Shown 2 Tighten muffler clamps Torque 44 ft Ibs 59 Nm N LS ad 3 Tighten muffler mounting screws e yc Torque 18 ft Ibs 24 Nm ERN G e 4 Tighten muffler bracket screws Torque 18 ft Ibs 24 Nm KA 3 1 Header Flange Nut 3 Muffler Mounting Screw 2 Muffler Clamp 4 Muffler Bracket Screw 103 Maintenance Remove and Install Seat The V92TC Touring and Deluxe Touring Cruiser has a combined operator and passenger seat amp WARNING Always make sure the seat is securely attached before riding the motorcycle A loose seat could cause a sudden shift in riding position causing you to lose control of the motorcycle 1 Remove the acorn nut from behind the seat 2 Lift rear of seat slightly to clear the rear mounting stud and slide seat rearward and off of the motorcycle 3 To reinstall the seat slide it forward and into position on the motorcycle Make sure the front seat mount is engaged Lower the seat onto the rear mounting stud and reinstall the acorn nut 104 Maintenance Battery The motorcycle uses a permanently sealed maintenance free battery Do not remove the battery cap strip for any reason Keep the battery connections clean and tight at all times A WARNING The battery contains sulf
121. uric acid which can cause severe burns Do not allow sulfuric acid to contact skin eyes or clothing Antidotes External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention BC f your Victory motorcycle will not be used for a period of 6 weeks or longer a maintenance charger should be connected to the battery A fused maintenance charger connection is provided beneath the left side cover The connector is designed for use with the Victory Maintenance Charger available at your authorized Victory dealer 105 Maintenance Remove Battery 1 Remove the left side cover 2 Remove the battery hold down strap 3 Disconnect the negative battery cables exposed connectors 4 Disconnect the positive cables covered with a red boot Disconnecting the positive cable first can produce an electric shock that could result in damage or injury 5 Slide the battery out BEC The multi function display clock will not function if the battery voltage drops below 11 5 volts The clock will reset to 12 00 if the battery is disconnected Charge Battery WARNING The battery may contain explosive gases Keep sparks cigarettes or any flame away from the battery Shield eyes and protect skin and clothing when handling or working near
122. ward the handlebars before you attempt to shift gears Forced shifting shifting without the clutch disengaged may damage the engine transmission and drive train causing you to lose control of the motorcycle The motorcycle is equipped with a five speed transmission The gear pattern is shown in the illustration to the right The motorcycle has a heel toe shift pedal which allows you to shift to a higher gear by depressing the rear of the pedal with your heel or by lifting the front of the pedal with your toe To shift to a lower gear depress the front of the pedal with your toe Neutral position is between first and second gear The transmission is in neutral when the motorcycle moves forward or backward freely while the clutch is engaged With the Ignition switch set to the On position the neutral indicator illuminates when the transmission is in neutral 62 Operation Shifting Gears continued To engage first gear start the engine see Starting the Engine page 60 With the engine at idle speed engage the front brake squeeze the brake lever and disengage the clutch squeeze the clutch lever Push the shift pedal down until you feel it stop in first gear Disengage the front brake release the brake lever Simultaneously moving both the clutch lever and the throttle control grip with a smooth gentle motion gradually engage the clutch release the clutch lever and open the throttle roll the throttle control grip towa
123. yiCTORY PELARIS Est 1954 THE NEW AMERICAN MOTORCYCLE 2002 V92TC V92TC DELUXE ZAWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm We ve created a web site just for YOU Technical tips e New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com POLARIS The Way Out All text photographs and illustrations 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 manual and the motorcycle Polaris Industries reserves the right to make production changes at any time without notice and without incurring any obligation to make the same or similar changes to motorcycles previously built yICTORyY OroRcYcL PELARIS 2002 OWNER S MANUAL V92TC V92TC Deluxe Victory Motorcycle Division Polaris Industries Inc 2100 Highway 55 Hamel Minnesota 55340 9800 Tele 763 542 0500 Fax 763 542 0599 Copyright 2001 Polaris Industries Inc All rights reserved Victory Motorcycles is a registered trademark of Polaris Industries Inc Dunlop is a registered trademark of Dunlop Tire Corporation Features of Victory motorcycles are covered by U S Patent Nos D397976 D398065 D407169 D409551 D416831 D4365

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