2010 Victory Vision Tour Service Manual

SPECIFICATIONS / GAUGE / AUDIO
CHAPTER 1
1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TRADEMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SERVICE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
2008 - 2009 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
2010 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
VIN NUMBER / MANUFACTURER LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
VECI / NECI / TIRE INFORMATION LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
KEY IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
PUBLICATIONS & TECHNICAL LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
MATERIAL SAFETY DATA SHEET (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
VICTORY TOUCH-UP & REFINISHING PAINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
VICTORY DETAIL & FINISH RESTORER KITS AND PRODUCTS . . . . . . . . . . . . . . . 1.13
PAINTING TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
PAINT COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
TRANSPORTING, ELEVATING, AND SECURING THE MOTORCYCLE . . . . . . . . . . . 1.22
INSTRUMENTATION / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
CLOCK, GEAR POSITION, TRIP ODOMETER, TEMPERATURE, ODOMETER . . . . . 1.25
CHANGING INFORMATION DISPLAY UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
CONSOLE MOUNTED SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
HAND GRIP HEATER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
HAZARD SWITCH (EMERGENCY FLASHERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
DRIVING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27
SEAT HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
LEFT HANDLEBAR SWITCH, MODE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
HEADLAMP HIGH / LOW BEAM SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
WINDSHIELD ADJUSTMENT SWITCH (MOTORIZED) . . . . . . . . . . . . . . . . . . . . . . . . 1.28
MANUAL WINDSHIELD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29
TURN SIGNAL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29
CLUTCH LEVER & STARTER INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29
RIGHT HANDLEBAR CONTROLS, ENGINE STOP SWITCH, STARTER BUTTON . . 1.30
AUDIO / COM / CRUISE CONTROL BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
LINKED BRAKE SYSTEM / ABS BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
FRONT BRAKE LEVER REACH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31
FOOT CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31
FUEL DOOR, FUEL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
GLOVE / STORAGE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
SADDLEBAGS, TRUNK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
1.1
© 2009 Polaris Sales Inc.
RADIO / AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
RADIO / AUDIO SYSTEMS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
RADIO FREQUENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
MAIN USER INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
LEFT HAND CONTROLS / REAR PASSENGER CONTROL . . . . . . . . . . . . . . . . . . . . 1.35
AUDIO SYSTEM POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
VOLUME CONTROL / AUDIO MUTE / AUDIO VOLUME / PASSENGER VOLUME . . 1.36
AUDIO SOURCE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37
AUDIO TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
MEMORY PRESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
AUDIO MODE MENUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
BASS, TREBLE, FADER, EXTERNAL SPEAKER SETTING, AVC . . . . . . . . . . . . . . . . 1.39
CB HEADSET VOLUME CONTROLS / CB HEADSET ENT MODE* . . . . . . . . . . . . . . 1.40
ICOM VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
TUNING (SEEK / SCAN MODES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
RADIO DATA SYSTEM (RDS) AUX MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
XM DISPLAY / XM TUNE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
XM CATEGORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
NOAA WEATHER BAND (WB OR WX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
CB RADIO / ICOM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
CB RADIO FCC RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
HEADSET USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
GETTING STARTED / CB CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
PUSH-TO-TALK (PTT) / SQUELCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
CB RADIO VOLUME SETTING (DRIVER / PASSENGER) . . . . . . . . . . . . . . . . . . . . . . 1.45
CB LO/DX* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
CB FREQUENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
ICOM SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
VOX BREAK SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
ICOM VOLUME SETTING (DRIVER / PASSENGER) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47
HEADSET RECEPTACLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47
AUX / IPOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
GETTING STARTED / AUX INPUT CABLE / INPUT CABLE SETUP . . . . . . . . . . . . . . 1.48
IPOD USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
AUX MODE (2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49
IPOD PLAY LISTS / IPOD TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49
XM RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
ABOUT XM RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
XM READY LEGAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
XM READY SUBSCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
GETTING STARTED - XM RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
XM RADIO RECEPTION / XM RADIO SPECIFIC MENU OPTIONS. . . . . . . . . . . . . . . 1.51
XM RADIO SETTINGS / XM CATEGORY SELECTION . . . . . . . . . . . . . . . . . . . . . . . . 1.51
XM CHANNEL SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
NAV MP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
TIPS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
GETTING STARTED / CHANGING AUX MODE TO NAV MP3. . . . . . . . . . . . . . . . . . . 1.53
CD CHANGER (2008-2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55
FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
1.2
GENERAL INFORMATION
TRADEMARKS
1
The following are REGISTERED trademarks of Polaris Industries Inc.:
VICTORY MOTORCYCLES, VICTORY, VICTORY PERFORMANCE, VICTORY VISION, NESS SIGNATURE SERIES
VICTORY VISION, FREEDOM, POLARIS; POLARIS THE WAY OUT; VEGAS; VEGAS JACKPOT; HAMMER; KINGPIN;
NESS SIGNATURE SERIES VEGAS JACKPOT.
Polaris acknowledges the following products mentioned in this manual:

LOCTITE, is a registered trademark of the Henkel Corporation
DUNLOP, is a registered trademark of the Dunlop Tire Corporation.
STA-BIL, is a registered trademark of Gold Eagle
NYOGEL, trademark of Gold Eagle
FLUKE, registered trademark of the Fluke Corporation
XM, a registered trademark of XM Satellite Radio, Inc.
SERVICE RULES
In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual and
familiarize themselves with the procedures before beginning. Notes, Cautions and Warnings have been included for
clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are necessary
to perform some procedures in this manual safely and correctly.
Use only genuine Victory service parts, including fasteners that require replacement if removed. Do NOT substitute
fasteners or hardware.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause damage
to precision parts. Clean the motorcycle before beginning service. Clean all parts before installing.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If
it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine
damage or in the case of steering, driveline, and chassis components, can result in loss of control during operation of
the motorcycle, which may result in severe personal injury or death.
If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand tighten.
Following the method and sequence indicated, tighten evenly to the specified torque value. When removing nuts, bolts
or screws from a component with several fasteners, loosen them all about 1/4 turn before removing them to prevent
distortion of that component.
Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating surfaces
for the gasket are clean and smooth to avoid leaks and maintain specified tolerances.
Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore,
they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand
or compress them beyond what is required for installation.
Victory lubricants and greases have been specially formulated to provide maximum performance and protection when
applied properly. In some applications, warranty coverage may be void if improper lubricants are used.
Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating grease
loses lubricity and may contain abrasive foreign matter.
Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or
any other fasteners as noted in this service manual with genuine Victory hardware from an authorized Victory dealer.
Working with batteries can be hazardous. Review all battery warnings and cautions.
1.3
SAFETY INFORMATION
Understanding Safety Labels & Instructions
READ AND BECOME FAMILIAR WITH ALL WARNING AND CAUTION SYSMBOLS AND STATEMENTS LISTED
BELOW AND IN THE TEXT OF THIS MANUAL BEFORE YOU BEGIN WORK.
This is the safety alert symbol. When you see this symbol
on the vehicle or in this manual, be alert to the potential
for personal injury. Your safety is involved! Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors or in a

Indicates a hazardous situation, which, if not avoided, could well ventilated area.
result in death or serious injury.  Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
 Do not overfill the tank. Do not fill the tank neck above
the fuel tank insert. Leave air space to allow for fuel
Indicates a hazardous situation, which, if not avoided, could expansion.
result in minor or moderate injury.  If you get gasoline in your eyes or if you swallow
gasoline, see your doctor immediately. Never try to
syphon gasoline using mouth suction.
 If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
NOTICE: change clothing.
Indicates a situation, which, if not avoided, could result in  Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause
damage to the motorcycle. loss of consciousness or death in a short time.
The engine exhaust from this product Improper repairs or service can create The engine and exhaust components on this
contains chemicals known to cause cancer, unsafe conditions that may cause severe product become very hot during operation
birth defects or other reproductive harm. personal injury or death. and remain so for a period of time after the
engine is stopped.
Never run the engine in an enclosed area Modifications to this motorcycle not approved Brake fluid is poisonous.
without a properly functioning exhaust gas by Victory may cause loss of performance,
evacuation system connected to the product. excessive emissions, and make the machine KEEP OUT OF REACH OF CHILDREN.
unsafe for use.
Wear insulated protection for hands and Brake fluid is poisonous. Do not ingest or Battery electrolyte is poisonous. It contains
arms or wait until hot components have allow brake fluid to contact eyes. Always sulfuric acid. Serious burns can result from
cooled sufficiently before working on the wear eye protection when working with contact with skin, eyes or clothing.
product. brake fluid.
Care should be taken to be sure the motorcycle NOTICE

will not tip or fall while elevated. Severe Brake fluid will damage plastic, painted and rubber parts. Protect
personal injury or death could occur if the these surfaces whenever the brake system is being serviced.
motorcycle tips or falls.
1.4
GENERAL SPECIFICATIONS
2008 - 2009 Vision Street / Vision Tour / 10th Anniversary Vision / NSS Vision Specifications 1
2008-2009 VICTORY VISION Models
Oil Capacity 5.0 Qt. (4.75 ltr) (Approximately 4.5 qts. or 4.25 ltr at oil & filter change)
C
A Fuel Capacity 6.0 US Gal (22.7 ltr) (1.0 U.S. gal / 3.8 ltr reserve)
P Fuel Type / Octane Minimum Premium Unleaded / 91 Octane
A
C Dry Weight Street: 809 lbs (367 kg) / Tour: 849 lbs (385 kg)
I Wet Weight Street: 844 lbs (383 kg) / Tour: 889 lbs (403 kg)
T
I Gross Vehicle Weight Rating Street: 1349 lbs. (612 kg) / Tour: 1414 lbs. (641 kg)
E Gross Axle Weight Rating Refer to Manufacturer Information label on vehicle
S
Maximum Load Subtract Wet Weight from GVWR. Never exceed GVWR*
&
D Overall Length Street: 103.5 in (262.9 cm) / Tour: 104.9 in (266.5 cm)
I
Overall Width 45.2 in (114.7 cm)
M
E Overall Height 58.5 (148.5 cm)
N Seat Height 26.5 in (67.3 cm)
S
I Ground Clearance 5.8 in (14.8 cm)
O Passenger Capacity 1
N
S Wheelbase 65.7 in (166.9 cm)
Rake / Trail 29 Degrees / 5.4 in. (13.7 cm)
Engine Type Victory Freedom V-Twin
Engine Configuration 50o SOHC V-Twin 4 Stroke
Engine Displacement 1731cc / 106 cubic inch 6 speed (106 / 6 engine)
Engine Cooling System Air / Oil
E
N Compression Ratio 9.4:1
G
Compression Pressure 210 - 225 psi (1448 - 1551 kPa)
I
N Valve Train 4 Valves per cylinder. Hydraulic Lifters & Cam Chain Adjusters (No Adjustment)
E Bore x Stroke 101 x 108 mm
Starter Electric / Direct Drive
Fuel System / Throttle Body Bore Size Closed Loop Sequential Electronic Fuel Injection / Dual Bore 45 mm
Exhaust System Type 2-1-2 Split Dual Exhaust With Crossover
Lubrication System Wet Sump
Spark Plug Type (Gap) NGK DCPR6E (.032 in. / .8 mm)
Dry Weight (Engine Approximate) 265 lbs. (120 Kg)
B Brake Type (Front / Rear) Disc / Disc
R
A Front Brake Dual Floating Disc / 3 Piston Calipers
K
E Rear Brake Linked, Single Floating Disc / 2 Piston Caliper
S
Specifications may change with the addition of custom order options and / or accessories. Polaris Sales Inc. reserves the right without prior notice to
discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.
1.5
2008-2009 Vision Street / Vision Tour / 10th Anniversary / NSS Vision Specifications (cont.)
2008 - 2009 VICTORY VISION Models
Transmission Type Manual, 6 Speed Overdrive, Constant Mesh
Clutch Type Wet, Multi-Plate Diaphragm Spring
D
Primary Drive Type Wet, Gear Drive w/ Torque Compensator
R
I Primary Reduction Ratio 1.5:1
V Final Drive Type / Belt Width / Carbon Fiber Reinforced Belt / 28mm /
E Final Drive Ratio 2.12:1
Gear Shift Pattern 1 Down, 5 Up
S Internal Gear Ratios 1st 3.15:1
Y 2nd 2.03:1
S
3rd 1.53:1
T
E 4th 1.24:1
M 5th 1:1
6th .84:1
Front Wheel (Size / Type) Cast or Billet / 3.00 x 18 (inch)
Rear Wheel (Size / Type) Cast or Billet 5.00 x 16 (inch)
S Front Tire Dunlop Elite 3 (130/70R18) 63H Radial
U
S Rear Tire Dunlop Elite 3 (180/60R16) 80H Radial
P Minimum Tread Depth .063 in. (1.6mm)
E
N Front Type 45mm (TYPE 1) Telescopic Cartridge Fork
S Front Travel 5.1 in. (13 cm)
I Front Tube Diameter 43 mm (1.7 in.)
O
N Rear Shock Type Single, Monotube Air Adjustable Shock
Rear Swingarm Type Cast Aluminum with Rising Rate Linkage
Rear Travel (inches) 4.7 in (12 cm)
Headlamp High / Low: H-4 55/60W
L Driving Lamp (Std / HID) HS1 35W / D1R 35W
I Turn / Brake / Tail Light 3157 27 / 9w
G License Plate / Trunk Running Light W5W 5w
H Courtesy Light (Trunk, if equipped) 6411 10W
T Fog Lamp (If equipped) 35W
S
Alternator / Battery 50 amp max output / 12V 18AH 310 CCA
Left Fuse Panel
Ignition 10 amp circuit breaker
Headlight 20 amp circuit breaker
Gauges 5 amp fuse
Radio 25 amp fuse
F Secondary Lighting 20 amp fuse
U
Horn 20 amp fuse
S
E Turn Signal / Brake 20 amp fuse
S Right Fuse Panel
Engine 15 amp circuit breaker
Windshield (Electric) 20 amp fuse
Fuel Pump / Ignition Coil 15 amp fuse
Chassis 20 amp fuse
Specifications may change with the addition of custom order options and / or accessories. Polaris Sales Inc. reserves the right without prior notice
to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.
1.6
2010 VICTORY VISION Tour / Tour ABS / 8-Ball / NSS Vision Specifications
VICTORY VISION TOUR / TOUR ABS VICTORY VISION 8-BALL / NESS
1
Oil Capacity 5.0 Qt. (4.75 ltr) (Approximately 4.5 qts. or 4.25 ltr at oil & filter change)
Fuel Capacity 6.0 US Gal (22.7 ltr) (1.0 U.S. gal / 3.8 ltr reserve)
C Fuel Type / Octane Minimum Premium Unleaded / 91 Octane
A
TOUR: 852 lbs (387 kg)
P Dry Weight 8-BALL / NESS: 800 lbs (363 kg)
TOUR ABS: 869 lbs (394 kg)
A
C
TOUR: 892 lbs (405 kg)
I Wet Weight 8-BALL / NSS: 840 lbs (381 kg)
TOUR ABS: 909 lbs (412 kg)
T
I Gross Vehicle Weight Rating (GVWR) 1414 lbs. (641 kg)
E
Gross Axle Weight Rating FRONT AXLE 513 lbs. (233 kg)
S
& Gross Axle Weight Rating REAR AXLE 901 lbs. (409 kg)
D
I Maximum Load TOUR: 522 lbs (237 kg)
8-BALL / NESS: 574 lbs (260 kg)
M (See page 1.9 for more information) TOUR ABS: 505 lbs (229 kg)
E
Overall Length 104.9 in (266.5 cm) 8-Ball / NESS: 103.5 in (262.9 cm)
N
S Overall Width 45.2 in (114.7 cm)
I Overall Height 58.5 (148.5 cm) 56.2 (142.7 cm)
O
N Seat Height 26.5 in (67.3 cm) 24.5 in (62.2 cm)
S Ground Clearance 5.8 in (14.8 cm) 4.8 in (12.2 cm)
Passenger Capacity 1 1
Wheelbase 65.7 in (166.9 cm)
Rake / Trail 29 Degrees / 5.4 in. (13.7 cm)
Engine Type Victory Freedom V-Twin
Engine Configuration 50o SOHC V-Twin 4 Stroke
Engine Displacement 1731cc / 106 cubic inch 6 speed (106 / 6 engine)
Engine Cooling System Air / Oil
E
N Compression Ratio 9.4:1
G
Compression Pressure 210 - 225 psi (1448 - 1551 kPa)
I
N Valve Train 4 Valves per cylinder. Hydraulic Lifters & Cam Chain Adjusters (No Adjustment)
E Bore x Stroke 101 x 108 mm
Starter Electric / Direct Drive
Fuel System / Throttle Body Bore Size Closed Loop Sequential Electronic Fuel Injection / Dual Bore 45 mm
Exhaust System Type 2-1-2 Split Dual Exhaust With Crossover
Lubrication System Wet Sump
Spark Plug Type (Gap) NGK DCPR6E (.032 in. / .8 mm)
Dry Weight (Engine Approximate) 265 lbs. (120 Kg)
B Brake Type (Front / Rear) Disc / Disc
R
A Front Brake Dual Floating Disc / 3 Piston Calipers (2010 - ABS if equipped)
K
E Rear Brake Linked, Single Floating Disc / 2 Piston Caliper (2010 - ABS if equipped)
S
1.7
2010 VICTORY VISION Tour / Tour ABS / 8-Ball / NSS Vision Specifications (cont.)
2010 VICTORY VISION Models
Transmission Type 6 Speed Constant Mesh With True Overdrive
Clutch Type Wet, Multi-Plate Diaphragm Spring
D Primary Drive Type Wet, Gear Drive w/ Torque Compensator
R Primary Reduction Ratio 1.5:1
I Final Drive Type / Belt Width / Carbon Fiber Reinforced Belt / 28mm /
V Final Drive Ratio 2.12:1
E
Gear Shift Pattern 1 Down, 5 Up
S Internal Gear Ratios 1st 3.15:1
Y 2nd 2.03:1
S 3rd 1.53:1
T 4th 1.24:1
E 5th 1:1
M
6th .84:1
Reverse 2009-2010 Only. Motorized Reverse (if equipped) See Electrical Chapter 19
Front Wheel (Type / Size) Cast or Billet / 3.00 x 18 (inch)
Rear Wheel (Type / Size) Cast or Billet / 5.00 x 16 (inch)
S Front Tire Dunlop Elite 3 (130/70R18) 63H Radial
U
S Rear Tire Dunlop Elite 3 (180/60R16) 80H Radial
P Minimum Tread Depth .063 in. (1.6mm)
E
N Front Type 45mm (TYPE 1) or (46MM TYPE 2) Conventional Telescopic Cartridge Fork
S Front Travel 5.1 in. (13 cm)
I Front Tube Diameter 46 mm (1.81 in.)
O
N Rear Shock Type Single, Monotube Air Adjustable Shock
Rear Swingarm Type Cast Aluminum with Rising Rate Linkage
Rear Travel (inches) 4.7 in (12 cm) [8-Ball & Ness - 3.5 in. (9.0 cm)]
Headlamp High / Low: H-4 55/60W
L Driving Lamp (Std / HID) HS1 35W / D1R 35W
I Turn / Brake / Tail Light 3157 27/ 7w
G License Plate / Trunk Running Light W5W 5w
H Courtesy Light (Trunk, if equipped) 6411 10W
T Fog Lamp (If equipped) 35W
S
Alternator / Battery 50 amp max output / 12V 18AH 310 CCA / Yuasa YTX20HL
Left Fuse Box
Ignition 10 amp circuit breaker
Headlight 20 amp circuit breaker
Gauges (Instruments) 5 amp fuse
Radio 25 amp fuse
F Secondary Lighting 20 amp fuse
U
Horn 20 amp fuse
S
E Turn Signal / Brake 20 amp fuse
S Right Fuse Box
Engine 15 amp circuit breaker
Windshield (Electric) 20 amp fuse
Fuel Pump / Ignition Coil 15 amp fuse
Chassis 20 amp fuse
ABS Fuse (if equipped) (2) 30A
1.8
VEHICLE LOADING
1
GROSS VEHICLE WEIGHT RATING (GVWR)
WARNING
Exceeding the gross vehicle weight rating of your motorcycle can reduce stability and handling and could cause loss
of control. NEVER exceed the gross vehicle weight rating of your motorcycle.
The maximum load capacity of your motorcycle is the maximum weight you may add to your motorcycle without
exceeding the GVWR. This capacity is determined by calculating the difference between your motorcycle’s gross vehicle
weight rating and the wet weight.
Refer to the specification section of this manual or the Manufacturing Information / VIN label on the motorcycle frame
for model-specific information. Refer to Information label section in this manual (page 1.11) for location on the
motorcycle.
When determining the weight you will be adding to your motorcycle, and to ensure you do not exceed the maximum load
capacity, include the following:
• operator body weight

• passenger body weight
• weight of all riders’ apparel and items in or on apparel
• weight of any accessories and their contents
• weight of any additional cargo on the motorcycle
1.9
VEHICLE INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
See “VIN NUMBER / MANUFACTURER LABEL” on page 1.11. for location on the vehicle.
SAE-assigned Chassis: Type: Series: Serial Number
World Manufacturing See chassis designators B = Standard A = Australia
Identifier listed under Model Number C = Custom C = Canada
(below) D = Deluxe / Tour D = Domestic (49 State)
S = Sport E = Europe
W = ABS L = California
U = United Kingdom
*5VPSB36D0A2000000*
Engine Size:
1 = 1507 cc Engine HP: Check Digit Model Year: Plant/ Line
2 = 1634 cc 6 = 78-94 (May be a number 8 = 2008 Code
3 = 1731 cc or a letter) 9 = 2009
A = 2010
MODEL NUMBER
See “VIN NUMBER / MANUFACTURER LABEL” on page 1.11. for location on vehicle.
Chassis:
A = Vegas 8-Ball Engine Size: Engine HP: Series:
B = Hammer 8-Ball 1 = 1507 cc 6 = 78-94 A = Australia
2 = 1634 cc C = Canada
C = Kingpin
3 = 1731 cc D = Domestic (49 State)
D = Cross Country
E = Europe
E = Cross Roads L = California
H = Hammer U = United Kingdom
K = Kingpin Low, 2009
L = Vegas Low, 2010 Vegas
P = Kingpin 8-Ball P = Premium Model
(Premium package equipped as
S = Victory Vision specified for model.
V = Victory Vision 8-Ball
X = Jackpot V10SD36DAP T = Top Premium Model
(Premium package and additional
upgrades as specified for model)
Example: 2010 - T designates ABS
VICTORY Type: Color Indicator

B = Standard
Model Year: C = Custom
08 = 2008 D = Deluxe / Tour
09 = 2009 S = Sport
10 = 2010 W = ABS
1.10
VIN NUMBER / MANUFACTURER LABEL VECI / NECI / TIRE INFORMATION LABELS 1

The Vehicle Identification Number (VIN) is stamped into the The Vehicle Emission Control Information (VECI), Noise
right side of the frame near the steering head (A), and Emission Control Information (NECI), and the Tire
printed on the Manufacturer Information Decal located Information labels (2008 & 2009 models) are located in the
under the rear console cover on the frame (B). left saddlebag and on the bag door (D).
A B
D
The Manufacturer Information Decal also includes the

following information:
KEY IDENTIFICATION NUMBER
Gross Vehicle Weight Rating (GVWR)
The key identification number (E) is stamped on a tag
Gross Axle Weight Rating (GAWR) attached to the key ring. If the key and the identification
number are lost or misplaced, the lock set must be
Date of manufacture replaced.
Key blanks are available from Victory. Locksmiths familiar
with the motorcycle industry will be able to cut a
ENGINE NUMBER LOCATION replacement key with the I.D. number and a Victory key
blank.
The engine number (C) is stamped into the right crankcase
boss. The stamping identifies the engine model and serial
number.
D E
1.11
PUBLICATIONS & TECHNICAL LITERATURE

PUBLICATION PART NUMBERS
Some Victory publications, such as Owner’s Manuals and Parts Books are available on-line and can be downloaded from
the Victory motorcycles web site (http://www.polarisindustries.com/en-us/Victory/). Click on the Riders pull down menu
and select Manuals and Parts.
Service Manuals can be purchased through any authorized Victory motorcycle dealer. The part numbers are listed in the
following table. Some manuals are available for purchase on-line at www.purepolaris.com.
VICTORY SERVICE MANUAL PART NUMBERS

2002 - 2006 Classic & Touring Cruiser 9919632
2003-2006 Vegas / Kingpin / Vegas 8-Ball /
9920337
Ness Signature Series Vegas & Kingpin
2005-2006 Hammer / 2006 Vegas Jackpot 9920340
2007 Vegas / Vegas 8-Ball / Kingpin / Kingpin Tour 9920837
2007 Hammer / Hammer S / Vegas Jackpot /
9920838
Ness Signature Series Vegas Jackpot
2008 Vegas / Vegas 8-Ball / Vegas Low / Kingpin / Kingpin
9921242
Tour / Kingpin 8-Ball
2008 Hammer / Hammer S / Vegas Jackpot /
9921247
Ness Signature Series Vegas Jackpot
2009 - 2010 Vegas, Kingpin, Hammer / Vegas Jackpot 9922432
2010 Victory Cross Roads & Victory Cross Country 9922647
MATERIAL SAFETY DATA SHEET (MSDS)

To review or print a Material Safety Data Sheet for Victory maintenance products, chemicals or lubricants:
DEALERS: visit www.polarisdealers.com / news forms & links / pure polaris OR contact Dealer Support
NON-DEALERS: please contact Polaris Customer Service at: 1-888-704-5290 (French speaking 1-204-925-7100)
1.12
REFINISHING
VICTORY TOUCH-UP & REFINISHING PAINT
1
Service Paint products are available in three different sizes and applications. Some paint colors require up to 3 com-
ponents to create a color. Prices subject to change without notice. Dealer is responsible for freight on paint and paint
products.
.6 ounce bottle: (Order Multiple of 2) For brush touch-up of small nicks.
10 ounce aerosol can: (Order Multiple of 2)
Apply light even coats for best results. Recoat time is from 30-60 minutes or after 4 days of drying to prevent lifting.
Quarts: (Sold as each)
For repaint of properly prepared plastic components or metal substrates.
Paint is a high quality acrylic urethane manufactured by U.S. Paint.
Mix as indicated on back of paint can. Paint can be recoated after paint is tack free or has “flashed off”.
Paint finish may be wet sanded and buffed after coating has cured.
How to order:
Authorized Victory Dealers only. Place your order via the dealer web site at:
www.polarisdealers.com / News Forms & Links / Pure Polaris
NOTE: There will be a 25% service fee charged for all returns. Polaris dealer will be responsible for return
freight
VICTORY DETAIL & FINISH RESTORER KITS AND PRODUCTS

A Detail Kit (polish, wax, and dressing) and a Restore Kit (polish, and swirl / scuff remover) is available from the Vic-
tory parts department for painted surface protection and to remove minor surface imperfections.
Visit www.purevictorypolishes.com for a complete list of genuine Pure Victory detailing products.
Detail Kit: 2872195 Includes Non-Abrasive Wash, Swirl Remover / Polish, Polywax Final Finish, Vinyl / Rubber Protector,
Applicator and Cloth.
Restore / Polish: 2872192 (12 oz. Aerosol)
PAINTING TERMS
The following terms describe the general operations referred to in the Paint Color Code chart on page 1.16.
E-Coat (Factory Applied): This material is used as a rust protection. It is also used to form a bond between bare metal
and the primer or base coat. Full-hide colors (such as black) do not require primer.
Primer: Primer is necessary when applying some colors such as Flame Yellow, Sonic Blue, Solar Red, etc. The purpose
of a primer coat is to prevent bleed-through or transparency in subsequent color coats.
Base Coat: A color paint layer applied under another color or under the clear topcoat to improve color matching and
consistency.
Top Coat: Outermost layer of paint or clear coat.
1.13
PAINT COLORS BY MODEL
The 8th Digit of the model number (either a C, D, L, or U) designates the Series:
(C = CANADA, D = Domestic (49 State), E = Europe, L = CALIFORNIA, and U = United Kingdom.
2008-2010 models - the 9th letter of the model number designates the color. “P” in the 10th position indicates Premium
model. Premium models were equipped with a comfort package (heated seat, grips, etc.) and premium lighting (HID
headlamp).
2009 models, a “T” or “C” in the 10th position indicates models equipped with “P” premium features plus chrome package
and additional audio gear.
2010 models, a “T” in the 10th position indicates models equipped with Anti-Lock Braking System (ABS).
NOTE: Refer to page 1.16 for paint color code. Detailed paint ordering information is available on the dealer
web site (www.polarisdealers.com) under News, Forms & Links / Pure Polaris / Paint Codes & Part Numbers.
Refer to page 1.10 for model number descriptor.
VICTORY VISION STREET MODEL YEAR 2008

Model Number Model
V08S136 VICTORY VISION Street - Feature / Option
V08SB36CA, CAP, DA, DAP, LA, LAP VICTORY VISION Street, Solid Black
V08SB36CC, CCP, DC, DCP, LC, LCP VICTORY VISION Street, Midnight Cherry
V08SB36CD, CDP, DD, DDP, LD, LDP VICTORY VISION Street, Supersteel Gray
VICTORY VISION TOUR MODEL YEAR 2008
V08S236 VICTORY VISION Tour - Feature / Option
V08SD36CA, CAP, CAT, DA, DAP, DAT, LA, LAP, LAT VICTORY VISION Tour, Solid Black
V08SD36CC, CCP, CCT, DC, DCP, DCT, LC, LCP, LCT VICTORY VISION Tour, Midnight Cherry
V08SD36CD, CDP, CDT, DD, DDP, DDT, LD, LDP, LDT VICTORY VISION Tour, Supersteel Gray
VICTORY VISION STREET MODEL YEAR 2009
V09SB36CAP, DA, DAP, LA, LAP VICTORY VISION Street, Solid Black
V09SB36DC, DCP, LCP VICTORY VISION Street, Blue Ice
V09SB36CSP, DS, DSP, LSP VICTORY VISION Street, Midnight Cherry

VICTORY VISION TOUR MODEL YEAR 2009
V09SD36CA, CAC, CAP, DA, DAC, DAP, LAC, LAP VICTORY VISION Tour, Solid Black
V09SD36CCC, CCP, DC, DCC, DCP, LC, LCP VICTORY VISION Tour, Blue Ice
V09SD36CSC, CSP, DS, DSC, DSP, LS, LSC, LSP VICTORY VISION Tour, Midnight Cherry
VICTORY VISION TOUR 10th ANNIVERSARY MODEL YEAR 2009
V09SZ36CT, DT, LT VICTORY VISION Tour, Antares Red w/ Black / Gold Pinstripe
NESS SIGNATURE SERIES VICTORY VISION MODEL YEAR 2009
V09SC36CM, DM, LM NSS VICTORY VISION Street, Solid Black
1.14
PAINT COLORS BY MODEL (Cont.)
1
VICTORY VISION TOUR MODEL YEAR 2010
V10SD36CGP, DGP, LGP VICTORY VISION Tour, Solid Pearl White
V10SD36CPP, DPP, LPP VICTORY VISION Tour, Ocean Blue/Sandstone Metallic
VICTORY VISION TOUR ABS MODEL YEAR 2010
V10SW36CAP, DAP, LAP, UAP VICTORY VISION Tour, Solid Black
V10SW36CPP, DPP, LPP, UPP VICTORY VISION Tour, Ocean Blue/Sandstone Metallic

VICTORY VISION 8-BALL MODEL YEAR 2010
V10VB36CA, DA, LA, VICTORY VISION 8-Ball, Solid Black
NESS SIGNATURE SERIES VICTORY VISION MODEL YEAR 2010
V10SC36CM, DM, LM NSS VICTORY VISION Street, Ness Custom
1.15
PAINT COLOR CODES
For current information Victory Dealers can go to www.polarisdealers.com/News, Forms, and Links. Enter PAINT
CODES in the search box.
PAINT COLOR: 2008 - 2010 PAINT NOTES
CODE
Cobalt Blue P-1278 P-574 Cobalt Blue / P-585 Tinted Black (1st Overlay) / P-500 Graphics
Blue Ice Metallic P-1280 P-564 Blue Ice Metallic / P-500 Graphics
Pearl White P-352
Vogue Silver P-354
Turbo Silver P-445 Paint kits require base coat with a topcoat of Clear Metallic (CM)
Flat Black P-463
Nuclear Sunset P-493
Victory Graphics P-500
Super Graphite P-509
Orange Crush P-516
Clear Pearl P-519
Sunset Red P-520
Boardwalk Blue P-524 Requires P-519 Clear Pearl Topcoat
Ness Metallic Purple P-543
Supersteel Gray P-553 Requires P-519 Clear Pearl Topcoat
Midnight Cherry P-554
Sands Metallic P-555
Anodized Aluminum P-565
Lucky Lime P-568
Ocean Blue Metallic P-576
Sandstone Metallic P-576
Tinted Black P-585
Sunset Red / Graphics P-1258 P520 / P500
Nuclear Sunset / Graphics P-1266 P493 / P500
Pearl White / Graphics P-1272 P352 / P500
Orange Crush / Graphics P-1276 P516 / P500
Black / Ness Graphics P-1278
Ocean Blue / Suede Metallic P-1284
Midnight Cherry / Suede Metallic P-1289
Metallic Flake Additive METALLIC Add vial of flake to quart of clear base
Silver Undercoater SU Base coat only
Antares Red Undercoater RU Base coat only
Clear C
Clear Metallic CM Clear with metal flake added
Clear Pearl CP Clear with pearl flake added
UNDERCOATERS WU, OWU, WU=White Undercoater; OWU=Off-White Undercoater;
(Base Coat Only) PWU, VVU PWU=Pearl White Undercoater; VVU=Victory Violet Undercoater
1.16
BREAK IN PERIOD
BREAK-IN PROCEDURE
1
There is never a more important period in the life of a new Victory motorcycle than the period between zero and 500 miles
(805 km). A Victory motorcycle is manufactured using the best possible materials and manufacturing techniques, but the
final machining process is the break-in. During break-in period, many parts in the engine wear and polish to correct
operating clearances. During this time, the operator should:
• Avoid prolonged full throttle operation.

• Avoid operation which might result in excessive heating of the engine.
The general break-in guidelines are as follows:
BREAK-IN GUIDELINES
Miles/km Throttle Notes
Position
0-90 miles 0-1/3 Avoid prolonged operation above 1/3 throttle. Stop engine and let it cool
following every hour of operation. Vary speed of motorcycle. Do not operate
machine at one set throttle position.
90-300 miles 0-1/2 Avoid prolonged operation above 1/2 throttle. Stop engine and let it cool
following every hour of operation. Vary speed of the motorcycle. Do not
operate machine at one set throttle position.
300-500 miles 0-3/4 Avoid cruising speeds above 3/4 throttle.
500 miles Replace the engine oil and engine oil filter. Perform 500 mile service on the machine.
See chapter 2 for more information.
500 + Avoid prolonged full-throttle operation. Vary the engine speed occasionally. Follow the pre-
ride inspection outlined in the owner's manual.
1.17
EMISSIONS
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify
that their motorcycles comply with applicable exhaust emissions standards during their useful life, and that motorcycles
built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 mi) after
the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided.
EMISSION SOURCES
An internal combustion engine produces carbon monoxide and hydrocarbons during operation. Hydrocarbons must be
controlled because under some conditions hydrocarbons react with sunlight to produce photochemical smog. Carbon
monoxide must be controlled because it is toxic.
EXHAUST EMISSION CONTROL
Victory Motorcycles have an electronic engine management system which controls fuel delivery and ignition timing to
control hydrocarbon and carbon monoxide emissions. Follow the Periodic Maintenance Interval Table on page 2.5 and
inspect the emission control system as outlined in this manual. No adjustments can be made to the EEC system.
NOISE EMISSION CONTROL SYSTEM

Tampering with Noise Control Systems is Prohibited. Federal law prohibits the following acts or causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement,
any device or element of design incorporated into the motorcycle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
2. The use of the motorcycle after such device or element of design has been removed or rendered inoperative.
Among those acts presumed to constitute tampering are the acts listed below:
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust
gases.
2. Removal or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving part of the motorcycle or parts of the exhaust / intake system with parts other than those
specified by the manufacturer.
CRANKCASE EMISSION CONTROL

The crankcase emission control system is comprised of a closed system that routes crankcase emissions through the
air cleaner into the combustion chamber.
EVAPORATIVE EMISSION CONTROL

California models are equipped with an Evaporative Emissions
Canister (A). Activated charcoal inside the canister temporarily
stores fuel vapor from the fuel tank vent system. The Electronic
Control Module (ECM) opens a canister purge valve that connects
the charcoal canister to the intake tract (when conditions are correct)
to purge the canister of vapors absorbed by the charcoal. Refer to
Chapter 5 for system diagram and Chapter 2 for system
maintenance.
1.18
SPECIAL SERVICE TOOLS 1

GENERAL / PRECISION MEASURING TOOLS
TOOL PART NUMBER
Bearing & Seal Driver Set PV-43558
Bodywork Removal Tool Set PV-49955
Bore Gauge Set, 50-100mm PV-3017
Decal, Service Bulletin Completion 7170107
(Order from Victory Parts Dept.)
Dial Caliper (Metric, 0-150mm) PV-26900-7
Dial Caliper (Electronic Conversion. English 0-6” / Metric 0-150mm) PV-39776
Dial Indicator, Adjustable (Metric. 10mm travel) PV-26900-12
Dial Indicator Stand, Flexible. Magnetic Base PV-34481
Engine Ear Listening Device PV-39565
Feeler Gauge Set PV-26900-8 or PV-26900-9
Outside Micrometer (0-25 & 25-50mm) PV-3006, PV-3007
Outside Micrometer Set (0-100mm) PV-3009
Small Hole Gauge Set Commercially Available
Straight Edge, Precision PV-34673
Surface Plate Commercially Available
Telescoping Gauge Set PU-45423
Torque Wrench (3/8” Drive 0-50 in-lb. beam type) PV-43543
Torque Wrench (1/2” Drive 0-150 lb-ft. beam type) PV-43552
Torque Wrench (3/8” Drive 15-100 lb-ft. click type) PV-43564
TUNE UP & MAINTENANCE TOOLS

TOOL PART NUMBER
Belt Tension Gauge PV-43532
Belt Tension - Sonic Tension Meter Commercially available
Cylinder Leakdown Tester PV-35667-A
Compression Gauge Set PV-33223
Oil Pressure Gauge Set PV-43531
Vacuum Brake Bleeder PV-50204
ELECTRICAL TOOLS
TOOL PART NUMBER
Ammeter Inductive Clamp for Fluke 73™ Multimeter PV-39617
Cruise Control Jumper Harness (Diagnostic) Kit (Not required on Vision) PV-49358
Electrical Connector Test Adapter Kit PV-43526
Inductive Timing Light PV-43537
Multimeter, Fluke 73™ PV-43546
1.19
ENGINE, CLUTCH, & TRANSMISSION TOOLS
TOOL PART NUMBER
Clutch Shaft Bearing Support PV-47331
(for clutch shaft installation)
Crankcase Assembly Tool (Crankcase Installer) PV-46299 (Must be used with PV-45030) and
Adapter (Extension) PVX-47429
Crankcase Assembly Tool Adapter PVX-47429
Crankshaft Bearing Protector PV-47207
Crankshaft Rotation Tool PV-48736
Crankcase Separator (Crankcase Removal) PV-47332-A
Engine Hoist or Lift Commercially Available
Engine Lock Tool PV-43502-A
Engine Stand Commercially Available
Exhaust Muffler Rotation Tool (All VICTORY VISION Models) PV-49946
Flywheel Puller PV-43533
Mainshaft (Clutch Shaft) Holder PV-45028
Crankcase Installation Tool (Crankcase Assembly) PV-46299 (Must be used with PV-45030)
Mainshaft (Output Shaft) Seal Installation Tool PV-43505
Piston Ring Compressor (97mm +) Includes PV-43570-1 Pliers, PV-43570-2 Band
(3 5/8” to 3 7/8”)
Valve Spring Compressors (Adapter is PV-43513-A) PV-1253 or PV-4019 (Quick Release)
STEERING & SUSPENSION TOOLS

TOOL PART NUMBER
Blind Bearing Remover Set PV-43551
Wheel Bearing Service Set PV-49462
Fork Spring Compressor PV-49463
Cartridge Shaft Extension (Hammer) PV-47060 or PV-49453**
Cartridge Holder (Required for Hammer TYPE 2 KYB forks) PV-49452
Damper Rod Holder (Jackpot) PV-43517
Fork Oil Level Gauge PV-59000-A
Fork Seal Driver 43mm, Inverted - Hammer TYPE 1 and TYPE 2 PV-47035
Fork Seal Driver, 43mm, Conventional (Jackpot) PV-47036
Fork Seal Guide Tool, 43mm (Hammer, Jackpot) PV-47037
Steering Bearing, Wheel Bearing Installation Set PV-43515
Steering Stem Bearing Adjustment Socket PV-43508
Steering Stem Bearing Spanner Wrench PV-43509
Shock Absorber Pre-Load Adjustment Spanner PV-46993
Shock Spring Compressor PV-43571
PV-47060 Damper Rod Extension tool is for TYPE 1inverted (MARZ, Hammer / KP) forks only. PV-49453 works on ALL
Victory cartridge forks including Type 1 and Type 2 (KYB) Vision forks.
1.20
WHEEL & TIRE TOOLS 1

TOOL PART NUMBER
PV-48909 (Victory Air Pump & Gauge) Or
Air Pressure Gauge
Commercially Available Tire Pressure Gauge
Tire Bead Breaker Commercially Available
(May be part of the tire removal equipment being used)
Tire Mounting Lubricant Commercially Available
Tire Removal Equipment Commercially Available
Rim Protector PV-43536
Wheel Balancing/Truing Stand Commercially Available
FUEL SYSTEM & FUEL INJECTION TOOLS

TOOL PART NUMBER
(See Chapter 5 for more information)
Victory/Polaris Diagnostic Tool Kit PU-46085-A
Digital Wrench Software: PU-48731
Standard Interface Cable: PU-47151
PU-46085-A (above) INCLUDES:
Victory Adapter: PV-46085-2
SmartLink Interface Kit: PU-47471
Fuel Pressure Gauge PU-43506-A
Fuel Pressure Gauge Adapter PV-48656
Fluke 73 Digital Multi-Meter or Fluke 77 DMM PV-48656 (Fluke 77 - PV-43568)
Laptop Computer (Refer to diagnostic software user manual Commercially Available
or HELP section for minimum specifications
TOOL ORDERING INFORMATION

Order Special Service Tools from SPX Corporation (Phone 800-328-6657 / FAX 586-578-7375) or use the link on the
Victory Dealer Web site.
If you are not a Victory dealer use the phone or FAX number listed above or visit http://polaris.spx.com/
1.21
TRANSPORTING, ELEVATING, AND SECURING THE MOTORCYCLE

GENERAL GUIDELINES
WARNING
Care should be taken to be sure the motorcycle will not tip or fall while elevated. Severe personal injury or
death could occur if the motorcycle tips or falls.
If you must transport the motorcycle or secure it to a lift table:

• Use a truck, trailer, or lift table designed or equipped properly for motorcycles. Review truck, trailer or lift
manufacturer’s recommendations.
• Do not tow the motorcycle with another vehicle, as towing will impair the motorcycle’s steering and handling,
which can cause a loss of control.
• Position and restrain the motorcycle so it remains upright on the truck, trailer, or lift table as gasoline may leak
out of the fuel tank vent if the motorcycle is transported at extreme angles. Gasoline is a fire hazard and it can
also damage the motorcycle’s finish.
• Do not restrain the motorcycle using the handlebars. Loosen the turn signals and slide them up the fork tube as
shown, enough to make room for a soft tie-down extension strap (no buckles). Place tie downs around the lower
triple clamp as shown, around the fork tube below the turn signal mount and above the lower triple clamp.
• Secure the rear of the motorcycle with tiedowns around the swingarm, being careful to avoid brake lines,
exhaust, drive belt, or drive belt guards.
• The motorcycle can be elevated by placing a stable, flat platform jack or lift mechanism on a firm flat surface and
lifting under the engine crankcase. The platform should be a minimum 12 inches square, and clear of any
components under the motorcycle. DO NOT attempt to lift the motorcycle without properly securing it with
straps.
Tiedown loop is on
front of frame.
(One tiedown each side)
Platform jack To shock/strut mount, or rear tip-over bar

(One tiedown each side)
1.22
INSTRUMENTATION / CONTROLS IGNITION SWITCH 1

The ignition switch has 4 positions - OFF, ON, ACC, and
IGNITION KEY LOCK. The switch is also used to open or lock the fuel door
The ignition key operates the ignition switch, fuel door on the right side of the console, and to lock the glove
(page 1.32) bag locks (page 1.33) and trunk lock (if compartment on the left side of the console. See table
below for switch function.
equipped, page 1.33). Key position and function is
described on the following pages. Ignition Switch Function
No electrical circuits are active. Ignition key
OFF
can be removed from the switch.
ON
OFF ACC All electrical circuits are energized. The
ignition key cannot be removed from the
switch. The headlamp (2008 only) taillight,
FUEL DOOR running lights, radio, and instrument lights
OPEN illuminate. Note: To energize headlamp
ON
circuit on 2009 - 2010 models, tap starter
button or start engine. ALL - With engine
LOCKED stop/run switch set to the RUN position you
(PUSH) can start the engine, activate emergency
flashers and turn signals.
Power is supplied to accessory circuits,
radio, instruments (fuel gauge, etc.), brake
light, turn signals (2008 only) windshield
motor, horn, and hazard (flasher) circuit.
Headlamp and tail lamps are OFF, and turn
ACC signals inactive (2009-2010 models - the
ECM must be powered up for turn signal
operation). The key can be removed. Use
ACC position whenever engine does not
need to be running to reduce electrical load
and conserve battery power.
With the key in the LOCK position, no power
is delivered to electrical circuits. The
steering, fuel door, and glove compartment
are locked. To lock the motorcycle, turn the
LOCK handlebars fully left. With the key in the OFF
position, push the key down, then rotate the
key counterclockwise (left) to the LOCK
position. The ignition key can then be
removed.
FUEL
See “FUEL DOOR” on page 1.32.
DOOR
1.23
INSTRUMENT CLUSTER VOLT METER

The instrument cluster includes the items listed on the (4) The volt meter displays battery voltage being supplied
following pages. The MODE button (page 1.28) is used to to main electrical circuits when the key is in the ON position.
toggle through various functions, change unit display (mph
to kph) and to reset all functions except the odometer and The meter will display approximate battery voltage when
fuel range. the key is ON without the engine running. With the engine
running, the meter will display approximate battery
charging voltage.
SPEEDOMETER
(1) The speedometer displays current motorcycle speed in
miles per hour (mph) or kilometers per hour (kph)
(international). To change display units, see page 1.26.
(1a) The light sensor port is located on the speedometer

3 4
face.
3. Fuel Gauge
TACHOMETER 4. Volt Meter
(2) The tach displays current engine speed in revolutions

per minute (RPM). A red line on the face indicates
maximum safe engine RPM. INDICATOR LAMP DISPLAY
(5) The indicator lamps are located on the upper display in
the center of the instrument panel. See the following pages
for a description of each and its function.
INFORMATION DISPLAY
1 2 (6) The information display, located below the indicator
1a
1. Speedometer
display, is a multi-function LCD unit. This panel will display
2. Tachometer
the time, gear position, ambient temperature, mileage
1a. Light Sensor (either trip or total vehicle mileage), fuel range, average
MPG, current fuel economy, trip time, and other trip
information as selected by the MODE button (page 1.28).
FUEL GAUGE See the individual feature described in this chapter for
more information. To change the unit display (U.S. to
(3) The fuel gauge operates when the key is in the ON or Metric) see page 1.26.
ACC position. For most accurate readings, sit on the
motorcycle and bring it to an upright position. To change
fuel units (English / Metric) on the Information Display, see
page 1.26.
5 6
5. Indicator Lamp Display

6. Information Display
1.24
CLOCK GEAR POSITION 1

(1) The clock is displayed with the key in the ON or ACC (2) The number of the current transmission gear is
position. To change from 12 hour clock to 24 hour clock,
displayed with the key in the ON position and the Stop/Run
see page 1.26.
switch in Run. The letter “N” is displayed in Neutral. “R” in
To set the clock: Reverse (2009 10th Anniversary or Reverse Kit equipped).
TRIP ODOMETER
(3) The trip odometer shows total miles traveled since the
trip odometer was reset. Use the MODE button
(page 1.28) to toggle between odometer and trip meter. To
reset the trip meter:
1 • Turn the key ON and toggle to the trip meter to

1. Clock
TRIP 1 or 2.
• Turn key to ON or ACC. • Hold the MODE button until the trip meter resets.
• Use the MODE button (page 1.28) to toggle • To change from miles to kilometers see page 1.26.
the display to the ODOMETER.
• Press and hold the MODE button until the TEMPERATURE
hour segment flashes, then release the
(4) Current ambient air temperature is displayed with the
button.
key in the ON or ACC position. The ambient temperature
• With the hour flashing, tap the MODE button sensor is located behind the left rear view mirror.
to advance the hour setting until the correct
hour is displayed.
• Press and hold the MODE button until the
10-minute segment flashes, then release
the button.
• Tap the MODE button to advance setting until the
correct 10-minute digit is displayed.
2 3 4
• Press and hold the MODE button until the single 2. Gear Position
minute segment flashes, then
3. Trip Odometer
release the button. Tap the Mode button until single
4. Ambient (Outside Air) Temperature
minute is correct, then press and hold MODE to
save the current time and exit clock set mode.
• Turn the key OFF. The clock is set until the battery is ODOMETER
disconnected or discharged.
(5) The odometer displays total mileage of the vehicle in
TRIP INFORMATION miles or kilometers. To change unit display from miles to
kilometers see page 1.26
Average speed, average fuel economy, and a trip timer are
displayed individually using the MODE button. Average
fuel economy data is most accurate when taken over
multiple trips or multiple tanks of fuel.
To RESET the above items, tap MODE button until desired

data item is displayed, then press and HOLD the MODE
button until the item resets.
5. Odometer 5
The Trip Timer accumulates time only when the ignition
switch is in the ON position.
1.25
CHANGING INFORMATION DISPLAY UNITS CONSOLE MOUNTED SWITCHES

Standard and Metric Information Display options are The console mounted switches are used to control the
available as indicated in the table: following features:
2008 Standard Metric

2010
2009 Display Display
4
X X DISTANCE Mi / Hour Km / Hour
I 3
1
FUEL (Imperial Gal)
X U.S. Gal 2
UNITS or
Liters
X TEMP F C
X X CLOCK 12 Hour 24 Hour
1. Hand grip heater 3. Driving lamp
To change the Information Display from English to Metric: 2. Hazard 4. Accessory switch
2008-2009 Models: HAND GRIP HEATER SWITCH

• With ignition key OFF, press and hold the MODE Press rocker switch toward Hi or Low position, depending
button on left handlebar switch (page 1.28). on the amount of heat required. Press rocker switch to
middle position to turn grip heaters OFF.
• Turn ignition key to ON or ACC.
• When display shows flashing Mi or Km, toggle HAZARD SWITCH (Emergency Flashers)
MODE button to desired screen display unit. The Hazard switch activates and de-activates emergency
• Press and hold the MODE button until the flashers. When emergency flashers are active, all turn
display returns to Odometer to exit set-up mode. signals flash.
2010 Models: Grip Heat Hazard
HIGH ON
NOTE: To exit set-up mode at any time, wait 10 seconds
and display will return to odometer.
OFF
• With ignition key OFF, press and hold the MODE
button on left handlebar switch (page 1.28). LOW OFF
• Turn ignition key to ON or ACC.

• When display shows flashing MI or KM, toggle
MODE button to desired screen display unit. DRIVING LAMP SWITCH
• Press and hold the MODE button until the When ignition key is ON, driving lamp switch operates the
display changes to the next item (FUEL units). center headlamp or HID lamp (if equipped).
• Toggle MODE button to desired screen display unit. The driving lamp is not controlled by the high / low beam
switch. It is an additional low beam lamp that can be on at
• Press and hold the MODE button until the
all times if selected on the console.
display changes to the next item (TEMP units)
• Toggle MODE button to desired screen display unit.
• Press and hold the MODE button until the ON
display changes to the next item (CLOCK units)
• Toggle MODE button to desired screen display unit. Driving Lamp
OFF
1.26
INDICATOR LAMPS 1
Low Fuel
High Beam
RH Turn
LH Turn
Oil
Cruise Pressure
Control Neutral
Low
Check Battery
Engine ABS
Light Sensor Gear Position
Port “R” displayed if in Reverse Gear (2009 -2010
equipped with Reverse Gear only)
Indicator Lamp Function Indicator Lamp Function

The Check Engine indicator (Malfunction
Indicator Lamp or “MIL”) is displayed during a
Illuminates when transmission is in neutral (and
system check. If system sensors report an
Key is in ON or ACC position)
abnormal condition, the indicator will continue
Neutral to illuminate as long as the fault condition
exists. An error code menu can be viewed on
(2010 if equipped) ABS Indicator always
the Information Display by using the MODE
illuminates when key is in the ON position and
button to toggle through the features until
remains on until the anti-lock system is initiated,
“Err” is displayed. Record the information that
which occurs when vehicle speed reaches 6
is displayed (e.g. “Err 3 - 520200”) and refer to
MPH (10 km/h). See ABS in Chapter 15.
page 5.28 for code conversion. NOTE: These
On 2009 -2010 models equipped with reverse Check codes are not stored. The “Err” screen will
Reverse gear, “R” is displayed on the LCD when Engine appear when toggling the display with the
2009 - transmission is in neutral, ignition key is in ON, MODE button only when the Check Engine
2010 and Reverse shift lever is in the Reverse light is on. If the key is turned OFF, the code
position (Up) and message is lost, but will reappear if the
fault is still present after re-starting the
6 Indicates current transmission gear selected
engine. Refer to Chapter 5 for more
information about “Err” messages.
(6th gear shown)
Gear The Low Oil Pressure indicator illuminates
Position when the ignition switch is in the ON position
and the engine is
not running. This demonstrates that the
Illuminates when the head lamp switch is set to indicator circuit is functioning properly. The
HIGH BEAM. Note: To energize headlamp indicator also illuminates when engine oil
circuit on 2009 models, tap starter button or pressure drops below safe operating
start engine.
High Low Oil pressure. If this indicator illuminates while
Beam Pressure engine is running, turn the engine off as soon
as safely possible and check the oil level. If the
Cruise Control indicator illuminates when cruise
oil level is correct and the indicator remains
control power is ON and a set speed is selected.
illuminated after the engine is restarted, turn
Review Cruise Control Safety & Operation in
the engine off immediately.
Cruise the Rider’s Manual before operating the Cruise
Control.
Control The Low Fuel indicator illuminates when
approximately 1.0 gallons (3.8 liters) of fuel
(L) (R) Flashes left arrow, right, or both (hazard) when remains in the fuel tank.
turn or hazard is activated. If a turn signal bulb Low Fuel
has failed, or if there is a short circuit in the
system, turn signal indicator flashes at more
Turn than twice the normal rate.
1.27
SEAT HEATER HEADLAMP HIGH / LOW BEAM SWITCH

The seat heater switches (if equipped) are located on the The headlamp high/low beam switch toggles the headlamp
seat under the left passenger hand grip. between high and low beam. Note: To energize headlamp
The driver and passenger seat heater settings are circuit on 2009 models, tap starter button or start engine.
independently controlled. The front switch controls the
driver’s seat and the rear switch controls the passenger’s High Beam
seat.
Switch
Low Beam
Location
Front
High Low
Off
LEFT Handlebar Switch
LEFT HANDLEBAR SWITCH

WINDSHIELD ADJUSTMENT SWITCH
MODE BUTTON (Motorized)
The MODE button is located on the front side of the left The motorized windshield adjustment switch changes the
handlebar switch. height (and angle) of the windshield.
The MODE button is used to toggle through the various
Information display items available, and to change the This button is active with the key in the ON or ACC position.
display from English (miles) to Metric (kilometers). To move the windshield UP:
Refer to the individual display feature throughout this • Press the upper portion of the switch
chapter for more information. To move the windshield DOWN:
NOTE: If “Err” is displayed while toggling through • Press the lower portion of the switch
the mode features, a system error has been logged in
NOTICE: Do not continuously cycle windshield more
the ECM (the CHK ENG light may or may not be
than once in a 60 second period.
illuminated). Refer to Check Engine light information
(page 1.27) and Chapter 5 for more information.
UP
DOWN
LEFT Handlebar Switch
1.28
MANUAL WINDSHIELD ADJUSTMENT TURN SIGNAL MOMENTARY FEATURE 1

1. Stop the motorcycle and turn the key OFF. When passing a vehicle or when changing lanes, you have
2. Remove the windshield trim panel. the option of using the momentary feature built in to the turn
signal auto-cancel system.
3. Remove the retaining clip (1).
4. Hold slight downward pressure on the bottom of the Push and hold the turn signal switch in the direction you
windshield (it is under slight upward spring pressure). wish to turn. Hold the switch through at least one complete
flash cycle (at least 1 second). This activates the
5. Remove the clevis pin (2), slide the windshield inner
momentary feature, and the signal will cancel the moment
bracket to align with one of the optional holes in the
you release the switch.
outer bracket, then reinstall the clevis pin.
6. Install the retaining clip in the clevis pin.
7. Install the windshield access panel. Hold Left or
Right for one
flash cycle
1
2
CLUTCH LEVER
To disengage the clutch, pull the lever toward the
TURN SIGNAL SWITCH handlebar. To engage the clutch, gradually release the
lever. For smooth clutch operation, pull the lever quickly
With the ignition key in the ON or ACC position, the turn and release it gradually.
signal switch will activate the turn signals.
• Push the switch left to activate left turn signals
Clutch Lever
• Push the switch right to activate right turn signals
• To manually cancel either turn signal, push the
switch straight in toward housing when the switch
is in the center position.
If activated below 15mph* (24 kph), the turn signals cancel
automatically, shortly after the vehicle speed reaches
15mph. If a signal is activated with vehicle speed above 15 Interlock Switch
mph, cancellation will occur based on distance traveled.
NOTE: If a signal is activated above 15 mph and vehicle LEFT Handlebar
speed drops below 15 mph, cancellation will occur shortly
after speed again reaches 15 mph.
* The 15mph speed is approximate. STARTER INTERLOCK
The motorcycle is equipped with a starter interlock switch
that prevents the electric starter from operating when the
transmission is in gear and the clutch is engaged (lever
released), or if the Reverse lever is in the Reverse (Up)
Turn position (2009 10th Anniversary or Reverse equipped).
CAUTION
Never start the motorcycle in gear with the clutch

disengaged unless you are seated on the bike in a
normal riding position with the front brake applied.
1.29
RIGHT HANDLEBAR CONTROLS MIRRORS

ENGINE STOP SWITCH The rear view mirrors are adjusted by applying light
The engine stop/run switch completes or interrupts the pressure to left, right, top, or bottom edge (A).
ignition, starter, and fuel pump circuits.
Press RUN side of engine stop/run switch (RUN position). A
Press STOP side of switch to interrupt circuits and stop the
engine. The engine should not start or run when the switch
is in the STOP position. Use STOP/RUN switch to turn
engine off under either normal or emergency conditions.
Turn key OFF after the engine stops.
Run
RIGHT LINKED BRAKE SYSTEM

Handlebar Switch
The front and rear brakes on the motorcycle are linked.
Application of the front brake lever activates only the top
and bottom caliper pistons on each front caliper.
ENGINE STARTER BUTTON
The starter button works only when STOP/RUN switch is in Application of the rear brake pedal activates the rear brake
RUN position and transmission is in neutral (or clutch is caliper fully. When firm pressure is applied to the pedal, the
disengaged). delay valve opens and the center piston in each front brake
caliper is also activated. See Chapter 15 for Brake System
Press right side of starter button. Note: 2009 models - The
service.
headlamp circuit is not enabled until the starter button is
tapped or pressed (engine started). For maximum brake effectiveness, the front brake lever
and rear brake pedal should be applied together, as you
would with non-linked brake system.
Start
RIGHT Handlebar
Switch
AUDIO / COM / CRUISE CONTROL BUTTONS

The remote audio control buttons are mounted below the
LH bar switch. Cruise control buttons are mounted below
ABS BRAKE SYSTEM
the RH bar switch (throttle side). See page 1.34 for an See Chapter 15 for ABS information.
overview of Audio System operation. Refer to Chapter 19
for Audio System and Cruise Control System diagnostic
information.
1.30
FRONT BRAKE LEVER REACH FOOT CONTROL ADJUSTMENT 1

ADJUSTMENT The brake pedal and shift pedal can be adjusted to one of
three positions. The controls are in the center position as
Front brake lever “reach” or distance to the hand grip is
delivered from Victory.
adjustable. To adjust the front brake lever reach:
To move the controls to the front or rear position, do the
• Pull the lever away from the grip (1) and hold.
following:
• Turn dial (2) to align a lower number with the arrow
1. Use a 6mm Allen wrench to remove screw (1).
(3) on the lever to increase lever reach distance.
2. Slide the control forward or rearward in its track until
Turn the dial to align a higher number with the arrow on the the threaded hole of the control aligns with the front (2)
lever to decrease reach distance. or rear (3) screw hole in the footrest support.
3. Install the screw and torque to 96 lb-in. (11 Nm).
2
3 3 1
2
4. After adjusting shift pedal, always readjust the shift
linkage rod.
2
90mm (3.5 in)
5. Loosen both jam nuts (4).
6. Turn linkage rod (5) until peg on shift pedal is about

90mm above floor board surface (or to desired height).
7. Tighten jam nuts to 96 lb-in. (11 Nm).
1.31
FUEL DOOR GLOVE COMPARTMENT

The fuel door is located on the right hand side of the To OPEN the glove compartment:
console. To open the fuel door:
• Turn the handlebars as required to clear the
• Turn the handlebars fully left. door. Press and release the inner edge of the
• From the OFF position, turn the ignition key door. The door will open under spring pressure.
counterclockwise to release the fuel door latch
To CLOSE the glove compartment:
and the door will open under light spring
tension. Do not depress the key while turning. • Push the door firmly until latched, then release.
• To close the door, be sure the fuel cap is in
place and secured properly, then close the To LOCK the glove compartment:
door and press downward until latched. • Close the glove compartment door.
Turn key • Turn the ignition key to the lock position.
counterclockwise
to open fuel door. The fuel door and glove compartment are locked when the
Do not depress key. steering is locked.
FUEL CAP
Open the fuel door with the ignition key
• Turn the fuel cap counterclockwise to open.
• Set the cap in the holder while fueling.
• To install the cap, turn the fuel cap clockwise
until seated.
• Close the fuel door by pressing downward until
latched.
The fuel door is locked with the steering lock (page 1.23).
Cap Holder
1.32
SADDLEBAGS 1
Use the ignition key to lock and unlock the saddlebags.
Lock the saddlebags when riding.
• Refer to loading information beginning on page 1.9.
UN
LO
C K
CK
LO
TRUNK OPERATION
Use the ignition key to Lock and unlock the trunk.
Lock the trunk when riding.
UNLOCK
LOCK
1.33
RADIO / AUDIO SYSTEM MAIN USER INTERFACE

1. LCD screen: The LCD screen displays information
RADIO / AUDIO SYSTEMS OPERATION for the active source or sources.
The following pages describe the operation and function of 2. Memory presets: Allows operator to store and recall
the various Radio and Audio systems such as AM/FM/WX up to 12 radio stations, directly-select any 1 of 10 CDs
audio system, CB radio / intercom, XM radio, auxiliary and in CD changer (2008-2009), or directly-access up to 11
iPod audio, NAV MP3 (2010 models), and CD changer iPod user-defined playlists.
(2008-2009 only).
3. Volume / Menu Option Select control: Adjust volume
or cycle through menu options in the MODE menus.
iPodis a registered trademark of Apple Inc.
4. Power ON / OFF: Press the power button to turn the

XM is a registered trademark of XMSatellite Radio Inc. system on or off.
NOTE: Ignition switch must be in ON or ACC position.
Not all motorcycles are equipped with all components
discussed in the audio section of this manual. 5. Source (SRC) - Mode: Press SRC to cycle through
available sources, or to exit MODE menus. Press and
Refer to Chapter 19 (Electrical Systems) for diagnostics. release MODE to enter the audio system mode menus.
Continue to press and release the MODE button until
2010 denotes information specific to model year 2010. the desired mode menu is displayed. Additional
information on each source is available in this section.
U.S. Sources:
• FM / AM / WX / AUX (NAV MP3, AUX or iPod) / XM
Radio / CD Changer
European Sources:
• FM / MW / LW / AUX (iPod or NAV MP3) / CD
Changer
Radio Panel Mode Menu Options:
LH Lower Bar Switch • Bass / Treble / Fader / External Speakers /
Automatic Volume Control (AVC) / CB Headset ENT
/ ICOM Volume / CB Volume / CB LO/DX / Tuning /
Radio Data System (RDS) / AUX Mode /
XM Display / XM Category / XM Tune Mode.
RADIO FREQUENCIES • Some Mode Menu Options have sub-menus. Refer
to detailed information about each in this chapter.
North America
Sources and menu options will only be displayed for
• AM 520 to 1720 kHz installed components.
• FM 87.9 to 107.9 MHz
1
• WX 162.40 to 162.55 MHz
European
• FM 87.5 to 108.00 MHz 2

• MW 522 to 1602 kHz
• LW 144 to 288 kHz
3 5
1.34
LOWER LEFT HAND CONTROL REAR PASSENGER CONTROL 1

Operation of the left handlebar audio control is outlined in 1. Rear PTT (Push to Talk): Press and hold PTT button
greater detail on the following pages. to transmit.
1. Volume control: Press to increase (+) or decrease 2. Rear Volume control: Press VOL (+) or (-) to raise or
(-) audio volume. Press and hold to rapidly increase lower rear passenger headset volume.
or decrease volume.
2. Tuner control: Press (+) or (-) to manually tune radio
stations, iPod tracks, or CD tracks. Press and hold to
automatically seek or scan.
3. Source/Exit - Mute select: Press S/E to cycle through
available sources or to exit the current mode.
4. Press MUTE to silence the audio and pause the iPod.
1 2 3 AUDIO SYSTEM POWER

The ignition key must be in the ACC or ON position to use
the audio system.
With the key in the ACC or ON position and audio system

OFF, the screen will display “VICTORY MOTORCYCLES”
or “VICTORY” (2010).
4
UPPER LEFT HAND CONTROL*

Operation of the left handlebar CB control is outlined in
VICTORY
greater detail on the following pages.
1. PTT (Push to Talk) - Press and hold top or bottom of NOTE: To prevent battery drain, do not leave the key
PTT button to transmit (page 1.44). in the ACC position for long periods. Victory
recommends using the audio system only when the
2. Squelch: Press SQ (+) or SQ (-) to adjust CB radio engine is running.
channel reception sensitivity (page 1.44).
3. COM - ICOM select: Press COM to turn the CB on or
off. Press and hold COM to select a COM channel.
Press the power button to turn the audio system on.
Press ICOM to turn the driver/passenger intercom on
or off. Press and hold ICOM to access Voice Activated
Switch (VOX) settings (page 1.46).
* If equipped with CB radio.
1 2 3
1.35
When powered, the screen will display the active VOLUME CONTROL
source(s).
The driver can set the volume level for the front and rear
1 5 speakers, turn the speakers off or on, and mute the system
2
audio.
2008-2009 Display AUDIO MUTE

Press and release MUTE to drop audio system volume. To
3 4 resume volume to prior level, press and release MUTE
again.
1 2 5
2010 Display 4
3
AUDIO VOLUME
Press and release (+) or (-) on console to raise or lower
NOTE: Screen style examples are shown above. volume. You can also press VOL (+) or (-) on left control.
Primary information is shown along the left side of
display on 2010 models.
1. Current audio source:

• (U.S.) FM / AM / WX / iPod - AUX / XM /
CD Changer
• (Euro) FM / MW / LW / iPod - AUX / CD Changer
2. Station preset number (P1 - P12).
3. CB radio active and active channel.*
PASSENGER VOLUME
4. Intercom system active.*
The passenger can control the rear headset music volume,
5. Stereo indicator. CB, and ICOM volume when either are active.
* If equipped. Press (+) or (-) on the passenger control to raise or lower

the rear headset volume.
NOTE: The audio system will always display the last
active source when turned on.
1.36
AUDIO SOURCE SELECTION NAV MP3 source active: 1

Press and release S/E or SRC until desired source is
active.
2010
Display
U.S. / European models
FM source active: iPod source active:
2008-2009
Display

2010
AM source active: Display
2008-2009 U.S. / European models

Display (skipped if not equipped)
2010 XM Radio source active:

Display
U.S. models only 2008-2009

Display
WX (Weather) source active:

2010
Display
U.S. models only

(skipped if not equipped)
AUX source active:
2008-2009 CD Changer source active:

Display
2008-2009
Display
2010 Display

(skipped if not equipped)
1.37
MW (Medium Wave) source: MEMORY PRESETS

2008-2009 The audio system features 12 user-defined presets that
2010 can be used to store favorite stations.
531 To set a preset, select the desired source (FM, AM, WX,
XM, MW, LW, or AUX-iPod).
European models only
Use TUNE or seek/scan to locate a radio station.
LW (Long Wave) source:
Press and hold one of the console preset buttons (P1 - P12)
2008-2009
2010
until the audio sound is muted for 1/2 second.
144
European models only
Once the station is given a preset location, the screen will

display its memory preset location.
AUDIO TUNING
Press and release TUNE (+) or TUNE (-) on the left hand
control to locate stations in single-step increments. AUDIO MODE MENUS
NOTE: Additional tuning features (double-click) are
To enter mode menus display:
available with some sources such as iPod. Refer to
specific source tuning information in this chapter for Press and release the MODE button on the console panel
more information. to enter the audio system mode menus.
Press and hold TUNE (+) or TUNE (-) to SEEK or SCAN Continue to press and release the MODE button until the
for stations (seek or scan depends on mode setting). desired setting is shown on the display screen.
Press and release TUNE (+), TUNE (-), or S/E to exit the
seek or scan function
To exit mode menus display:

:
Press S/E on the left control or the SRC button on the
console to exit the screen and return to the main display.
NOTE: After 5 seconds of inactivity, the system will
exit the menu and return to the default display.
1.38
BASS SETTING EXTERNAL SPEAKERS 1

Press (+) or (-) on the console panel to adjust the level. Press (+) or (-) on the console panel to turn the speakers
(See page 1.38 to enter and exit mode menus). on or off. (See page 1.38 to enter and exit mode menus).
2008-2009
Display 2008-2009
Display
2010
Display
2010
Display
AUTOMATIC VOLUME CONTROL (AVC)

TREBLE SETTING When set, this feature will lower or raise the speaker/
headset volume automatically, based on vehicle speed.
Press (+) or (-) on the console panel to adjust the level.
(See page 1.38 to enter and exit mode menus). (See page 1.38 to enter and exit mode menus).
Press the console panel (+) or (-) button to set the

2008-2009 Automatic Volume Control settings.
Display
• AVC Off = No AVC. Volume will not adjust.
• AVC Low = Least aggressive AVC setting.
• AVC Medium = Moderate AVC setting.
• AVC High = Most aggressive AVC setting.
2010
Display
2008-2009
Display
FADER SETTING
Press the console panel (+) or (-) button to adjust the front
and rear speaker output ratio. This setting is skipped when
the external speakers are off.
(See page 1.38 to enter and exit mode menus).
2010
Display
2008-2009
Display
2010
Display
1.39
CB HEADSET VOLUME CONTROLS* ICOM VOLUME*

The headsets have 3 separate volume settings: Intercom (See page 1.38 to enter and exit mode menus).
(ICOM) volume, CB receive volume, and entertainment
(ENT) volume. Always position headsets with the speakers Press (+) or (-) on the console panel to change settings.
directly over your ears to ensure the best sound quality and
2008-2009
volume. Display
NOTE: The driver can turn off the external speakers
and listen to audio only through the headsets. 2010
Display
Passenger
Item Driver Controls
Controls
Press VOL (+) or VOL (-) on the left control
CB RECEIVE VOLUME*
ENT
or press the console panel (+/-) (while Press (+) or (-) on the console panel to change settings.
Volume
listening to ENT).
Press VOL (+) or VOL (-) on the left control 2008-2009
Press (+) or
ICOM (when VOX is in use) or press the console Display
(-) on the
Volume panel (+/-) when the ICOM volume screen is
passenger
active from the mode menu. 2010
control.
Display
Press VOL (+) or VOL (-) on the left control
CB
(when receiving a CB transmission) or press
Receive
the console panel (+/-) when the CB volume
Volume
screen is active from the mode menu. CB LO/DX* MODE
Press (+) or (-) on the console panel to change settings.
CB HEADSET ENT MODE*
See page 1.45 for more detailed information.
Reference the CB / ICOM section for more information.
Press the console panel (+) or (-) button to set the CB
Headset ENT settings. 2008-2009
Display
2010 2010
Display Display
Shown
TUNING (Seek / Scan Modes)

OFF: Only communications are audible in the headsets. Press (+) or (-) on the console panel to set the tuner SEEK
Riders can listen to navigation commands and or SCAN mode.
entertainment with the external speakers while reserving
the headset for communication. 2008-2009
Display
MIX: The audio source volume drops lower than the
ICOM volume whenever the voice operated switch (VOX)
is opened. The audio source volume gradually returns to
its original level after the VOX is closed. 2010
Display
MUTE = The audio source volume is muted when the VOX
is opened. The audio source volume gradually returns to its
original level once the VOX is closed. *Setting skipped when CB radio is not present.
1.40
RADIO DATA SYSTEM (RDS) XM DISPLAY* 1

(See page 1.38 to enter and exit mode menus). (See page 1.38 to enter and exit mode menus).
2010 models only: 2008-2009:

Press (+) or (-) on the console to turn RDS on or off. ON Press (+) or (-) on the console panel to set the screen to
setting will display artist, song title, etc. (if available in the display the artists or song title name when the XM radio is
radio signal you are receiving). active.
2008-2009
Display
2010:
Press (+) or (-) on the console panel to set the screen to
display channel name or category when the XM radio is
AUX MODE
active.
Press (+) or (-) on the console panel to set the mode to AUX
(for iPod or any other MP3 player connected in the left
storage compartment) or to NAV MP3 for navigation unit
MP3 player use. 2010
Display
NOTE: NAV MP3 mode will override any device
connected with an input cable in the left storage bin.
*Setting skipped when XM radio is not present.
2010
Display XM TUNE MODE*
Press (+) or (-) on the console panel to change the mode.

NOTE: If using NAV MP3 mode, always pause the
In SCAN mode, TUNE (+) or TUNE (-) will tune to the next
Garmin unit before changing sources. Otherwise,
higher or lower XM channel, remain there for up to 5
music from the NAV unit will interrupt the new
seconds, then automatically tune to the next higher or
source, interpreting it as navigation commands, not
lower channel until TUNE (+) or TUNE (-) is pressed again.
music.
In SEEK mode, TUNE (+) or TUNE (-) will find the next
higher or lower station and stop.
2010
Display
*Setting skipped when XM radio is not present.
1.41
XM CATEGORY* NOAA WEATHER BAND (WB or WX)

(See page 1.38 to enter and exit mode menus). Weather band channels are broadcast by the National
Oceanic and Atmospheric Administration (NOAA). NOAA
Press (+) or (-) on the console panel to set the music operates more than 940 transmitters covering the United
selection category when tuning XM. States, Puerto Rico, the U.S. Virgin Islands, U.S. Pacific
Territories, and adjacent coastal waterways.
These categories are downloaded from XM whenever the
XM antenna is receiving a signal and may change from Typically, only one weather band channel will be available
time to time. for a given location. When traveling, if a channel becomes
unavailable, search for another active channel.
When the WB source is selected (WX on 2010 models), a

total of 7 weather band channels are available.
2010
Display 2008-2009
Display
2010
Display
NOTE: Selecting a category will then limit the

channels available to those within that category until
WX Channels
ALL CHANNELS or another category is selected.
WX CH. FREQ.
*Setting skipped when XM radio is not present. 1 162.400
2 162.425
3 162.450
4 162.475
5 162.500
6 162.525
7 162.550
Access each WX channel by pressing P1 - P7 on the

console, or use Tune (+) (-).
1.42
CB RADIO / ICOM SYSTEM CB CHANNELS 1

When the CB radio system is active, “CB” and the active
INTRODUCTION - CB RADIO FCC RULES
channel will display.
In the U.S.A., refer to the Federal Communications
Commission (FCC) Plain Rules pamphlet accompanying (2010 Display
Shown)
the rider’s manual on the motorcycle for a comprehensive
guide of citizens band (CB) radio rules and regulations.
HEADSET USE Press and hold COM on the upper LH control to access the
CHANNEL ADJUST screen.
The use of helmet-mounted headsets may be restricted or
prohibited in some areas. Always obey all applicable
regulations and laws.
The headsets have three separate volume settings:

Intercom (ICOM) volume, CB receive volume and
entertainment (ENT) volume. See page 1.40 for more
information.
Push COM or ICOM on the left control or (+) or (-) on the
GETTING STARTED - CB / ICOM console panel to change channels.
NOTE: To minimize distractions while riding, always

2008-2009
make adjustments to the CB/ICOM system prior to Display
operating the motorcycle.
NOTE: To prevent battery drain, do not leave the key

in the ACC position for long periods. Victory 2010 Display
engine is running.
NOTE: Changing to a new channel may require
The ignition key must be in the ACCESSORY or RUN changing the squelch setting.
position to use the audio system.
Press S/E on the lower LH control, or allow the system to
Press the power button to turn the audio system on. time-out to exit the CHANNEL ADJUST screen and
return to the main display.
Press COM on the upper left handlebar control to activate

the CB-COM system.
1.43
PUSH-TO-TALK (PTT) SQUELCH

Press and hold the top or bottom of the PTT button on the Squelch blocks undesired signals and noise by allowing
upper LH control to transmit over CB radio. the reception of signals only over a specified level.
The passenger push and hold the rear PTT button. Press and release the SQ(+) or SQ(-) buttons to adjust the
squelch level to any level between OPEN and CLOSED.
2008-2009
Display
2010
Display
When squelch is set to OPEN, no filtering occurs. Setting

squelch to CLOSE blocks all signals, including strong
“TX” will display on the console screen when one of the signals.
PTT buttons is pressed.
To set the squelch level, first lower the squelch level until
“RX” will display when the CB is receiving a transmission. noise or static is audible.
2008-2009
Gradually increase the squelch level until the noise or static
Display is gone.
Transmitting
Press S/E on the lower LH control or allow the system to
time-out to exit the SQUELCH set screen and return to the
2010 Display main display.
Transmitting
2010 Display
Receiving
1.44
CB RADIO VOLUME SETTING (Driver)* CB LO/DX* 1

*Setting skipped when CB radio is not present. *Setting skipped when CB radio is not present.
Press and release the MODE button on the console panel Press and release the MODE button on the console panel
to enter the audio system mode menus. to enter the audio system mode menus.
Continue to press and release the MODE button until CB Continue to press and release the MODE button until the
VOL is shown on the display. desired setting is shown on the display screen.
Press (+) or (-) on the console panel to adjust settings. Press (+) or (-) on the console panel to set the CB to
Press S/E to save and exit. LOCAL (LO) or DISTANT (DX) mode.
NOTE: The CB volume can also be set using the Press S/E to save and exit.
hand control (VOL +/-) when the CB is receiving.
2008-2009
Display
2008-2009
Display
2010 2010
Display Display
CB RADIO VOLUME SETTING (Passenger)*

Distant: Use this setting for weaker signals. Receiver
*Setting skipped when CB radio is not present. sensitivity will be increased. Static and noise levels are
increased.
The passenger can control rear headset volume when the
Entertainment, CB radio or ICOM is active (each volume Local: Use this setting for stronger signals or in high
setting is independently adjustable.) density areas. Receiver sensitivity will be decreased. Static
and noise levels are decreased.
Press (+) or (-) on the passenger control to raise or lower
the rear headset volume.
1.45
CB FREQUENCIES ICOM SYSTEM

The FCC has designated 40 citizen band (CB) channels for Press and release ICOM on the upper LH control to
consumer use. activate the intercom system.
NOTE: Channel 9 is designated as an EMERGENCY
channel for emergency use only.
CB Channels / Frequencies
C FRE C FRE FRE When the intercom system is active, ICOM will be
CH.
H. Q. H. Q. Q. displayed on the console screen.
1 26.965 8 27.055 15 27.135
2008-2009
Display
2 26.975 9 27.065 16 27.155
3 26.985 10 27.075 17 27.165
4 27.005 11 27.085 18 27.175 2010

Display
5 27.015 12 27.105 19 27.185
6 27.025 13 27.115 20 27.205
7 27.035 14 27.125 21 27.125
VOX BREAK SETTING

The intercom is opened and closed using a voice operated
switch (VOX). The volume sensitivity level required to open
22 27.225 31 27.315 40 27.405 the intercom can be adjusted using the VOX sensitivity
23 27.255 32 27.325
setting.
24 27.235 33 27.335
Press and hold ICOM on the upper LH control to access the
VOX sensitivity set screen.
25 27.245 34 27.345
26 27.265 35 27.355
27 27.275 36 27.365
28 27.285 37 27.375
29 27.295 38 27.385
Push COM or ICOM or (+) / (-) on the console panel to
30 27.305 39 27.395 adjust the sensitivity setting.
Lower settings require less volume to open the intercom.
If wind, or ambient vehicle noise trigger the VOX to open,

set the VOX sensitivity to a higher level.
2008-2009
Display
2010
Display
1.46
Press S/E on the lower LH control to exit the VOX volume ICOM VOLUME SETTING (Passenger)
set screen and return to the main display.
The passenger can control the rear speaker volume only 1
when the CB radio, ICOM, or rear headset speakers are
active.
Press (+) or (-) on the passenger control to raise or lower

the rear speaker volume.
“VOX” will be display on the console screen whenever the
driver or passenger are communicating over the intercom
system.
2008-2009
Display
2010
Display
ICOM VOLUME SETTING (Driver)*

*Setting skipped when CB radio is not present.
Press and release the MODE button on the console panel

to enter the audio system mode menus.
Headset Receptacles
A headset receptacle is provided for both the driver and
passenger (if equipped).
Driver Headset Receptacle
Continue to press and release the MODE button until the 12V
desired setting is shown on the display screen.
Press (+) or (-) on the console panel to adjust settings.
Volume can also be adjusted using LH control when VOX

is open.
Passenger Headset Receptacle
2008-2009
Display
2010
Display
Press S/E on the LH control at any time to exit the system

setting menus and return to the default screen.
1.47
AUX / iPod iPod Use
GETTING STARTED - AUX / iPod The ignition key must be in the ACCESSORY or RUN
position to use the AUX / iPod function.
To use your iPod, connect the iPod input cable.
in the ACC position for long periods. Victory
AUX Input Cable recommends using the audio system only when the
engine is running.
iPod Input Cable
2008-2009 2010 Press and release the S/E button on the lower LH control...
Input Cable Setup

The AUX and iPod input cables are connected to the audio
system through a small hole in the left-side console
storage bin. Only one input cable can be connected at any ...or SRC on the console panel until AUX or iPodis active.
given time.
To change an input cable:
1. Open the left-side console storage bin.
2. Locate the input cable and sealing grommet at the
bottom of the bin.
3. Carefully pull the cable along with both connectors
inside the bin. When AUX is active, the console screen will display “AUX”
4. Disconnect the cable from the harness by carefully as the active source.
pushing up on the green tab (2008-2009) or by
pushing down on the locking tab (2010). Aux harness 2008-2009
uses one connector, iPod uses two (2010). Make sure Display
the unused connector is capped when the Aux cable
is used. Do not allow the harness to drop back through 2010
Display
the hole.
5. Install the desired input cable.
6. Carefully push sealing grommet back into the hole. When iPod is active, the console screen will display the
name of the iPod (2008-2009) or iPod as the active source
and iPod information in the display screen (2010).
2008-2009
Display
2010
Display
1.48
AUX MODE (2010) Press and release preset buttons (2) through (12) to
To change the mode, press the MODE button on the

access your iPod user-defined play-list(s).
1
console repeatedly as required to toggle to the AUX 2008-2009
MODE screen. Display
Use the console + / - button to change the mode to AUX

(for iPod or any other MP3 player use) or to NAV MP3 for 2010
Display
navigation unit MP3 player use.
NOTE: NAV MP3 mode will override any device
connected with an input cable in the left console iPod TUNING
storage bin.
ALL: Press and release the TUNE (+) or (-) button on the
left control to move 1 track forward or 1 track backward.
2008-2009 Only: Press and release the TUNE (+) or

TUNE (-) button on the lower LH control twice (double
click) to move 10 tracks forward or 10 tracks backward.
2010
Display 2010 Only: Press TUNE (+) or TUNE (-) button twice
(double click) to bring up the track selection screen, then
use the TUNE button to move forward and backward
through the playlist. When the desired track is highlighted,
press any preset button on the console to select the track.
To exit the screen without changing tracks, press S/E.

iPod PLAY LISTS 2010 Models
Access the iPod main music library and user-defined play-

lists with the console preset buttons.
ALL: Press and hold the TUNE (+) or TUNE (-) button on
lower left control to fast forward or fast reverse the track.
NOTE: Generic MP3 players can play music, but

cannot be controlled though the audio system (for 2010 Only: To browse tracks by artist, playlist, or album,
example, selecting tracks or playlists). press and hold any preset button to bring up the selection
Press and release preset button (1) to access the iPod screen. Press TUNE (+) or (-) to make a selection.
main music library.
2010 Models
2008-2009 MY iPod
Display
Then press any preset button to bring up the items in the
selected list. Press TUNE (+) or (-) to make a selection.
Press and release any preset button to play the track.
2010
Display
2010 Models
1.49
XM RADIO Activate your XM Satellite Radio service in the U.S. online
at http://activate.xmradio.com or call 1-800-XMRADIO (1-
About XM Radio 800-967-2346). Activate your XM Satellite Radio service
in Canada online at https://activate.xmradio.ca or call 1-
XM is North America’s number one satellite radio 877-GET-XMSR (1-877-438-9677). You will need a major
company, offering an extraordinary variety of credit card. XM will send a signal from the satellites to
commercial-free music, plus the best in premier sports, activate the full channel lineup. Activation normally takes
news, talk radio, comedy, children’s and entertainment 10-15 minutes, but during peak busy periods you may
programming, broadcast in superior digital audio quality need to keep your XM Ready audio system on for up to an
coast to coast. hour. When you can access the full lineup on your XM
Ready audio system you are done.
For more information, or to subscribe, U.S. customers visit
xmradio.com or call XM Listener Care at 1-800-XMRADIO
(1-800-967-2346); Canadian customers visit xmradio.ca
or call XM Listener Care at 1-877-GETXMSR (1-877-438- GETTING STARTED - XM Radio
9677).
the XM radio.
XM Ready Legal NOTE: To prevent battery drain, do not leave the key
XM monthly service subscription sold separately. XM Mini- in the ACC position for long periods.
Tuner and Home Dock required (each sold separately) to Victory recommends using the audio system only
receive XM service. It is prohibited to copy, decompile, when the engine is running.
disassemble, reverse engineer, hack, manipulate or Press the power button to turn the audio system on.
otherwise make available any technology or software
incorporated in receivers compatible with the XM satellite Press and release the S/E button on the left control, or
Radio System. Installation costs and other fees and taxes, SRC on the console panel, until the XM radio is the active
including a one-time activation fee may apply. All fees and source.
programming subject to change. Channels with frequent
explicit language are indicated with an XL. Channel
blocking is available for XM radio receivers by calling 1-
800-XMRADIO (U.S.residents) and 1-877-GETXMSR
(Canadian residents). Only available in the 48 contiguous
United States and Canada. ©2007 XM Satellite Radio Inc.
All rights reserved. When the XM Radio is active, the console screen will
display:
(2008-2009) the XM radio channel, and either the song
XM Ready Subscription artist’s name or the name of the current song;
Once you have installed the XM Mini-Tuner Home Dock, (2010) XM will appear in the display as the active source
inserted the XM Mini-Tuner, connected the XM Mini-Tuner with the channel number, preset number (if applicable),
Home Dock to your XM Ready audio system, and installed the channel name or category, the artist, and song title.
the antenna, you are ready to subscribe and begin
receiving XM programming. There are three places to find 2008-2009
your eight character XM Radio ID: On the XM Mini-Tuner, Display
on the XM Mini-Tuner package, and on XM Channel 0.
Record the Radio ID below for reference.
Record the Radio ID below for reference: 2010

Display
NOTE: The XM Radio ID does not use the letters “I”,

“O”, “S” or “F”.
1.50
XM RADIO RECEPTION XM RADIO SETTINGS
If XM radio is not receiving a signal due to being indoors (2010 Models) 1
(or any overhead obstruction) “No Sgnl” appears in the
display. To access XM specific menus, turn the audio system
power ON and change the active source to XM using the
SRC button on the console.
Press the MODE button on the console repeatedly to

toggle to the XM DISPLAY menu.
Press (+) or (-) on the console panel to select CATEGORY

or CHANNEL NAME.
If the XM antenna becomes disconnected, “Antenna”
appears in the display.
Antenna
In the CATEGORY mode, the category of a selected

XM RADIO SPECIFIC MENU OPTIONS station will display in the upper right corner of the screen.
The XM radio system has unique menus that apply only to

this system when XM radio is the active source.
Some Audio System settings such as BASS, TREBLE,

FADER, etc., apply to both the audio system and the XM
radio system. In CHANNEL NAME mode, the name of the selected
channel will display.
Menus specific to the XM radio system are:
XM Display (You can select CATEGORY or CHANNEL

NAME to be displayed)
XM Category (Rock, Country, Traffic, Sports, Talk News,

All Channels, etc.)
XM Tune Mode* (You can set channel search to SEEK

XM CATEGORY SELECTION
channels or SCAN channels)
With audio system power ON and XM as the active source,
* The XM TUNE MODE is unique to the XM radio system. use the MODE button on the console to scroll to the XM
Audio System SEEK / SCAN setting will not affect the XM Category menu.
channel search setting.
Press TUNE (+) or TUNE (-) button on the left control to
change the category.
1.51
XM CHANNEL SELECTION NAV MP3
Press TUNE (+) or TUNE (-) button on the left control to
BEFORE YOU BEGIN - NAV MP3
change the channel.
Here are a few helpful tips for VICTORY VISION
motorcycles equipped with the Garmin® zumo® 660 NAV
MP3 player and the Audio Integration Kit.
• Be sure to read the Owner’s Manual and all

information included with your Garmin® zumo® 660
to become familiar with the operation of and
access to all available features.
The ALL CHANNELS category must be selected to scroll • The Audio Integration kit must be installed to
through every available channel in numerical order. enable outputs from the NAV MP3 (such as
navigation instructions or user-loaded MP3 media
If a specific category (other than ALL CHANNELS) is files) to play through the headsets or the speakers.
selected, only channels within that category will be
selected with the TUNE button. • The NAV MP3 unit is fully functional without the
NOTE: If a Preset button is used to select a channel Audio Integration kit installed, but there will be no
that is not within the currently selected category and interface with the audio system on the motorcycle.
the TUNE + / - button is used to change the channel,
• Review general Audio system operation information
it will tune stations within the previously selected
beginning on page 1.34 to set the Aux Mode
category, not within the category of the Preset
station.
TIPS FOR OPERATION
EXAMPLE:
Signal Priority
Country is the selected category.
• Signals coming from the NAV MP3 unit will
Preset 6 is used to switch to a channel within the Rock override any source of the motorcycle’s audio
category. system to ensure navigation instructions are
communicated when needed. Navigational
Pressing TUNE + / - on the lower left control will continue instructions will also override the MP3 player.
to only select stations available in the Country category.
Volume Settings - IMPORTANT!
• You must set volume levels within the NAV MP3

unit. Volume settings in the motorcycle’s audio
system control NAV MP3 volume, but navigation
instructions may be difficult to hear if volume levels
in the unit are set too low. See the GARMIN
information for setting procedures.
Recommended initial setting are:
MASTER - 100%
NAVIGATION - 90%
MEDIA - 90%
1.52
To switch to the radio when the MP3 player is in use: CHANGING AUX MODE TO NAV MP3
• Pause or stop the MP3 player to switch to radio. There are two AUX Modes available: 1
AUX (iPod) and...
To switch from radio to the MP3 player: NAV MP3
• Change the active source to AUX Press the MODE button on the console panel repeatedly
to toggle to the AUX mode.
• For best sound quality, change the AUX MODE
setting on the radio to NAV MP3 when listening to Press the console panel (+) or (-) button to set the mode
the MP3 player in the NAV unit. Audio works in the to AUX (for iPod or any other MP3 player use) or to NAV
AUX setting, but the levels are not optimized. MP3 for navigation unit MP3 player use.
• Refer to Getting Started (below) for instructions on

how to change the active source to AUX and the
AUX Mode to NAV MP3.
• If playing MP3 files from the Garmin® zumo® 660

unit, you may need to turn down the “MEDIA
VOLUME” on the Garmin unit to avoid distortion.
GETTING STARTED - NAV MP3

the NAV MP3 player.
in the ACC position for long periods.
Victory recommends using the audio system only
when the engine is running.
Press and release the S/E button on the lower LH control

or SRC on the console panel until AUX is the active
source, then set the AUX MODE to NAV MP3.
1.53
CD CHANGER (2008-2009) CD Player Cartridge
1. With ignition switch ON or in ACC, open the CD
Getting Started
changer door.
The ignition key must be in the ACC or ON position to use 2. Press the EJECT button.
the CD changer. 3. Remove the CD cartridge from the CD player.
With the key in the ACC or ON position and audio system 4. Slide one of 10 trays out of the cartridge. Insert a CD
OFF, the screen will display “VICTORY (data side down) into the tray.
MOTORCYCLES”. 5. Slide the tray back into the cartridge.
NOTE: To prevent battery drain, do not leave the key 6. Carefully insert the cartridge back into the CD player.
in the ACC position for long periods. Victory 7. Close and latch the CD player door.
engine is running. Selecting CDs
The CD changer can hold up to 10 CDs. Each CD can be
accessed by using the console preset buttons.
Press and release one of the console preset buttons (P1
- P10) to access a CD.
Press and release the S/E button on the lower LH control...

If no disc is located in the location pressed, the CD
changer will move to the next highest disc location until a
disc is found.
If preset buttons P11 or P12 are pressed, “NO DISC” will
be shown on the console display.
...or SRC on the console panel until the CD changer is

active.
When a disc is found, the disc number (A), track number
(B), and track time duration (C) will be shown on the
console display screen.
(A) (B) (C)
When the CD changer is active, the console screen will

display the CD Track Selection
Press and release TUNE (+) or (-) button to move
forward or reverse 1 track on the CD.
Press and hold TUNE (+) or (-) button to fast forward or
fast reverse through a CD track.
1.54
REFERENCE DECIMAL EQUIVALENTS
SAE TAP DRILL SIZES 1/64 ................ .0156 1
Thread Size/ Drill Size Thread Size / Drill Size 1/32. . . . . . . . . . . . . .0312 . . 1 mm = .0394"
3/64 ................ .0469
#0-80 3/64 1/2-13 27/64 1/16. . . . . . . . . . . . . .0625
#1-64 53 1/2-20 29/64 5/64 ................ .0781 . . 2 mm = .0787"
#1-72 53 9/16-12 31/64 3/32. . . . . . . . . . . . . .0938
#2-56 51 9/16-18 33/64 7/64 ................ .1094 . . 3 mm =.1181"
1/8. . . . . . . . . . . . . . .1250
#2-64 50 5/8-11 17/32 9/64 ................ .1406
#3-48 5/64 5/8-18 37/64 5/32. . . . . . . . . . . . . .1563 . . 4 mm = .1575"
#3-56 45 3/4-10 21/32 11/64 ................ .1719
#4-40 43 3/4-16 11/16
3/16. . . . . . . . . . . . . .1875 . . 5mm = .1969"
13/64 ................ .2031
#4-48 42 7/8-9 49/64 7/32. . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................ .2344 . . 6 mm = .2362"
#5-44 37 1-8 7/8 1/4. . . . . . . . . . . . . . .25
#6-32 36 1-12 59/64
17/64 ................ .2656 . . 7 mm = .2756"
9/32. . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................ .2969
#8-32 29 1 1/8-12 1 3/64 5/16. . . . . . . . . . . . . .3125 . . 8mm = .3150"
#8-36 29 1 1/4-7 1 7/64 21/64 ................ .3281
#10-24 24 1 1/4-12 1 11/64
11/32. . . . . . . . . . . . .3438 . . 9 mm = .3543"
23/64 ................ .3594
#10-32 21 1 1/2-6 1 11/32 3/8. . . . . . . . . . . . . . .375
#12-24 17 1 1/2-12 1 27/64 25/64 ................ .3906 . . 10 mm = .3937"
#12-28 4.6mm 1 3/4-5 1 9/16 13/32. . . . . . . . . . . . .4063
1/4-20 7 1 3/4-12 1 43/64
27/64 ................ .4219 . . 11 mm =.4331"
7/16. . . . . . . . . . . . . .4375
1/4-28 3 2-4 1/2 1 25/32 29/64 ................ .4531
5/16-18 F 2-12 1 59/64 15/32. . . . . . . . . . . . .4688 . . 12 mm = .4724"
5/16-24 I 2 1/4-4 1/2 2 1/32 31/64 ................ .4844
3/8-16 O 2 1/2-4 2 1/4
1/2. . . . . . . . . .5 . . . . . 13mm = .5118"
33/64 ................ .5156
3/8-24 Q 2 3/4-4 2 1/2 17/32. . . . . . . . . . . . .5313
7/16-14 U 3-4 2 3/4 35/64 ................ .5469 . . 14 mm = .5512"
7/16-20 25/64 9/16. . . . . . . . . . . . . .5625
37/64 ................ .5781 . . 15 mm = .5906"
19/32. . . . . . . . . . . . .5938
METRIC TAP DRILL SIZES 39/64 ................ .6094
5/8. . . . . . . . . . . . . . .625 . . . 16mm =. 6299"
Tap Size Drill Size Decimal Nearest 41/64 ................ .6406
Equivalent Fraction 21/32. . . . . . . . . . . . .6563 . . 17 mm = .6693"
3x.50 #39 0.0995 3/32 43/64 ................ .6719
11/16. . . . . . . . . . . . .6875
3x.60 3/32 0.0937 3/32 45/64 ................ .7031 . . 18 mm = .7087"
4x.70 #30 0.1285 1/8 23/32. . . . . . . . . . . . .7188
4x.75 1/8 0.125 1/8 47/64 ................ .7344 . . 19 mm = .7480"
3/4. . . . . . . . . . . . . . .75
5x.80 #19 0.166 11/64 49/64 ................ .7656
5x.90 #20 0.161 5/32 25/32. . . . . . . . . . . . .7813 . . 20 mm = .7874"
6x1.00 #9 0.196 13/64
51/64 ................ .7969
13/16. . . . . . . . . . . . .8125 . . 21 mm =.8268"
7x1.00 16/64 0.234 15/64 53/64 ................ .8281
8x1.00 J 0.277 9/32 27/32. . . . . . . . . . . . .8438
55/64 ................ .8594 . . 22 mm = .8661"
8x1.25 17/64 0.265 17/64 7/8. . . . . . . . . .875
9x1.00 5/16 0.3125 5/16 57/64 ................ .8906 . . 23 mm = .9055"
9x1.25 5/16 0.3125 5/16 29/32. . . . . . . . . . . . .9063
59/64 ................ .9219
10x1.25 11/32 0.3437 11/32 15/16. . . . . . . . . . . . .9375 . . 24 mm = .9449"
10x1.50 R 0.339 11/32 61/64 ................ .9531
11x1.50 3/8 0.375 3/8
31/32. . . . . . . . . . . . .9688 . . 25 mm = .9843"
63/64 ................ .9844
12x1.50 13/32 0.406 13/32 1............... 1.0
12x1.75 13/32 0.406 13/32
1.55
FAHRENHEIT TO CELSIUS MEASUREMENT CONVERSION CHART
o
C to oF: 9 (oC + 40)  5 - 40 = oF UNIT OF MEASURE MULTIPLIED BY CONVERTS TO
oF to oC: 5 (oF + 40)  9 - 40=oC ft-lb x 12 = in-lb
in-lb x.0833 = ft-lb
DEGREES F DEGREES C ft-lb x 1.356 = Nm
in-lb x.0115 = kg-m
32 0 Nm x.7376 = ft-lb
kg-m x 7.233 = ft-lb
41 5
kg-m x 86.796 = in-lb
50 10 kg-m x 10 = Nm
in x 25.4 = mm
59 15
mm x.03937 = in
68 20 in x 2.54 = cm
mile x 1.6 = km
77 25 km x.6214 = mile
Ounces (oz) x 28.35 = grams (g)
86 30
grams (g) x.035 = Ounces (oz)
95 35 cc’s x.03381 = Fluid Ounces (oz)
lbs x.454 = kg
104 40
kg x 2.2046 = lbs
113 45 = Cubic
Cubic Inches x 16.387
Centermeters
122 50 Cubic Centimeters x.061 = Cubic Inches
Imperial pints x.568 = liters (l)
131 55
liters (l) x 1.76 = Imperial pints
140 60 Imperial quarts x 1.137 = liters (l)
liters (l) x.88 = Imperial quarts
149 65 Imperial quarts x 1.201 = US quarts
158 70 US quarts x.833 = Imperial quarts

US quarts x.946 = liters
167 75 liters x 1.057 = US quarts
US gallon x 3.785 = liter
176 80
liter x.264 = US gallon
185 85 Pounds force per
x 6.895 = Kilo pascals (kPa)
square inch (psi)
194 90 = Pounds force per
Kilo pascals (kPa) x.145
square inch (psi)
203 95
212 100
1.56
MAINTENANCE
CHAPTER 2
MAINTENANCE 2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
TUNE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PERIODIC MAINTENANCE INTERVAL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
AIR FILTER / AIR BOX DRAIN HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
REVERSE IDLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
IDLE SPEED / FAST IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
THROTTLE CABLE INSPECTION / LUBRICATION / FREE PLAY . . . . . . . . . . . . . . . . . 2.9
CRUISE CONTROL CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRONT BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRONT BRAKE LEVER REACH / LEVER RESERVE . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
CLUTCH LEVER LUBRICATION (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
CLUTCH PULL ROD BUSHING LUBRICATION (HYDRAULIC) . . . . . . . . . . . . . . . . . . 2.12
CLUTCH LEVER LUBRICATION (CABLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
CLUTCH LEVER FREE PLAY (CABLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
SHIFT PEDAL / BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
CRANKCASE VENTILATION / EVAPORATIVE EMISSION CONTROL . . . . . . . . . . . . 2.16
FUEL TANK VENT INSPECTION (49 STATE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
FUEL FILTER / FUEL SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE COMPRESSION TEST / CYLINDER LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . 2.21
SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
DRIVE BELT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
DRIVE BELT WEAR ANALYSIS / CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
DRIVE BELT TENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
DRIVE BELT ADJUSTMENT / ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
HEADLAMP AIM INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
SIDESTAND INSPECTION / SIDESTAND PAD INSPECTION . . . . . . . . . . . . . . . . . . . 2.27
SIDESTAND & SPRING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
SIDESTAND PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
REAR SUSPENSION / SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
REAR SUSPENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
STEERING HEAD / FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
IGNITION SWITCH AND LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
CLEANING, WASHING, WAXING, POLISHING, APPLYING PROTECTANTS . . . . . . 2.33
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.1
MAINTENANCE
SERVICE SPECIFICATIONS
TUNE UP
ITEM SPECIFICATION (2008 - 2010)
Brake Pedal Freeplay (Rear) 1-2mm (.031") Gap At Pedal Stop
Brake Lever Reserve (Front) See test procedure page 15.44.
Brake Pad Friction Material Thickness (All) 1.0 mm (.039 inch) Minimum
Clutch Lever Freeplay (Hydraulic) -
Clutch Lever Freeplay (Cable) .5 - 1.5mm (.020-.060")
Compression Pressure (Cylinder) 210-225 (1448-1551 kPa) (page 2.21)
Drive Belt Deflection: 2008-2010
(All Models Except 2010 Vision 8-Ball & Ness) 32 mm +/- .5mm (1 1/4" +/- 1/64) with 10 lb force
(See page 2.23)
Drive Belt Deflection: 2010 Vision 8-Ball & Ness
15 mm +/- .5mm (19/32" +/- 1/64) with 10 lb force
(See page 2.23)
Drive Belt Frequency
Frequency: (All except 2010 8-Ball & Ness) 20 Hz +/- 1 Hz
(Using Sonic Tension Meter)
Frequency: (2010 8-Ball & Ness) 26 Hz +/- 1 Hz
(See page 2.23 for required data)
Idle Speed / Fast Idle Speed NOT ADJUSTABLE (ECM / IAC valve controlled) (See page 2.8)
Oil Pressure, Lubrication @ 3000 rpm 552 kPa (80 psi) (Minimum 40 psi)
Oil Pressure, Cooling @ 3000 rpm (See special notes Chapter 4)
Rear Shock Air Pressure See page 2.30 or decal in LH saddlebag
Spark Plug Type / Gap NGK DCPR6E / .8 mm (.032")
Throttle Cable Freeplay 2 - 4 mm (5/64 - 5/32") (page 2.9)
Refer to page 2.8 or decal on motorcycle (2008-2009 in left
Tire Pressure
saddlebag; 2010 - on Manufacturing Decal under console cover)
OIL CHANGE
Start the engine and warm it up for several minutes. While warming up, check for oil leaks. If any leaks are found, stop
the engine immediately and determine the source of the problem before starting the engine again.
TIGHTENING TORQUE
Drain Plug (new sealing washer) 20 Nm (15 ft. lbs. )
Oil Filter 3/4 full turn after contacting seal surface
OIL TYPE / QUANTITY

Oil Type Victory Semi-Synthetic 20W40 Engine Oil
Oil Capacity (Oil & Filter Change) Approximately 4.25 liters (4.5 quarts)
Oil Capacity (Dry) Approximately 4.75 liters (5.0 quarts)
Use Victory 20W40 Synthetic Blend 20W40 engine oil for all temperatures. If Victory oil is not available, use a high
quality 20W40 motorcycle designed for use with wet clutches (such as those with a JASO MA rating).
NOTICE
Do not put chemical additives in the oil. Victory motorcycle oil has been specially designed for this application.
Additional additives are not necessary and have not been approved by Victory Engineering.
2.2
MAINTENANCE
FASTENER TORQUE SPECIFICATIONS

MAINTENANCE ITEMS 2
APPLY /
DESCRIPTION TORQUE
NOTES
N-m Lb-ft (Lb-in)
Air Filter Mount Screws 9.8 (87)
Axle Nut, Rear 88 65
Axle Adjuster Nut, Rear 10.8 (96) Tighten Axle First
Battery Terminal Bolts 4.5 (40) Dielectric Grease
Battery Cover Bolt 10 (85)
Battery Cable To Solenoid or Starter Motor 6.8 (60) Dielectric Grease
Brake Lever Pivot Screw (Front) 1.0 (9)
Brake Lever Pivot Screw Nut (Front) 6.0 (52)
Circuit Breaker Terminal Nut (Main Breaker) 2.8 (25)
Clutch Lever Pivot Screw (Hydraulic) 1.0 (9)
Clutch Lever Pivot Nut 6 (52)
Drive Sprocket Nut 244 180 Loctite™ 262
Drive Sprocket Nut Retainer Plate Screws 10 (85)
Exhaust / Muffler Refer to Chapter 3
Floorboard Assembly to Frame 47.5 35
Oil Drain Plug 20 15 12x1.5mm
Oil Filter 3/4 Turn Past Gasket Contact
Reverse Idler Shaft Lubrication Access Screw 6.8 (60)
Seat 4 (36)
Side Stand Pivot Bolt & Nut 47.5 35
Spark Plug 14.5-19.5 10.8-14.5 Anti-seize compound
Swingarm Pivot Shaft 88 65
SPECIAL TOOLS
MAINTENANCE TOOLS
• Belt Tension Gauge PV-43532 (Sonic Tension Meter is optional and commercially available)
• Spanner Wrench - PV-46993
• Compression Gauge Set PV-33223
• Victory Air Pump & Gauge 2876654 or PV-48909
2.3
MAINTENANCE
MAINTENANCE PRODUCTS
LUBRICANTS / CHEMICALS
MAINTENANCE PRODUCT PART NUMBERS
Product Part Number
All Purpose Grease 2872187
Brake Cleaner 2872191
Brake Fluid, DOT 4 2872189
Carb and Throttle Body Cleaner, 13 oz. Aerosol 2872890
Dielectric Grease (Nyogel™) 2871329
Electrical Contact Cleaner 2872864
Fork Oil - Cartridge Forks - Vision TYPE 1 (MARZ)

2874828
(All 2008 and some 2009)
Fork Oil - Cartridge Forks - Vision TYPE 2 (KYB)

2874568
(Some 2009 and all 2010)
Fuel Additive, Carbon Clean 2872190
Fuel Stabilizer 2872280
Hand Grip Adhesive (Three Bond 1501) (10ml tube) 2872575
Loctite 262™ (50cc Tube) 2871951
Moly Assembly Paste 2871460
Multi-Purpose Lubricant 2872863
Oil Change Kit 2873551
Paint Detail Kit - Polish, Wax, and Dressing

2872195
(also see www.purevictorypolishes.com)
Paint Restore Polish, 12 oz. Aerosol 2872192
Paint Wax and Final Finish 2872193
Primer N™ (25g Aerosol) 2870585
Semi-Synthetic 20W/40 Engine Lubricant 2872175 (Quart) 2872176 (Gallon)
Vinyl and Rubber Dressing 2872194
2.4
MAINTENANCE
PERIODIC MAINTENANCE
Periodic Maintenance Interval Table
ENGINE ODOMETER READING in MILES (KILOMETERS) 2
10,000 (16,000)
12,500 (20,000)
15,000 (24,000)
17,500 (28,000)
20,000 (32,000)
22,500 (36,000)
25,000 (40,000)
27,500 (44,000)
30,000 (48,000)
32,500 (52,000)
35,000 (52,000)
37,500 (60,000)
40,000 (64,000)
42,500 (68,000)
45,000 (72,000)
50,000 (80,000)
47,500(76,000)
7,500 (12,000)
2,500 (4,000)
5000 (8,000)
500 (800)
PAGE
Component
(see operation codes below)

Air Filter 2.6 I I I I R I I I R I I I R I I I R I I I R
Crankcase Vent System 2.16 I I I I I I I I I I I
Drive Belt 2.23 I I I I I I I I I I I I R I I I I I I I I
Engine Compression 2.21 I I I I I I
Engine Oil* 2.7 R R R R R R R R R R R R R R R R R R R R R
Engine Oil Filter* 2.7 R R R R R R R R R R R R R R R R R R R R R
Evaporative Emission 2.16 I I I I I I I I I I I
Exhaust System Ch. 3 I I I I I I I I I I I I I I I I I I I I I
Fuel Filter 2.17 R
Fuel System 2.17 I I I I I I I I I I I I I I I I I I I I I
Reverse Idler Shaft 2.7 I L L L L L L L L L L L L L L L L L L L L
Spark Plugs 2.18 I I I I I I R I I I I
Throttle / Cruise Cable End 2.9 I I I I L I I I L I I I L I I I L I I I L
CHASSIS ODOMETER READING in MILES (KILOMETERS)
Battery 2.19 I I I I I I I I I I I
Brake Fluid** 2.14 I I I I I I I I I I I R I I I I I I I I I
Brake Pads 2.15 I I I I I I I I I I I I I I I I I I I I I
Cable (Ends) 2.9 I I I I L I I L I I I L I I I I L I I I L
Clutch Fluid** 2.13 I I I I I I I I I I I R I I I I I I I I I
Clutch and Brake Lever 2.10 L L I L I L I I L I L I L I L L I L I L I
Fasteners 2.32 I I I I I I I I I I I
Front Fork Oil** 2.31 I I I R I I R I I R I
Front Forks and Front Axle 2.31 I I I I I I I I I I I
Gear Shift Pedal 2.16 I I L I L I L I L I L
Headlamp 2.26 I I I I I I
Ignition Switch & Locks 2.32 L L L L L L L L L L
Radio / Radio Software 19.36 Update software annually
Rear Brake Pedal 2.16 I I L I L I L I L I L
Rear Shock Absorber 2.29 I I I I I I I I I I I I I I I I I I I I I
Rear Wheel Alignment 2.24 I I I I I I I I I I I
Road Test - P P P P P P P P P P P P P P P P P P P P P
Sidestand 2.27 I I L I L I L I L I L
Sidestand Pad 2.27 I I I I I I I I I I I I I I I I I I I I I
Steering Bearings 2.31 I I I I I I L I I I I I L I I I I I L I I
Suspension, Rear, Rocker 2.29 I I I L I I L I I L I
Swing Arm and Rear Axle 2.29 I I I I I I I I I I I
Tires / Wheels 2.8 I I I I I I I I I I I I I I I I I I I I I
Operation Codes:
I-Inspect (tighten, clean, adjust, correct or replace if necessary) R-Replace/Rebuild P-Perform
L-Lubricate with proper lubricant
*Replace at specified interval or annually **Replace at specified interval or every 2 years
2.5
MAINTENANCE
AIR FILTER ENGINE OIL LEVEL

The standard Victory air filter element is a dry paper 1. Warm the engine for several minutes until operating
design - do not apply air filter oil. temperature is reached.
1. Remove (2) screws (A). 2. Stop engine and wait for 3-5 minutes.
3. Place the machine on a level area and hold it in an
upright position.
B
4. Remove and clean the oil off of the dipstick (D).
2. Pull lower edge of filter toward front of motorcycle then

lower it to release two tabs (B) at top edge. Remove
filter. D
3. Clean filter sealing surface on frame.
4. Install new air filter, engaging tabs at top edge of filter
5. Screw the dipstick in until seated.
with filter case.
6. Remove dipstick and view oil level.
5. Install retaining screws.
7. Oil level should be between ADD and FULL lines on
6. Torque screws to 87 lb- in. (10 Nm).
dipstick. If oil level is low, add Victory 20-40 Semi-
Synthetic engine oil to raise level to FULL mark. DO
AIR BOX DRAIN HOSE NOT overfill.
Check drain hose for fluid sediment whenever air filter is
inspected or serviced.
1. Pull hose out from behind left leg fairing.
2. Remove plug (C) and drain any liquid into a waste oil
container. Dispose of properly.
3. Install plug and place hose behind left leg fairing.
1/2 qt.
Screw in to check
2.6
MAINTENANCE
ENGINE OIL AND FILTER CHANGE 11. Reinstall dipstick. Start and run engine until it reaches
normal operating temperature.
Change engine oil at intervals listed in the Periodic
NOTE: After an oil change, the low oil pressure
Maintenance Table.
indicator light could remain on longer than usual. Do
2
1. Start and run engine until it reaches normal operating not rev the engine while the light is on. If light does
temperature. Stop engine. not go out within 5 seconds of starting the engine,
stop the engine immediately and investigate.
2. Securely support motorcycle on sidestand.
3. Place an oil drain pan under the drain plug (A) and oil 12. Stop engine and make sure there are no leaks around
filter (B). the drain plug and oil filter.
13. Check oil level and adjust if needed.

NOTICE: Recycle used oil and filter in accordance
with local regulations.
ENGINE OIL CAPACITY AT Approx. 4.5 qt.

CHANGE (WITH FILTER) (4.25 liter)
ENGINE OIL CAPACITY AT Approx. 4.0 qt.

CHANGE (WITHOUT FILTER) (3.75 - 4.0 liter)
A B
20 Nm (15 lb-ft)
REVERSE IDLER SHAFT LUBRICATION
4. Remove drain plug (6mm Allen wrench) and allow oil
On motorcycles equipped with Reverse, lubricate the
to drain completely.
reverse idler shaft at every oil change or as required for
5. Remove oil filter with a 2 1/2 inch (63.5 mm) filter proper reverse actuator lever movement.
wrench.
1. Remove access bolt (A).
6. Clean drain plug sealing surface on crankcase.
Remove old seal washer from drain plug and install a
2. Spray Victory Multi-Purpose spray lubricant (2872863)
new one.
into center of shaft for 2-3 seconds while moving the
7. Install drain plug and tighten to proper torque. DO NOT Reverse actuator lever up and down through the travel
overtighten. range until it operates smoothly and freely.
8. Clean oil filter gasket sealing surface on crankcase.
3. Install screw and torque to 6.8 Nm (60 lb-in.)
9. Make sure new oil filter gasket is properly seated in the
new oil filter, and apply a thin film of clean engine oil
to the gasket. Screw new filter on until gasket contacts
the filter mounting plate. Tighten filter by hand an
additional 3/4 turn.
10. Add approximately 4.5 quarts (4.25 liters) of oil
through dipstick hole. Use only Victory brand Semi-
Synthetic 20W-40 Motor Oil or equivalent oil for use
with wet clutches such as JASO MA rating.
NOTICE
Do not add chemical additives to the engine oil. Some
automotive engine oils contain additives that could
damage or reduce the service life of the wet clutch in
the motorcycle.
2.7
MAINTENANCE
IDLE SPEED / FAST IDLE SPEED TIRE INSPECTION

NOTE: Idle speed is continuously monitored and
adjusted by the ECM via the IAC valve. DO NOT tamper WARNING
with or attempt to “adjust” the throttle plate flow screw (A)
or plate stop screw (B)! They are factory pre-set. If idle is Victory motorcycles are produced using the
erratic or if idle speed is incorrect, refer to troubleshooting designated tires listed below as original equipment.
in this section to find the cause of the problem. Tampering This includes field testing to ensure stability and
with these screws will not correct an idle speed or control superior handling. Use of tires other than original
problem. equipment may cause instability. A review of all tire
related warnings can be found in Chapter 14.
1. Inspect tires for weather checking, cuts, embedded

foreign objects, abnormal wear, and surface damage.
2. Inspect front and rear wheels for damage / runout.

Refer to Chapters 12 and 13 for procedure.
3. Measure tread depth at center of tread (C). Measure

in 3-4 places equally spaced around the tire and record
the smallest measurement.
A B
NOT ADJUSTABLE. DO NOT TAMPER!
TIRE PRESSURE
NOTE: Refer to the Tire Information label (located
inside the left saddlebag on the motorcycle on 2008
and 2009 models) or to the Manufacturing
Information label (located under the rear console
cover in front of the seat) for more information. Tire WARNING
pressure should be checked when the tires are cool.
It is dangerous to ride with a worn tire. When a
tire reaches the minimum tread depth listed
Up to 200 201 (91 kg+)
below, replace the tire immediately.
Tire Load  pounds (91 kg) - Max Load
Load Capacity MINIMUM TIRE TREAD DEPTH
FRONT: FRONT TIRE MINIMUM REAR TIRE MINIMUM

36 psi 38 psi TREAD DEPTH TREAD DEPTH
Dunlop Elite 3
(248 kPa) (262 kPa)
130/70R18 63H 1.6mm (.063") 1.6mm (.063")
(1/16 inch) (1/16 inch)
REAR:
38 psi 40 psi
Dunlop Elite 3
(262 kPa) (276 kPa)
180/60R16 M/C 80H
2.8
MAINTENANCE
THROTTLE CABLE INSPECTION / THROTTLE CABLE FREE PLAY

LUBRICATION Throttle cable freeplay, the amount of control grip
NOTE: Control cable casings are lined with a low friction
movement from the rest position to the point of cable 2
resistance, should be .080-.160 (2-4 mm).
sleeve and are factory lubricated for reliable operation.
Periodic lubrication of cables is not required and could be
detrimental to cable performance. Only cable ends must
be periodically inspected and lubricated in accordance
with the Periodic Maintenance Schedule (page 2.5).
NOTICE
Do not kink, bend or twist inner cable or cable
casing during removal or installation.
.080-.160 (2-4mm)
Throttle Cable Freeplay Adjustment Procedure:

1. Remove triangular IAC cover from right side of Throttle Opening Cable Adjustment
motorcycle by pulling straight outward at each corner
to release the three tabs. 1. With engine OFF and handlebars pointed straight
ahead, loosen cable lock nuts by turning them
2. Inspect cables for proper routing, smooth movement, counter-clockwise (viewed from throttle grip) until they
and for damage to the external casing. Inspect the stop against the throttle housing.
exposed inner cable for fraying, kinks, or corrosion. 2. Turn both cable adjusters toward lock nuts until they
Replace any damaged cables or cables that are sticky lightly contact the lock nuts.
or sluggish to return. 3. Turn throttle opening cable adjuster (front cable) out
3. Spray each barrel end (A) with Victory Multi Purpose until freeplay is within specified range.
Lubricant 2872863. 4. Hold adjuster in place and tighten lock securely (by
hand) against the adjuster.
A
DO NOT tamper
with these screws!
Freeplay Lock nut is tightened

4. After lubricating barrel ends, inspect cable free play. Reduce Increase against adjuster, not
the switch housing!
NOTE: The cruise control cable is not manually
adjustable and does not require periodic adjustment.
Adjuster Lock Nut
If the cruise control cable, cruise control module, or
Loosen
throttle body is replaced, perform the “Lash Learn”
procedure outlined in Chapter 19.
2.9
MAINTENANCE
Throttle Closing Cable Adjustment FRONT BRAKE LEVER

1. Hold throttle grip lightly in closed position. 1. Squeeze the brake lever and release it. The lever
should move smoothly without binding and return
2. Turn throttle closing cable (rear cable) adjuster out until freely to the rest position.
you feel slight resistance at the adjuster.
2. Remove nut (B), pivot screw (C), and lever with pivot
3. Hold adjuster in place and tighten lock nut securely (by bushing. Lubricate screw, bushing, and lever with
hand) against the adjuster. Victory All Purpose Grease.
4. Verify throttle grip moves smoothly and returns freely 3. Assemble lever with bushing and install screw. Torque
when released in all handlebar positions. screw first, then torque nut.
4. Check front brake lever movement before it develops

CRUISE CONTROL CABLE firm resistance. You should feel firm resistance in the
lever within the first 19mm (3/4 inch) of brake lever
1. Remove triangular IAC cover from right side of
travel, measured at ball end of lever (D).
motorcycle by pulling straight outward at each corner
to release the three tabs.
1.0 Nm (9 lb-in)
1. Inspect throttle body end of cruise control cable in B
area (A) for fraying and be sure end is secured in
bracket. Inspect outer cable casing for damage.
2. Inspect exposed inner cable for fraying, kinks, or

corrosion. Replace any damaged, frayed or corroded
cables. C
D
3. Spray each barrel end with Victory Multi Purpose 19mm (3/4) Max 6.0 Nm (52 lb-in)
Lubricant 2872863.
NOTE: The cruise control cable is not manually
adjustable and does not require periodic adjustment. 5. Check brake pads as outlined on page 2.15.
If the cruise control cable, cruise control module, or 6. If brake system was disassembled or purged of air
throttle body is replaced, perform the “Lash Learn” (bled) verify Brake Lever Reserve as outlined on
procedure outlined in Chapter 19. page 2.11.
2.10
MAINTENANCE
FRONT BRAKE LEVER REACH CLUTCH LEVER LUBRICATION

Lever “reach” or distance to the hand grip is adjustable. (HYDRAULIC)
To adjust the front brake lever reach:
1. Squeeze the clutch lever to the handlebar and release
2
• Pull the lever away from the grip (1) and hold.
it. The lever should move smoothly and quietly without
• To INCREASE lever reach distance, turn dial (2) to
binding and return smoothly to the released position.
align a lower number with the arrow (3).
• To DECREASE lever reach distance, turn dial to 2. Remove nut (A) and pivot screw (B).
align a higher number with the arrow.
3 A
3. Remove lever, clean and inspect parts (C) for wear.
FRONT BRAKE LEVER RESERVE 4. Apply Special Grease PN 2203685 (or Moly Assembly
1. Front brake lever reserve is the minimum pull force Paste PN 2871460) to parts and assemble to master
required before the brake lever makes contact with the cylinder. If pushrod (D) was removed, assemble with
hand grip. Test brake lever reserve whenever brake rounded edge inward, against master cylinder piston.
system bleeding or repairs have been performed. Use
PV-50104 and refer to page 15.44 for procedure.
PV-50104
C
D
WARNING
Do not operate vehicle if lever contacts hand grip at
less than specified pull force. Repeat the bleeding
process and repeat the test.
2.11
MAINTENANCE
5. Tighten pivot screw first, then install and tighten nut. CLUTCH LEVER LUBRICATION (CABLE)
1. Disconnect clutch cable from lever arm at primary
cover as described for Clutch Pull Rod Bushing
1.0 Nm (9 lb-in) Lubrication.
2. Clean lower cable bushing and cable. Inspect inner

cable wire for damage or frayed strands. Replace
cable if damaged.
3. At handlebar end, pull outer cable casing (B) out of

perch then pull clutch lever to handlebar. Carefully
rotate inner cable to align with lever slot. Do not kink
cable. Slide barrel end of cable down and out of lever.
6.0 Nm (52 lb-in)
6. Verify proper lever operation.

B
CLUTCH PULL ROD BUSHING LUBRICATION

(HYDRAULIC)
1. Pull clutch lever to handlebar.
2. Using a pliers or adjustable wrench with non-marring
jaws, rotate lever arm on primary cover inward until pull VIEW FROM BOTTOM
rod can be released from lever arm.
NOTE: Use care not to bend pull rod when releasing
4. Remove nut (C). Push pivot bolt upward to remove it,
it from the arm.
then remove lever pivot bushing (D).
C
6 Nm (52 lb-in)
5. Clean all parts. Inspect bushings and lever for wear.

3. Clean pull rod bushing and inspect for wear. Inspect inner cable wire for broken strands.
6. Lubricate lever, bushing, and barrel end of cable with

4. Lubricate bushing, pull rod, and lever arm with Moly
Moly Assembly Paste (2871460).
Assembly Paste PN 2871460.
7. Install barrel of cable in lever then install cable in perch.
5. Install bushing on pull rod and reassemble to lever arm
8. Assemble lever, bushing, pivot bolt and nut.
in the same manner as removal.
6. Check clutch lever operation. 9. Lubricate and attach lower end of cable to lifter arm on
primary cover, and adjust lever free play.
2.12
MAINTENANCE
CLUTCH LEVER FREE PLAY (CABLE) CLUTCH FLUID

1. With handlebars pointing straight ahead, measure the 1. Set the vehicle upright on a level surface and turn
clutch lever free play (A). handlebars until top of reservoir is level. 2
2. View fluid level through sight glass.
Minimum Level Maximum Level
.5 - 1.5 mm (.020 - .060”)
2. If adjustment is required, remove right side cover

(page 3.27).
Slave Cylinder
3. Hold cable nut (B) and loosen adjuster jam nut (C).
3. If level is low, check for signs of clutch fluid leaks
around hoses, fittings, reservoir, and slave cylinder.
B
4. To add fluid, remove the three reservoir cover screws,
cover, and diaphragm.
5. Add DOT 4 Brake Fluid from a sealed container to

proper level. Reinstall cover. Torque screws to 25 lb-
C in. (3 Nm). Wipe cap area clean to remove brake fluid.
6. Check all hoses for signs of deterioration or damage.

D
4. Turn cable adjuster (D) in or out until clutch freeplay is

correct.
5. Tighten adjuster jam nut securely to cable nut.
2.13
MAINTENANCE
FRONT BRAKE FLUID LEVEL REAR BRAKE FLUID

1. Set vehicle upright on a level surface and turn
handlebars until top of reservoir is level.
Minimum Level
MAX
MIN
1. Set vehicle upright and view the rear brake fluid

reservoir through the right leg fairing with the top of the
2. View the fluid level through the sight glass. reservoir level.
3. If level is low, check brake pads for wear (page 2.15). 2. The fluid level must be between the MIN and MAX level
If pads are not worn past the service limit, inspect the lines on the reservoir.
brake system for leaks. Check for signs of brake fluid
leaks around hoses, fittings, reservoir, and brake 3. If level is low, check brake pads for wear (page 2.15).
caliper pistons (behind brake pads). If pads are not worn past the service limit, inspect the
rear brake system for leaks. Check for signs of brake
4. To add fluid, remove the three reservoir cover screws, fluid leaks around hoses, fittings, reservoir, and brake
cover, and diaphragm. caliper pistons (behind brake pads).
5. Add DOT 4 Brake Fluid from a sealed container to the 4. To add fluid, remove reservoir cover with diaphragm by
proper level. turning it counter-clockwise (as viewed from top).
6. Clean and dry the sealing surfaces of the reservoir, 5. Add DOT 4 Brake Fluid from a sealed container to bring
reservoir cover, diaphragm, and diaphragm plate with the level between the MIN and MAX marks.
a clean lint-free cloth.
6. Clean and dry the sealing surfaces of the reservoir,
7. If the diaphragm is extended, return it to the retracted reservoir cover, diaphragm, and diaphragm plate with
(neutral) position (A). a clean lint-free cloth.
7. If the diaphragm is extended, return it to the retracted
A (neutral) position (B).
8. Reinstall diaphragm, plate, and cover.

9. Torque screws to 25 lb-in. (3 Nm).
10. Check for deterioration of hoses. 8. Check for deterioration of hoses.
2.14
MAINTENANCE
FRONT BRAKE PAD INSPECTION REAR BRAKE PAD INSPECTION

Wear indicator grooves are provided on each front brake Wear indicator grooves are provided on each rear brake
pad to allow for a visual inspection without pad removal. pad to allow for a visual inspection without pad removal. 2
Inspect pads by viewing from rear of caliper. Inspect pads from top of caliper behind swingarm.
Replace pads if worn to bottom of grooves or near the Replace pads if worn to bottom of grooves or near the
minimum thickness. minimum thickness.
Refer to Chapter 15 to remove pads for further inspection Refer to Chapter 15 to remove pads for further inspection
or to replace if worn. or to replace if worn.
Minimum Thickness: Minimum Thickness:

Front Pad: 1.0mm (.040 in.) Rear Pad: 1.0mm (.040 in.)
Grooves Grooves
2.15
MAINTENANCE
SHIFT PEDAL CRANKCASE VENTILATION SYSTEM

1. Check all shift pedal and linkage fasteners to be sure 1. Remove left side cover (Chapter 3).
they are tight. Torque values are shown on page 9.6.
2. Inspect condition of breather hose (A) and hose
clamps.
2. Lubricate the shift pedal pivot bushing with Victory All

Purpose Grease P/N 2872187 (page 9.6).
REAR BRAKE PEDAL EVAPORATIVE EMISSION CONTROL

SYSTEM (California Models)
1. Check the amount of rear brake pedal movement
before it develops firm resistance. It should not move NOTE: The fuel tank vent is routed to evaporative
more than 3/8 inch (8mm) before pedal is firm. canister (B). Inspect all hoses for abrasion or wear.
Check that all connections are securely attached.
Refer to Chapter 5 for hose connection diagram and
inspection procedure.
Max 3/8 in. (8 mm)
B B
2. Lubricate the rear brake pedal pivot bushing with
Victory All Purpose Grease P/N 2872187 (see
page 9.6).
3. Check brake pads for wear as outlined on page 2.15.
FUEL TANK VENT INSPECTION (49 State)

1. Refer to Chapter 5 for fuel tank vent inspection.
2.16
MAINTENANCE
FUEL FILTER 6. Remove IAC cover.

The fuel filter is attached to the electric fuel pump located
7. Inspect fuel supply hose (A), fuel rail (B), connectors,
inside the right fuel tank (see Chapter 5). No periodic fuel
filter maintenance is required, however, the fuel filter and fittings for signs of deterioration, damage, 2
should be replaced at the interval specified in the Periodic abrasion, cracks, leakage, or kinks.
Maintenance Table on page 2.5.
FUEL SYSTEM INSPECTION A

Inspect fuel system hoses regularly in accordance with
the Periodic Maintenance Table on page 2.5.
Inspect hoses, clamps, connectors, and fittings for signs
of deterioration, damage, abrasion, cracks, leakage, or
kinked areas. B
1. Replace components that fail inspection (described
above) with genuine Victory replacement parts only.
2. Pull straight forward at the bottom of the lower fuel tank
communication hose cover (C) to release clips from
lower hose. Slide cover to left to release dart (D).
WARNING
A D The fuel supply hose and fuel rail are subjected to high
pressure. Replace with genuine Victory replacement
parts to reduce the possibility of fuel line failure. Be sure
fuel lines are routed properly and do not come in contact
with sharp or hot objects, or anything that may cause
C wear or damage.
3. Inspect communication hose (E) for deterioration or

damage.
4. To install the cover, press lower edge until clips are
secured to hose.
5. Align hole at top of cover with hole in frame and secure
it in place with the dart.
2.17
MAINTENANCE
SPARK PLUG REMOVAL & INSPECTION
WARNING
HOT COMPONENTS Wear insulated gloves and/or
allow engine and exhaust to cool before handling
these parts.
1. With the engine at room temperature, grasp the spark

plug boot (A) at the base to disconnect. DO NOT pull
on the wire or spark plug wire may be damaged.
2. Clean the area around spark plug base with

compressed air to remove loose debris.
3. Remove spark plugs.
4. Inspect spark plugs for:
• Insulator damage
• Worn electrodes
• Deposits
SPARK PLUG INSTALLATION

Inspect spark plug gap with a wire gauge. If gap
adjustment is necessary, bend ground electrode carefully
using a spark plug gap tool.
.8 - .9 mm
(.032 - 036”)
TORQUE: 14.5-19.5 Nm (10.8-14.5 lb-ft)
5. Apply anti-seize compound sparingly to spark plug

threads, avoiding the bottom 2 or 3 threads.
6. Torque spark plugs to specification.
7. Apply a light film of dielectric grease to each spark plug
boot and install securely on spark plugs.
2.18
MAINTENANCE
BATTERY BATTERY CHARGING

This motorcycle is equipped with a maintenance free Refer to “BATTERY CHARGING - GENERAL” on page
battery which is located in front of the engine. DO NOT 16.5. 2
remove cell caps or add distilled water to the battery.
Refer to Chapter 16 for battery and charging system
diagnostic procedures. BATTERY STORAGE
When the motorcycle is not used for periods of one month
WARNING or longer, charge the battery using the charging plug
harness or remove battery from motorcycle and charge it.
Battery electrolyte is poisonous. It contains sulfuric Store battery in a cool, dry place. (See Chapter 16).
acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:
WARNING
External: Flush with water.
Battery charging can create explosive gasses;
keep sparks, flames, cigarettes or anything that
Internal: Drink large quantities of water or milk.
could ignite the gasses away. Provide adequate
Follow with milk of magnesia, beaten egg, or
ventilation when charging in an enclosed space.
vegetable oil. Call physician immediately.
Batteries contain acid that is caustic. Wear
protective clothing and a face shield or protective
Eyes: Flush with water for 15 minutes and get
eyewear when working with the battery. KEEP OUT
prompt medical attention.
OF REACH OF CHILDREN.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always BATTERY INSPECTION
shield eyes when working near batteries. KEEP
CHILDREN AWAY FROM BATTERY. Battery terminals and connections should be kept free of
corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash with a solution of one
NOTICE tablespoon baking soda to one cup water. Rinse well with
tap water and dry off with clean rags. Coat terminals with
Whenever removing the battery, disconnect the
dielectric grease.
negative (black) cable first. When reinstalling the
battery, connect the negative (black) cable last.
1. Visually inspect the exterior of the battery. Replace
battery if case damage is evident or if the case is
Do not remove the battery cables while the engine
swollen, deformed or leaking electrolyte.
is running. Doing so may damage the Electronic
Control Unit (ECM).
2. To remove corrosion, remove battery from motorcycle
and wash terminals with water and baking soda
Take great care not to reverse the battery leads
solution. Clean terminals, bolts, and cable ends with a
when installing the battery. Reverse power applied
brass wire brush. Apply a thin film of dielectric grease
to the ECM will damage it instantly.
to the terminal bolt threads.
3. Measure battery voltage.
Specification: 12.5Vdc minimum
4. If battery voltage is below 12.5 VDC, charge it

thoroughly (refer to page 16.5). Replace battery if it will
not accept a charge.
2.19
MAINTENANCE
BATTERY REMOVAL BATTERY INSTALLATION

2.0 Nm
(18 lb-in)
A
9.6 Nm
(85 lb-in)
5.4 Nm
2 (48 lb-in)
1
1 1
B
85 lb-in. 36 lb-in. 85 lb-in.
(10 Nm) (4 Nm) (10 Nm) 4.5 Nm
(40 lb-in)
C
NOTICE FRONT
Do not disconnect the positive cable before the 9.6 Nm (85 lb-in)
negative cable. Disconnecting the positive cable
first increase the risk of sparks and an electric
shock that could result in damage or injury.
NOTICE
1. Turn handlebars fully right.
Do not connect the negative cable before the
2. Remove five belly pan screws (1) with a 6mm Allen positive is connected. Connecting the negative
wrench. cable first increases the risk of sparks and an
3. Remove screw (2) that joins the two side grills. electric shock that could result in damage or injury.
NOTE: Grill bolt is placed in FRONT hole; center
NOTICE
belly pan screw in rear hole.
4. Remove the negative (-) battery cable from battery On CB Radio equipped vehicles, be sure the CB
terminal (3) with a 10mm wrench. antenna is installed and connected to the radio
before connecting the battery.
Viewed from right front side
1. Inspect battery tray and outer bracket for damage. Be
sure fasteners are tight, and foam pads are in good
condition and properly located.
3
4
2. Install battery into box with terminals facing forward.
Tip front battery box with battery toward battery box
and install bolt (A). Be sure tabs (B) engage slots (C).
3. Apply dielectric grease to terminal bolt threads.

5 4. Install positive battery cable first. Torque bolt to
specification.
5. Lift the red protective boot (4) off of the positive (+) 5. Install red protective boot over + (positive) terminal.
cable end to expose positive terminal. Remove the
positive cable from the battery terminal (10 mm 6. Install negative cable. Torque bolt to specification.
wrench).
7. Connect grill halves and install scoop (see illustration
6. Remove front battery box bolt (5) with a 10mm socket. above left).
7. Tip front box forward and lift battery up to clear case
and then out right side.
2.20
MAINTENANCE
ENGINE COMPRESSION TEST CYLINDER LEAKAGE TEST

If compression is low, perform a cylinder leakage test to
1. Warm engine to operating temperature. determine where leakage is occurring. Follow instructions
provided with test equipment.
2
2. Shift transmission into neutral and stop engine.
3. Disconnect spark plug caps and remove one spark Cylinder Leakdown Tester: PV-35667-A
plug.
4. Connect a spark plug to each cap and connect center
ENGINE COMPRESSION TEST (WET)
electrode of plug to engine ground.
If a leakage tester is not available, perform a wet cylinder
1. Install compression tester in spark plug hole (leave the
compression test.
spark plug in the other cylinder).
1. Pour 3-5 cc of clean engine oil into one spark plug
hole. Repeat cylinder compression test. Repeat for
the other cylinder.
2. If compression increases substantially, inspect
cylinder, piston, and rings. If compression does not
increase, inspect valves and valve seats.
SPROCKET INSPECTION
1. Inspect front and rear sprocket teeth (Chapter 11) for
wear or damage from foreign material. Closely inspect
2. Open throttle and crank engine until needle on drive belt condition at the same time.
compression gauge stops rising (about 5 seconds).
3. Repeat procedure for other cylinder. Cylinder
compression should be within 10% of each other. DRIVE BELT CLEANING
Engine Compression: Drive belt and sprocket service life is maximized and
drive line noise minimized by proper cleaning. Cleaning
STD: 210-225 psi interval is approximately every tire change, or more often
(1448-1551 kPa) if operated in dirty, dusty, or high debris environments.
SERVICE LIMIT: 1. Mix a few drops of mild dish soap with a cup of warm
Below 180 PSI water a use a soft nylon brush to clean the belt and
sprocket teeth.
High engine compression may indicate: 2. Pay close attention to corner areas (A) where road
• Carbon deposits on piston crown / cylinder head debris and belt dust can collect.
• Engine modification
• Addition of performance parts
• Faulty gauge
Low engine compression may indicate: A
• Debris / carbon on valve face or valve seat.
• Worn piston and/or piston rings
• Piston ring stuck in the piston ring groove
• Leaking valves or head gasket
3. Rinse thoroughly with clear water. Dry thoroughly.
• Slow starter motor cranking speed
NOTE: Do not inspect or adjust drive belt tension
• Valve timing incorrect when the belt is wet. Improper adjustment will result.
• Faulty gauge
2.21
MAINTENANCE
DRIVE BELT WEAR ANALYSIS
Internal Tooth Cracks (Hairline) External Tooth Cracks Missing Teeth Chipping (Not Serious)
OK to run, but monitor condition. Replace Belt Replace Belt OK to run, but monitor condition.
Fuzzy Edge Cord Hook Wear Stone Damage Bevel Wear (Outer Edge Only)
OK to run, but monitor condition. Replace Belt Replace belt if damage is on edge OK to run, but monitor condition.
DRIVE BELT CONDITION DRIVE BELT TENSION GAUGE

Replace the drive belt if it is cracked or has broken teeth Proper use of the belt tension gauge PV-43532 is
or frayed edges. No matter its condition, the drive belt important for accuracy. During the measurement
should be replaced in accordance with the Periodic procedure, be sure the gauge is seated squarely against
Maintenance Interval Table on page 2.5. the belt and in alignment with the belt centerline.
90
Drive Belt Side View
PV-43532
Belt Cross
Section
DO NOT attempt to check belt tension if the belt has been


exposed to rain or washing within a 24 hour period or if
the belt is hot from riding. Allow the belt to cool down to
Tool
ambient temperature before measuring belt tension.
Body 90
Replace drive belt and both sprockets as a set if drive belt O-Ring Set to 10 lb mark
has over 5,000 miles (8,000 km) of service at the time of
damage or failure. Gauge
Push plunger until

End View O-ring contacts body
2.22
MAINTENANCE
DRIVE BELT TENSION - INSPECTION 7. Slide O-ring on belt tension gauge to the 10 lb. mark.
8. Place tape measure or ruler next to drive belt at mid-
WARNING span (Fig. 2) and align a major graduation mark on the 2
ruler with the lower edge of the belt surface. (Fig. 3) Do
Care should be taken to be sure the motorcycle will not move the ruler from this position.
not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls.
1. Secure motorcycle in an upright position.
2. Shift transmission into NEUTRAL.
3. ELEVATE rear wheel off the ground when checking

deflection or adjusting the belt.
4. Do not attempt to check belt tension if the belt has been

exposed to rain or washing within a 24 hour period or Fig. 2
if the drive system is hot from riding. Allow the system
to cool to room temperature (60-80 F / 15-27 C) before
measuring belt tension. Replace drive belt and both
sprockets as a set if the drive system has over 5,000
miles (8,000 km) of service at the time of damage or
failure.
5. See page 2.22 for instructions for proper use of belt
tension gauge PV-43532.
Finding The Tight Spot In The Drive System
6. Use the tire valve stem as a reference. Rotate wheel
in a CLOCKWISE rotation as viewed from belt side of
Fig. 3
motorcycle until valve stem is at the bottom. (Fig. 1)
9. Place belt tension gauge squarely against belt at until
90 push up on center plunger until O-ring just touches tool
body. Record the total amount of deflection as
measured on the ruler.
10. Rotate wheel 90 degrees (valve stem is at rearmost
position). Measure and record the deflection.
11. Repeat measurements with the valve stem at the top
90 90 and forward positions and record the deflection.
12. Compare all measurements and use the point of least
deflection (tightest spot) as your reference point to
determine if belt requires adjustment.
13. Rotate the wheel in normal drive direction
(CLOCKWISE) 1-2 revolutions back to your reference
(tightest) point.
Start Forward 14. If belt deflection is greater than specified, tighten the
belt. If deflection is less than specified, loosen the belt.
Rotate clockwise only during this procedure Refer to specification table on page 2.24.
Fig. 1
2.23
MAINTENANCE
SPECIFICATIONS: DRIVE BELT DRIVE BELT ADJUSTMENT / ALIGNMENT
BELT DEFLECTION Rear Wheel Alignment / Belt Adjustment
Model Deflection @ 10 lbs. force

WARNING
All 2008-2010
(Except 2010 8-Ball 32.0 mm ± .5mm A mis-aligned rear axle can cause drive line noise
& 2010 Ness (1 1/4 ± 1/32") and damage the drive belt, causing possible belt
Signature Series) failure and loss of control of the motorcycle.
2010 8-Ball & 2010 1. Marks (A) and (B) are used as a reference for initial
15.0 mm ± .5mm
Ness Signature wheel alignment. Marks should be in same position on
(19/32 ± 1/32")
Series both left and right sides of wheel.
2. Loosen axle nut (C).
SONIC TENSION DATA

A
The following data is provided for use with the Gates 507C
Sonic Tension Meter or an equivalent. Follow Steps 1-4 B
and the instructions included with your sonic tension
meter.
Required Data For

Sonic Tension Specification C
Meter
Span 708.65mm
Belt Width 28mm

Marks are for initial alignment only. Refer to
Belt Mass Constant 8.4 procedure for final alignment.
Tension
(All 2008-2010 Models 20 Hz (± 1 Hz)
Except Vision 8-Ball)
3. Safely elevate motorcycle with tire off floor.
Tension
26 Hz (± 1 Hz)
2010 Vision 8-Ball
2.24
MAINTENANCE
4. Turn adjuster nuts (D) to achieve: 6. Rotate the wheel BACKWARD. Tighten LEFT rear axle
adjuster until belt begins to track to right sprocket
• Recommended belt tension flange (outboard) during backward wheel rotation.
2
• Wheel alignment (marks equal both sides)
Rear Wheel Alignment - Final

5. When belt tension is correct, check and adjust final 7. Rotate the wheel in FORWARD direction. Loosen
wheel alignment as follows: LEFT rear axle adjuster until belt moves off the right
flange and begins to track to left sprocket flange
NOTE: To minimize change in belt tension, use LEFT (inboard) during forward wheel rotation.
SIDE adjuster only (E) to make final adjustments to
belt alignment. Be sure to keep axle seated forward
against axle adjusters during this procedure.
8. Tighten rear axle nut to 88 Nm (65 lb-ft).

9. Torque both axle adjuster nuts to 11 N-m (8 lb-ft).
10. Pump rear brake pedal several times to reset brake

pad distance.
11. Verify wheel rotates smoothly and freely without drag
when brake pedal is released.
2.25
MAINTENANCE
HEADLAMP AIM INSPECTION HEADLAMP AIM ADJUSTMENT

The headlamp high beam should shine straight ahead. The headlamp adjustment knob can be accessed through
The low beam will spread more to the right (U.S. / the opening in the headlamp housing mount under the
Canada). The top of the HIGH beam should be slightly windshield access panel.
below the height of the center of the headlamp bulbs, at a
distance of 25 ft. (7.6 meters). Headlamp Adjuster Access
To check for proper headlamp aim:
• Set tire pressure (page 2.8) and rear

suspension air pressure for load (page 2.30).
• Straddle motorcycle in an upright position

and sit in the operator’s seat.
• Turn ignition switch ON. Raise Lower

(Rear View)
• Select HIGH BEAM.
NOTE: On 2009-2010 models, tap the starter button Knob

to turn the headlamp on or start the engine (it will
remain on until key is switched OFF).
• Remove windshield access panel (page 3.6).
• Compare to illustration and adjust if necessary.
• Reach through opening in headlamp
housing mount.
Wall
• To LOWER headlamp beam, turn knob

CLOCKWISE (as viewed from operator’s seat).
25 feet (7.6m)
• To RAISE headlamp beam, turn knob COUNTER-
CLOCKWISE (as viewed from operator’s seat).
Height of center of
headlamp bulbs
(not driving lamp)
Floor
2.26
MAINTENANCE
SIDESTAND INSPECTION SIDESTAND & SPRING REMOVAL

1. Support the motorcycle in an upright position.
WARNING 2
2. Inspect sidestand spring for damage or loss of tension.
Be sure stand returns to fully retracted position. The sidestand spring is under tension. Wear eye
3. Inspect sidestand for smooth movement. and face protection when removing and installing
the spring and sidestand. Be sure the vehicle is
properly secured before you begin.
35 lb. ft. (47.5 Nm)
A 1. Sidestand will be moved between the UP (retracted)
and DOWN (extended) position during removal and
installation. Be sure vehicle is properly secured.
35 lb. ft.
(47.5 Nm)
UP to remove/install spring
4. Inspect sidestand pivot bolt nut for proper torque.
DOWN to remove/install bolt
5. Replace sidestand if it is bent. Do not attempt to
straighten sidestand.
2. Remove sidestand pivot nut using a 15mm socket
6. Inspect sidestand pad for wear.
while holding bolt with a 6mm hex wrench.
SIDESTAND PAD INSPECTION 3. Place sidestand in the DOWN position, then remove
the bolt.
Sidestand Pad Inspection
4. Grasp sidestand firmly and move it to the UP position.
1. Inspect the sidestand rubber pad (A) for wear. Be sure 5. Pull sidestand straight rearward against spring tension
pad is secured in place and not damaged or torn. until mounting flange on sidestand is clear of the
Replace pad if worn to or beyond the wear mark (B). recessed mounting boss on the frame cradle.
See page 2.28 for replacement procedure.
6. Remove spring.
7. Installation: Attach spring to sidestand.
B 8. Lightly grease sidestand mounting boss on frame rail
and the shouldered portion of the pivot bolt.
9. Place loose end of spring through hole in frame rail.
10. With sidestand in the retracted position (up), pull stand
A straight rearward against spring tension until the
mounting flange on the sidestand drops into the
recessed mounting boss on the frame cradle.
11. Swing sidestand to the extended position to align bolt
hole and install bolt and nut.
Leading Edge Trailing Edge 12. Torque nut to 35 ft.lbs. (47.5 Nm) and wipe off any
excess grease.Cycle the sidestand to be sure it moves
freely, and returns to the fully retracted position.
Front of Motorcycle 13. Cycle the sidestand to be sure it moves freely, and
returns to the fully retracted position.
2.27
MAINTENANCE
SIDESTAND PAD REPLACEMENT Sidestand Pad Installation

1. Install new sidestand pad with open end on trailing
Sidestand Pad Removal
edge of stand.
1. Remove side stand from frame.
2. Place sidestand in a soft-jawed vise. 2. Install new rivets from top to bottom.
3. Remove rubber pad with a pliers to expose the rivets. 3. Invert sidestand and place washers over rivets.
4. Using an angle grinder, cut off the head of both rivets 4. Hold washers and rivets in place and set sidestand on
on the top side of the sidestand foot (A). Be careful to a hard surface (such as the anvil of a vise) with hollow
avoid grinding wheel contact with the finished area of end of rivets facing upward. Push washers as far down
the stand. as possible. Be sure washers are at least 1/16 - 1/8
inch (1.5-3mm) below hollow end of rivets.
5. Drive rivets out of sidestand foot from top to bottom
with a suitable drift punch (B). 5. Peen hollow end of rivets with a commercially available
rivet tool. Be sure rivets, washers and pad are secure.
B Flare Washer
End View of rivet tool
Rivet
NOTE: An alternative method is to use a center punch to

start a flare on hollow end of rivet, then use a 1/4 inch drift
(flat) punch to complete the peening operation.
6. Apply touch up paint or primer to exposed bare metal.
2.28
MAINTENANCE
REAR SUSPENSION / SWINGARM 7. Remove the seat (page 3.5).

INSPECTION 8. Inspect fasteners, bushings, and bearings on all
suspension components, including shock absorber top
2
WARNING mount (D), strut (E), and rocker arm (F).
Care should be taken to be sure the motorcycle will

1. Sit astride the motorcycle. Compress the rear

F
suspension several times and check for smooth and
quiet operation (A).
D
A
E
2. Verify rear axle nut and swingarm nuts are tightened

to 88 Nm (65 lb-ft).
88 Nm 65 lb-ft)
3. Secure motorcycle with rear wheel elevated.
4. Grasp the rear wheel and push firmly side-to-side (B).
If movement is detected, determine if movement is at Fig. 4
axle area (C) or swingarm pivot area (front of swingarm
shown in Fig. 4 above right). Refer to Chapter 13 for
wheel bearing and swingarm bearing replacement.
C
G
B
5. Rotate rear wheel and inspect for smooth rotation of 9. Check lower shock and strut fasteners, and bushings
rear wheel bearings. If roughness or unusual sounds for wear (G).
are detected, inspect rear wheel bearings (Chapter 10. If radial movement or excessive play is detected at any
13), belt tension and alignment (page 2.23 - 2.24), and of the pivots, or if bushings are cracked, worn,
brake pads (page 2.15). displaced or damaged, remove rear shock absorber
6. Inspect rear shock for signs of oil leakage and all rear assembly and replace parts as required. (Chapter 13).
suspension components for damage or loose
fasteners.
2.29
MAINTENANCE
REAR SUSPENSION ADJUSTMENT NOTE: The shock has a small air volume. Each time
pressure is checked with the gauge provided in the tool
MAX OPERATING PRESSURE:
72 PSI (496 kPA) kit (or similar style tire pressure gauge) approximately 4
PSI (27.5 kPa) is lost to fill the volume of the gauge. Once
you’ve set the pressure with the gauge, remove it quickly
to minimize leakage, and expect to see a reduction from
the previous reading of about 4 PSI if you re-check the
pressure with the tool kit gauge.
2008-2010 All
1. Open left saddlebag door.
Vision except 2010
8-Ball and NSS 2. Remove cap from air fitting (1) in left bag.
3. Read recommended air pressure from decal for total
cargo and occupant weight. Use the appropriate
column (with trunk or no trunk).
4. Screw hose fitting securely onto air fitting and read air
pressure on gauge.
5. To REDUCE air pressure, push the bleed button (2)
2010 Vision 8-Ball located on side of gauge. Bleed pressure in small
2010 Ness Signature amounts until desired pressure is indicated on gauge.
Series Vision Remove the tool hose from air fitting and install the cap.
3
2876654
To provide the most comfortable ride and proper ground 2

clearance, adjust air pressure in the rear shock absorber
as specified on the decal (located in left saddlebag area)
for total cargo and occupant weight.
Follow these guidelines to check and adjust air pressure:
6. To INCREASE pressure, install the gauge select the
• Rest motorcycle firmly on sidestand on level desired pressure from the chart as described in steps
ground. 1-4 above. Pump the handle (3) until pressure
• Remove all cargo from the saddlebags and trunk. increases to the desired amount, then remove the hose
• Victory Air Pump & Gauge 2876654 or PV-48909 and install the cap.
is the preferred tool for checking and adjusting rear
suspension air pressure. If not available, use a DO NOT exceed 110 PSI (758 kPa) when filling the
pressurized dry air source with a maximum line shock.
pressure of 110 PSI and the pressure gauge
provided in the tool kit (or a similar 0-100 PSI tire DO NOT operate the motorcycle with air pressure
pressure gauge). above 72 PSI (496 kPa) (pressure measured with
• Use ONLY A DRY AIR SOURCE, such as a system motorcycle on the side stand).
with a water separator or airline dryer to prevent
moisture from entering the shock. The shock has
a small volume. Air pressure increases VERY
quickly when using pressurized air.
2.30
MAINTENANCE
FRONT SUSPENSION INSPECTION STEERING HEAD / FRONT WHEEL

INSPECTION
WARNING 2
WARNING
Damaged, worn, or loose suspension components
may cause loss of control, increasing the chance of Care should be taken to be sure the motorcycle will
a crash or possible injury. Damaged, worn, or loose not tip or fall while elevated. Severe personal injury
suspension components must be repaired before or death may occur if the motorcycle tips or falls.
the motorcycle is operated. See Chapter 12.
NOTE: Be sure control cables, hoses and wiring are not
1. Place motorcycle on sidestand and inspect front forks.
interfering with handle bar rotation.
Make sure no fork oil present on the outer fork tubes,
fork seals, or around the inner tubes (A). 1. Secure motorcycle with front wheel elevated.
2. Turn handlebars from full left to full right and inspect
A for smooth, free movement.
2. Clean fork tubes with mild soap and water as required 3. Point front wheel straight ahead, grasp fork tubes and
to remove bugs, tar, or buildup which may cause seal pull/push fork tubes back and forth (C).
wear or leakage.
3. Inspect outer surfaces of inner fork tubes for scoring, 4. If steering binds, feels rough or uneven, or if movement
scratches, and damage from foreign objects. is detected at steering stem, adjust or replace steering
head bearings as necessary. Refer to Chapter 12.
4. With motorcycle upright, apply front brake and pump
forks through travel range several times (B). Fork 5. Rotate front wheel and inspect for smooth rotation of
operation should be smooth and quiet. front wheel bearings. If roughness or unusual sounds
are present, replace front wheel bearings (Chapter 12).
6. Turn handle bars full right or left and hold against the
fork stop. Attempt to move front wheel side-to-side (D).
If movement is observed, inspect front axle, wheel, and
bearings (Chapter 12).
5. Verify all fasteners are tight. Refer to Chapter 12 for

front wheel and suspension torque specifications, and
Chapter 15 for brake system component torque
specifications.
D
6. Replace worn or damaged parts.
2.31
MAINTENANCE
FUSE REPLACEMENT FASTENERS

To access the relays and fuses: Inspect all fasteners on the vehicle to be sure they are
tight. Refer to the appropriate chapter as required for
RH Fuse Box LH Fuse Box torque specifications.
LOCK AND IGNITION SWITCH LUBRICATION

1. Insert spray nozzle of Victory Multi-Purpose Lubricant
into the ignition switch and each lock cylinder and
spray for 1-2 seconds.
Push Center UP 2. Insert key and turn it to all positions to distribute the
lubricant.
3. Wipe any excess lubricant from lock or switch.
• Remove the windshield access panel

(page 3.6).
• Push center of darts upward and remove the

fuse box cover panel(s).
• Pull the tabs to release the cover(s).
• The fuse application and size is printed on

the cover label.
NOTICE
Use only the recommended fuse to prevent
electrical system damage.
2.32
MAINTENANCE
CLEANING WASHING, WAXING, POLISHING, APPLYING

PROTECTANTS
NOTE: Refer to page 2.4 for Pure Victory Cleaning
Product part numbers, and the Owner’s Manual for more (NOTE: For Windshield care and special information 2
information. Pure Victory cleaning and polishing products regarding care of Suede finish, see page 2.34.
and accessories have been specifically designed to offer
the best care possible for a Victory motorcycle. In addition
to the products recommended here, Pure Victory WARNING
products are also available for removing scratches,
Do not use a protectant on the seats, handgrips, or
scuffs, and swirls in paint or clear coat, cleaning or
footpegs that leaves a slippery coating after it dries.
enhancing black or silver engines, cleaning tires and
If these surfaces are slippery, you may have
wheels, and removing brake dust.
difficulty holding your position on the motorcycle
Before washing the motorcycle, do the following: while riding, which may cause you to lose control of
• Be sure exhaust has cooled completely. Cover the motorcycle. Follow manufacturer's instructions
each pipe opening with a plastic bag secured with a and safety precautions on wax, polish, and
strong rubber band to prevent water from entering protectant labels to prevent injury or damage.
exhaust system.
There are two styles of motorcycle washing and there is a
• Check that the spark plugs, spark plug wire caps,
Pure Victory Polish product for each style.
oil dipstick, fuel cap, and other filler caps are
properly seated. Bucket Wash
• Avoid spraying the air box / air filter area or This is the conventional way of washing a motorcycle. Use
electrical connectors and wiring. Pure Victory Bike Wash Concentrate, a concentrated
gentle product formulated to clean without diminishing the
• Removing excess dirt with water running at low
life of any durable polish. This product does not contain
pressure. Use as little water as possible when
alkalis, acids or abrasives and is formulated to perform as
washing near the air intake or exhaust pipe
a wetting agent to soften bugs, road grime and soil, and to
openings. Dry thoroughly before starting the engine
prevent abrasion from a wash mitt or cloth. This product
or operating the motorcycle.
also decreases drying time without streaking or spotting.
• Make sure brakes are functioning properly before Follow complete directions on the label.
operating the motorcycle.
Spray- Rinse-and-Ride Wash
• Do not use abrasive cleaners. Paint wear or other
cosmetic damage can occur if abrasives are used. This is the new way to clean a Victory motorcycle quickly
and easily, then resume riding. Pure Victory Spray Rinse
NOTICE and Ride bike wash is safe and will not harm any surface
that water won’t harm. This product can be mixed 50/50
Electrical components may be damaged by water. Do not with water for frequent washing. Spray the product on
allow water to contact electrical components or surface after they are cool to the touch. DO NOT spray on
connectors. a hot motorcycle. When applied, this product softens dirt,
soil, bugs, and road grime. Follow complete directions on
NOTICE the label.
Quick Clean-Ups
Do not use pressurized water to wash the motorcycle.
Water may seep in and deteriorate wheel bearings and For quick clean-ups or when water is not available, use
seals, brake caliper assemblies, brake master cylinders, Pure Victory Spray & Wipe Instant Detailer, it’s a complete
electrical connectors, steering head bearings, and spray and wipe product designed to clean and polish all
transmission seals if excessive pressure is used. surfaces, works quickly and easily, and is silicone-free so
it leaves no oily or white residue. It provides protection from
UV rays, acid rain, and dirt, will remove bugs, road tar, and
NOTICE road grime from windshields, painted parts, and chrome. It
is safe for all surfaces, including pin striping, custom paint,
Do not use glass cleaners, water or soil repellents, and
murals, Plexiglas, Lexan, Acrylic or factory-coated
petroleum or alcohol based cleaners on the windshield (if
windscreens. It’s non-streaking, and it provides polish
equipped), as these products can damage the
protection and a water repellent shine. Follow complete
windshield.
directions on the label.
2.33
MAINTENANCE
WINDSHIELD CARE of the combustion process, and corrosion may result

unless the engine is operated long enough to bring the oil
Rinse windshield with water to remove loose dirt and dust. and exhaust system to normal operating temperature.
Wash the windshield using one of the Pure Victory wash
products described on page 2.33 (follow directions on the
container for the product you choose) then rinse (if
recommended in the directions) and wipe with a Pure
Victory Microfiber Chamois or Plush Microfiber Towel to dry
virtually spot free.
NOTICE
Do not use glass water and soil repellents,
petroleum or alcohol based cleaners as these
products can damage the windshield.
Blocks
NOTICE
Set floor jack under the center of the engine. Raise
Windshield material is polycarbonate plastic. Do not vehicle off the floor and set 2 blocks underneath the
use cleaners or rain protective products meant for bike as shown. Set bike down on blocks.
glass surfaces on the windshield.
SUEDE FINISH CARE

STORAGE Suede paint is different from Victory’s usual high gloss
NOTE: Refer to page 2.4 for cleaning products. finish. Like suede fabric, suede paint changes as you
interact with the finish. It will change with time, exposure
To prevent storage damage due to long-term storage (60 to elements, and use. Although the quality of the paint is
days or more) the following guidelines should be fol- not affected by these changes, special care is required
lowed. when cleaning a suede finish.
1. Top off fuel tank with fresh fuel and add fuel stabilizer Suede paint cannot be buffed out if it becomes scratched
to fuel. or scuffed. If polished, the finish will become less flat or
2. Run motorcycle for 15 minutes or more to distribute matte. This finish cannot be repaired if it receives heavy
fuel stabilizer throughout fuel system. damage like a scratch or a chip.
3. Clean motorcycle completely. Suede Finish Cleaning Instructions
4. Dry machine thoroughly and wax all painted surfaces. 1. Spray Pure Victory Polish Suede Finish Cleaner
5. Change engine oil as outlined in Chapter 2. (#90949) directly on all suede bodywork.
6. Block frame to take some of the weight off of front and 2. Using a Pure Victory Polish 100% Microfiber Polishing
rear wheels. Towel (#90962), wipe cleaner into the surface, then
wipe dry using a clean, dry surface of the towel.
7. Secure a plastic bag over the exhaust outlets to
prevent moisture from entering the exhaust system. 3. After suede bodywork is clean and dry, apply Pure
Victory Polish Suede Finish Protectant to maintain and
IMPORTANT: Make certain exhaust system is cool prior to
securing plastic. protect the beauty of your Victory Motorcycle.
8. Remove battery and charge it. Suede Finish Protectant Instructions
9. Store battery in a cool, dry area and charge it once a 1. Spray Pure Victory Polish Suede Finish Protectant
month. (#90950) onto clean suede bodywork and use
10. Cover motorcycle with a genuine Victory cover, or a Polishing Towel (#90962) or Microfiber Applicator
covering made of fabric that allows for adequate (#90965) to rub protectant thoroughly into the surface.
ventilation. Do not use plastic or tarps, as corrosion 2. Using a clean, dry microfiber towel, wipe surface to
may result. achieve that showroom-new Suede Finish.
IMPORTANT: Be sure to apply Pure Victory Polish
IMPORTANT: Starting the motorcycle periodically during
Suede Finish Protectant after every cleaning.
storage is not recommended. Water vapor is a by-product
2.34
FRAME-BODY-EXHAUST
CHAPTER 3
FRAME-BODY-EXHAUST
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
BODY FASTENER TYPES / SPECIAL TOOLS / HOW TO USE THIS CHAPTER . . . . . 3.3
3
REMOVAL / INSTALLATION PROCEDURES - FRONT BODY . . . . . . . . . . . . . . . . . . . . 3.4
FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
CONSOLE COVER / AIR DEFLECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
IAC COVER / LEFT ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
WINDSHIELD ACCESS PANEL / WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6-3.7
INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
VISOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CONSOLE / SPEAKER GRILL / SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
FUEL TANK COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
BELLY PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
LEG FAIRING AND GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TURN SIGNAL LENS, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
FAIRINGS (FRONT OUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ASSEMBLY VIEWS - FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
WINDSHIELD / WINDSHIELD MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
BELLY PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CONSOLE / CONSOLE ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CONSOLE / RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
FRONT SUPPORT / SPEAKER / SPEAKER VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
VISOR / FRONT SPEAKER GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
FUEL TANK COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
LEG FAIRING / LEG FAIRING SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22-3.23
FRONT TURN SIGNAL HEADLAMP / FAIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
LOWER FRONT FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
BATTERY BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
REMOVAL / INSTALLATION PROCEDURES - REAR BODY . . . . . . . . . . . . . . . . . . . . 3.27
SEAT / SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
LOWER ACCESS PANELS (SADDLEBAG LOWER PANEL) . . . . . . . . . . . . . . . . . . . . 3.28
STREET TRIM PANEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
TRUNK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
TAIL LIGHT TRIM (“M” PANEL) / REAR BUMPER COVER . . . . . . . . . . . . . . . . . . . . . 3.31
TAIL LIGHT / TAIL LIGHT HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
SADDLEBAG DOOR / SADDLEBAG (INNER BAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
SADDLEBAG SUPPORT PLATE (PASSENGER HAND GRIP AND TRIM) . . . . . . . . . 3.34
ASSEMBLY VIEWS - REAR BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
TAIL TRIM “M” PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
TRUNK MOUNT AND ATTACHMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
TRUNK BASE / TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37-3.38
SADDLEBAG INNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
TAIL LIGHT / TAIL LIGHT HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
FLOORBOARD / FOOT CONTROL MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
PASSENGER FLOORBOARD MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
LOWER ACCESS PANEL / PASSENGER HAND GRIP / SIDE COVER. . . . . . . . . . . . 3.43
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ASSEMBLY VIEW - EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ASSEMBLY VIEW - MUFFLER & HEAD PIPE SHIELDS . . . . . . . . . . . . . . . . . . . . . . . 3.45
EXHAUST MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
HEAD PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
3.1
FRAME-BODY-EXHAUST
SAFETY
GENERAL PRECAUTIONS
This section covers the removal and installation of the frame body panels and exhaust system. Always replace
exhaust system sealing gaskets when exhaust components are removed. Inspect the system for leaks after
installation.
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck above the fuel tank insert.
Leave air space to allow for fuel expansion.
If you get gasoline in your eyes or if you swallow gasoline, see your doctor
immediately. Never try to syphon gasoline using mouth suction.
If you spill gasoline on your skin or clothing, immediately wash it off with
soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered
engine exhaust fumes are poisonous and can cause loss of
consciousness and death in a short time.
The engine exhaust from this product contains Improper repairs or service can create unsafe
chemicals known to cause cancer, birth defects conditions that may cause serious injuries or
or other reproductive harm. death to your customers or others.
Never run the engine in an enclosed area without Engine and exhaust components get hot and
a properly functioning exhaust gas evacuation remain hot for a period of time after the engine
system connected to the product. is stopped. Wear insulated protective clothing
or wait for components to cool sufficiently
before working on the machine.
Engine exhaust from this product contains poisonous Modifications to this motorcycle not approved by
carbon monoxide gas that can cause loss of Victory may cause loss of performance, excessive
consciousness and may lead to death. emissions, and make the machine unsafe for use.
3.2
FRAME-BODY-EXHAUST
GENERAL INFORMATION Also used on the Victory Vision are fasteners with 10mm
and 13mm hex drive heads common to other Victory
BODY FASTENER TYPES models.
NOTICE SPECIAL TOOLS

Review the following general information before • PV-49955 Body Panel Tool Kit or commercially 3
removing body panels to reduce the chance of cosmetic available equivalent.
damage to the motorcycle.
With a few exceptions, body panels and trim on the PV-49955

Victory Vision are fastened by two main fastener types -
a 4mm internal hex button head and a 6mm internal hex
button head shown below. A ball drive socket is needed
for some fasteners located in areas of limited clearance.
Note locations and fastener types during removal and
refer to assembly views.
4mm
Drive
HOW TO USE THIS CHAPTER
• Body components in this chapter are arranged by

their general location on the motorcycle - either
FRONT or REAR body.
• For torque values of fasteners, fastener type,
fastener location, and special notes refer to the
Assembly View for the component or group of
components if torque is not listed in the procedure.
• For specific removal and installation procedures
refer to the instructions for the individual
6mm component.
Drive
• Use care when removing and installing panels.
Some panels friction-fit tabs in addition to
mechanical fasteners. Apply pressure as close to
the tab as possible, supporting both parts until the
tab releases or connects.
• Work carefully and review the removal procedure

until you are familiar with bodywork removal
procedures.
• A non-marring wedge is essential to lift edges of
mating panels without damage. Body Panel Tool
Kit PV-49955 recommended. The instrument
bezel and dash panel are two panels that require
this tool.
3.3
FRAME-BODY-EXHAUST
REMOVAL / INSTALLATION PROCEDURES - FRONT BODY

FRONT FENDER Installation
Removal 1. Install lower fender to fork legs. Tighten (2) mounting

screws finger tight until stepped flange engages the
1. Lift center of each dart (A) and remove darts. fender. Do not fully tighten.
2. Remove upper fender screws (B). 2. Install upper fender to fork legs. Start all (4) screws
until stepped flange engages the fender but do not
3. Remove lower fender screws (C). fully tighten.
3. Align upper and lower fender and install darts.
4. Torque upper fender screws, then lower fender

screws to specification.
Front wheel removal see Chapter 12
C Black Fastener
5.4 Nm (48 lb-in) A
16 Nm (12 lb-ft) B
3.4
FRAME-BODY-EXHAUST
CONSOLE COVER AIR DEFLECTORS

Removal Removal
1. Open glove compartment door and fuel door. 1. Rotate deflector fully outward to allow easier access
to rear screw.
2. Lift the rear console cover straight upward at each 3
corner to remove it. Do not tip the panel backward.
2. Remove (2) T-20 Torx screws that attach deflector to

pivot hub.
Installation
14 lb-in. (1.6 Nm)
1. Lubricate grommets with soap and water solution.
2. Align pegs with grommets.
3. Push cover evenly downward until seated.
Installation
1. Place deflector in position, align holes and install

screws.Tighten evenly to 1.6 Nm (14 lb-in).
3.5
FRAME-BODY-EXHAUST
IAC COVER / LEFT ENGINE COVER WINDSHIELD ACCESS PANEL

With access panel removed, you can access:
Removal
• Fuse boxes
1. Grasp left engine or Idle Air Control (IAC) cover (right • Windshield adjustment mechanism or motor
side) and pull outward to release 3 clips (A). • Headlamp adjustment knob
• Front turn signal bulbs
• Fasteners for mirrors and other components.
Left Side 1. Release corners of panel by lifting straight
upward at each end (1).
A 2. Carefully slide panel toward windshield to
disengage lower tabs (2) and remove panel.
3. Disconnect antenna cable (3) (front right of panel).
4. To install, reverse above steps.
Right Side
Installation 3
1. Be sure clips are in place and in good condition. Push

cover evenly inward until seated.
3.6
FRAME-BODY-EXHAUST
WINDSHIELD INSTRUMENT BEZEL

Removal
Removal
Refer to Assembly View page 3.15.
1. Remove windshield access panel (page 3.6). 1. Use a non-marring tool such as PV-49955 Body Tool
Kit (shown) or an auto body windshield tool as a
2. Loosen all screws (A) about 1 turn. wedge. 3
3. Support windshield. Remove screws. Catch T-nuts
(B) as screws are removed.
B
2. Lift both sides of bezel away from dash, then pull
straight outward with fingers on each side to release
bezel retainer tabs.
Installation
1. Place new foam washers over center of (3) holes (C)

and single dimple (D) on each side (total 8 washers).
Installation
D
1. Align tabs with slots.
2. Push bezel straight inward until seated.

2. Place windshield in position and align screw holes.
3. Loosely install all screws and T-nuts. Do not tighten

any screw until all are installed, then lightly tighten
each screw past shoulder.
4. Starting in the center of windshield, tighten each

screw to 4 Nm (36
IMPORTANT: Windshield will crack if foam washers
are not in place or if screws are over-tightened.
5. Install access panel.
3.7
FRAME-BODY-EXHAUST
MIRRORS Installation
Refer to Assembly View page 3.20. 1. Engage tab (C) of mirror in slot (D) of housing.
2. Install screws and windshield access panel.

1. Remove windshield access panel (page 3.6).
2. Remove (A) (6mm hex). C
4.0 Nm (36 lb-in)

A D
B
4.0 Nm
(36 lb-in)
3. Hold mirror so it does not fall out and remove (B) with
a 10mm socket.
3.8
FRAME-BODY-EXHAUST
VISOR Installation
Removal 1. Slide visor into place. Tip windshield to align bracket

Refer to Assembly View page 3.20. holes and install pin (manual) or bolt (motorized).
2. Install pin retaining clip (manual) or torque bolt

1. Remove windshield access panel (page 3.6). 3
(motorized) to 16-19 Nm (12-14 lb-ft).
2. Lift center pin of fuse box cover darts (A) and remove
3. Generally align visor screw holes so tabs (D) in center
darts and covers.
of panel support are engaged with visor slots.
3. Move windshield to fully UP position.
4. Hold downward pressure on center of visor to be sure
4. Remove (4) screws (B) (4mm hex). slots engage tabs.
A
D
5. Snap top edge into place on panel support, starting at

center and working outward to edges until visor is
5. Pull outer edge of visor rearward and upward to secured.
separate one edge (C). Slide body tool inward to lift
front edge and separate front lip of visor.
C
6. Install visor screws and torque to 4.0 Nm (36 lb-in).
6. Remove windshield bracket adjustment pin (on

manual windshield) or bolt (motorized).
7. Tip windshield bracket rearward.
8. Slide visor panel up and out toward rear.
3.9
FRAME-BODY-EXHAUST
CONSOLE SPEAKER GRILL / SPEAKER

Removal Removal
Refer to Assembly View page 3.17. Refer to Assembly View page 3.19.
1. Remove instrument bezel (page 3.7).
1. Remove instrument bezel (page 3.7), windshield
2. Open fuel door and glove compartment. access panel (page 3.6), and mirrors (page 3.8).
3. Remove (5) console screws (4mm & 6mm hex). Note 2. Remove (3) 4mm button head screws.
location of ground wire (A) under right rear screw.
4.0 Nm
6mm (36 lb-in)
6mm
4mm
3. Pull panel straight outward to release tabs.
4. Lift console up and lay it on a protective pad on the 4. Mark corner of speaker and housing, or note
left side. orientation of speaker in housing for installation.
Remove (4) speaker screws and speaker.
5. Disconnect wires from each switch at front of console, Installation
noting wire colors and locations for assembly. Wire
connections are shown below (as equipped). 1. Connect “+” (wide) and “-” (narrow) speaker wires.
2. Install speakers (if removed) with wires oriented to

ACC upper inside quadrant (B). Install speaker screws.
FRONT Tighten evenly to 1.7 Nm (15 lb-in).
DRIVING 3. Align clips with slots press grill into place.
LAMP
PK/GN & GN/PK 4. Install screws.
Hand Warmer
HAZARD 5. Install mirror(s), windshield access panel, and bezel.
Power BU/PK
BU/W & BK/W
Hand Warmer B
LOW - Brown
Hand Warmer
on front tab
High - Blue
on rear tab
6. Disconnect antenna cable from radio.
7. Disconnect wire harness from radio by pushing side

tab to release connector.
Installation
1. Reverse removal steps to install.
3.10
FRAME-BODY-EXHAUST
FUEL TANK COVERS 6. 2008-2009: Lift green tab UP with a scribe or small
screw driver just far enough to disengage lock tab.
Removal 2010: Push tab down to release from catch.
Refer to Assembly View page 3.21. Disconnect accessory power wire(s) from socket on
bottom of left panel.
1. Remove console (page 3.10).
3
2. Remove studs (A) on each side of tank cover panels
(13mm wrench).
A
Lift
2008-2009
2010
3. Remove screw (B) at front left corner of glove

compartment and (C) at front right corner of fuel door
Push
(6mm hex).
4. Remove screws (D) at front (6mm hex).

BELLY PAN
D Removal
Refer to Assembly View page 3.16.
C 1. Remove screw (E) from center belly pan (6mm hex).
2. Remove screws (F) on each side (6mm hex).
F
9.6 Nm (85 lb-in)
E 4.0 Nm (36 lb-in)

5. Disconnect cables from ignition switch by lifting outer
casing out of bracket and rotating cable wire to align Installation
with slot. 1. Align pan and install all screws until lightly seated. Do
NOTE: Fuel door cable can be disconnected at the not tighten any screws until all are installed.
cover end by lifting cable out of bracket and pulling 2. Torque four outer screws to 9.6 Nm (85 lb-in) and
cable and door latch plunger out of cover. center screw to 4.0 Nm (36 lb-in).
3.11
FRAME-BODY-EXHAUST
LEG FAIRING 6. Remove the screws at the front and rear of each outer
NOTE: Inner and outer leg fairings are removed as leg fairing.
an assembly with grills attached. Refer to Assembly
View page 3.22.
1. Remove air deflectors (page 3.5) and fuel tank
covers (page 3.11)
2. Remove two screws that secure tip-over boards to
support brackets on each side (6mm hex).
7. Pull top of leg fairing / grill assembly straight out to

release center tab (A).
3. Remove belly pan (page 3.11).

4. Remove center grill bolt.
8. Slide assembly forward carefully until it clears footrest

and seat. Disconnect lit badge wire harness (if
equipped).
5. Remove front grill screws near headlamp housing.
GRILL
1. Follow instructions for leg fairing removal to remove
grill (B, above) and leg fairing as an assembly. Then
remove grill from leg fairing. Refer to page 3.22 for
fastener torques.
3.12
FRAME-BODY-EXHAUST
TURN SIGNAL LENS, FRONT 9. Carefully lift outside end of turn signal assembly
upward while pulling inside end forward slightly to
Removal disengage peg (F) on headlamp housing from
alignment hole (G) of turn signal lens.
1. Remove windshield access panel (page 3.6) and
fuse box covers.
3
2. Rotate turn signal and running light bulb sockets 1/4
turn counterclockwise (viewed from rear) and remove
sockets with bulbs.
3. Remove visor (page 3.9).
4. Remove speaker grills and speakers (page 3.10).
5. Remove (2) darts (A) to release speaker volume.
6. Rotate speaker volume (B) to clear fuse box and

remove speaker volume for access to lower turn
signal screw.
LH Side Shown
G
F
Installation
A
1. Engage hole on inside front edge of lens with peg on
headlamp housing and set signal lens in place.
B 1.7 Nm (15 lb-in)
2. Install all screws and tighten to specification.
7. Remove inner screw (C) (6mm internal hex). 3. Place speaker volume in position and install two darts
to hold it in place.
8. Remove outer screw (D) (10mm wrench) and two
lower screws (E) (10mm socket). 4. Install speaker, speaker grill, mirror, visor, and
instrument bezel.
LH Side Shown
5. Connect / install turn signal and running light bulbs.
C 6. Install fuse box cover and windshield access panel.
2.7 Nm 2.7 Nm
(24 lb-in) D E (24 lb-in)
3.13
FRAME-BODY-EXHAUST
FAIRINGS (FRONT OUTER) INSTRUMENT DISPLAY

Removal Removal
1. Remove windshield access panel (page 3.6). 1. Remove windshield access panel (page 3.6) and
radio console (page 3.5).
2. Remove fuse box covers.
2. Follow steps to remove left and right fuel tank cover
3. Remove left and right leg fairings (page 3.12).
fasteners (page 3.11) so covers are loose and can be
NOTE: Both leg fairings and headlamp can be moved rearward when necessary later. It is not
removed as an assembly by removing the four necessary to remove the covers completely.
headlamp mounting bolts and outer fairing screw (D)
only. 3. Locate instrument cluster electrical connector through
the left side of the windshield access panel opening.
4. Remove inner screw (A) and outer screw (B) from
each fairing (6mm internal hex). 4. Lift front edge of red lock tab (A) on instrument cluster
electrical connector and slide it out (forward). Push
5. Remove screw (C) from inner corner of each fairing gray tab and pull connector off display.
(4mm internal hex).
B
A A
5. Lift front tab of fuel tank covers to disengage them

C
from each other and slide the covers rearward. Set
front edges of tank cover under screw boss on fairing
shell to keep them out of the way for instrument
6. Pull rear corner out to disengage peg (D) from removal.
grommet.
6. Loosen all four instrument mounting screws. Remove
7. Pull fairing forward to disengage peg (E) at headlamp. screws one at a time, using a magnet or shop cloth to
catch the T-nut in the fairing shell as each screw is
8. Rotate bulb socket 1/4 turn and remove socket from removed. DO NOT drop T-nuts.
lens.
7. Pull display straight rearward to remove
Installation
Installation
1. Reverse removal steps. Be sure to engage peg (E) at
front inner edge of fairing before fitting the grommet 1. Be sure grommets and spacers are in place on
peg (D). instrument display.
2. Refer to page 3.24 for fastener torques. 2. Reverse removal steps to install. Tighten mounting
screws to 4 Nm (36 lb-in).
3.14
FRAME-BODY-EXHAUST
ASSEMBLY VIEWS - FRONT BODY

WINDSHIELD / WINDSHIELD MOTOR
Install ALL screws lightly past

shoulder before tightening
3
any to final torque.
Tighten in order 1-6.
4.0 Nm (36 lb-in) 3
4 6
2
1
5
T-Nuts
Pad washers
(3 each outside end)
(2 in center)
9.5 Nm (84 lb-in)
17.6 Nm (13 lb-ft)
Washer
9.5 Nm (84 lb-in)
O-Ring
Assemble with flange OUT.
3.15
FRAME-BODY-EXHAUST
BELLY PAN
Windshield Access
Panel
Fairing
Air Deflector
Leg Fairing
Grill
Belly Pan
Bottom View - Windshield Access Panel
Clean with isopropyl alcohol

before applying antenna pad
3.16
FRAME-BODY-EXHAUST
CONSOLE / CONSOLE ATTACHMENTS
3
Hand Grip Heater Hazard Driving Lamp Accessory
(If equipped) Wire color: Wire color:
Wire color: BU/W / BK/W PK/GN / GN/PK
Front - BN
Center - BU/PK
Rear - BU
3.17
FRAME-BODY-EXHAUST
CONSOLE / RADIO
Protect the console finish with a soft

cloth when removing or installing
wires or attachments.
3.18
FRAME-BODY-EXHAUST
FRONT SUPPORT / SPEAKER / SPEAKER VOLUME
3.19
FRAME-BODY-EXHAUST
VISOR / FRONT SPEAKER GRILL
Pad placement
3.20
FRAME-BODY-EXHAUST
FUEL TANK COVER

RIGHT
Cigarette Lighter
Style (late)
TANK COVER FASTENERS
LEFT
3.21
FRAME-BODY-EXHAUST
LEG FAIRING
Grill T20 Torx

LEFT
Leg Fairing
T20 Torx
2.0 Nm (18 lb-in)
Inner Leg Fairing
RIGHT
2.0 Nm (18 lb-in)
Route antenna guide tube between

grill and fairing mount tabs
3.22
FRAME-BODY-EXHAUST
LEG FAIRING SUPPORT
T20 Torx
T20 Torx
Leg Fairing Support
Assembly Order: Leg fairing support must be placed, fastened,

and torqued to the main instrument panel before placing the rear
bolts to the frame, or air deflectors may not align with mounts.
2.0 Nm (18 lb-in)
3.23
FRAME-BODY-EXHAUST
FRONT TURN SIGNAL HEADLAMP / FAIRING
Fairing
This screw secures front

inner edge of fairing to
headlamp housing.
3.24
FRAME-BODY-EXHAUST
LOWER FRONT FRAME
3.25
FRAME-BODY-EXHAUST
BATTERY BOX
3.26
FRAME-BODY-EXHAUST
REMOVAL / INSTALLATION PROCEDURES - REAR BODY

SEAT SIDE COVER
Removal
Removal
1. Remove seat (1).
WARNING 3
2. Pull center of both darts out and remove (1).
Always make sure the seat is securely fastened
before riding the motorcycle. A loose seat could
cause a sudden shift in riding position, causing you
1
to lose control of the motorcycle.
1. Remove rear console cover (page 3.5).
2. Remove two seat bolts (A) (4mm hex) and washers

below each screw.
3. Open both saddlebag doors.

4. Pull cover out at rear corner (2) and top front (3) to
release grommets from pins.
5. Support lower access panel and pull bottom edge of
cover straight outward to release tab (4).
A
A
3. Lift front of seat upward and pull forward to disengage
tab at rear of seat. Disconnect wire harness for heated
3 B
seat (if equipped).
2
Installation
4
1. To install, reverse above process. Be sure rear tab of
seat is engaged in slot.
2. Press and hold light inward pressure on front corners
Installation
of seat to minimize finish gap while screws are
tightened. 1. Install right side cover first. Lubricate rubber
grommets with mild soap and water solution.
3. Torque seat bolts to 36 lb-in (4 Nm).
2. Engage tab in bottom center of cover with slot in lower
access panel and align grommet at rear.
3. Push cover evenly inward until tab and grommet are
secured.
4. Install left side cover with front edge covering front
edge of right cover.
5. Align holes at front and install darts. Push center pin
of each dart until seated.
3.27
FRAME-BODY-EXHAUST
LOWER ACCESS PANELS (SADDLEBAG 6. Pull straight outward at rear of access panel to
LOWER PANEL) disengage rear-most tab (A) and hold it clear of the
peg on tail trim panel.
Removal 7. Press tail trim panel back down into place until
secured in its original position (B).
1. Remove seat (page 3.27).
2. Remove side covers (page 3.27). B
3. Open saddlebag doors. A
4. Remove (5) 4mm button head screws from access
panel.
8. Close saddlebag door.

5. Lift rear of tail trim panel (“M” shaped panel) straight
upward to disengage rear tabs.
C
9. Starting at rear of access panel, carefully twist bottom

edge of access panel outward (hold top edge in,
toward the motorcycle while doing this).
Lift high enough to release peg that secures
rear of lower access panel. 10. Work forward, pulling panel out below saddlebag
carefully and away from motorcycle to disengage (3)
spring clips (C).
11. Repeat for other side.
Installation
1. Reverse removal steps to install panel(s). Install all

fasteners lightly and fully seat spring clips before fully
tightening any screws. Torque all screws to 4 Nm (36
lb-in).
3.28
FRAME-BODY-EXHAUST
STREET TRIM PANEL REMOVAL STREET TRIM PANEL INSTALLATION

Victory Vision Street Victory Vision Street
1. Remove seat (page 3.27). 1. Lift tail light trim (“M” panel) enough to provide
clearance to install street trim panel.
2. Remove license plate and plate bracket by 3
removing two 4mm internal hex drive screws (1). 2. Set street trim panel in place and align tabs with slots.
3. Push straight down evenly until all four tabs are

1 2
5 secured in slots.
36 LB-IN.
(4 Nm) 4. Press each tab of “M” panel in reverse order of
removal until tabs are secured.
5. Install seat (page 3.27) and license bracket.

3
LICENSE PLATE BRACKET (EUROPE)

See page 3.37.
4
3. Lift edges of tail light trim (“M” panel) at indicated

points in order (2), (3), then (4) to release tabs.
NOTE: Lift “M” panel enough to provide clearance
to remove street trim panel. It is not necessary to
completely remove the “M” panel.
4. Lift street trim panel (5) straight upward to release

all four tabs.
5. Align tail trim and push it down firmly into place,
reversing order of removal.
6. Install seat and license bracket.
3.29
FRAME-BODY-EXHAUST
TRUNK REMOVAL 5. Remove compartment cover by squeezing

between notches (3) and lift cover away.
Victory Vision Tour

2. Locate and disconnect trunk wire harness (1) and any
accessory wiring.
3
6. Remove three of four trunk mount bolts (4) with a 13

mm socket, leaving front right bolt for last.
Remove last
3. Remove license plate and then remove plate bracket Install first
by removing two button head screws (2) (4mm internal
hex).
7. Support trunk and remove front right bolt.
TRUNK INSTALLATION
4. Open trunk and remove all contents.
Trunk Installation Notes: Reverse steps above.
Install new foam pads.
Torque trunk mounting bolts to 26 lb-ft. (35 Nm)
Torque license plate bracket screws to 36 lb-in. (4 Nm).
3.30
FRAME-BODY-EXHAUST
TAIL LIGHT TRIM (“M”) PANEL Installation
Removal 1. Be sure all spring clips are in place on “M” panel tab
posts.
1. Remove license plate to access bracket screws.
Remove bracket screws and bracket. 2. Trunk Equipped Models: Engage front tabs on panel
with top slots on tail lamp housing and carefully slide 3
2. Starting at lower edge of “M” panel, lift straight away “M” panel forward, keeping it clear of trunk.
to disengage spring tabs along each edge.
3. Align all “M” panel tabs with their respective mounting
3. Lift center of “M” panel to disengage center tabs near slots and push straight down into place, starting at top
license plate mount. and moving downward until all are firmly seated. Be
sure peg at bottom of panel is aligned with hole in each
4. Pull top corners up to disengage top tabs on each lower access panel.
side.
NOTE: On Victory Vision Tour models (equipped
with a trunk), the “M” panel must be moved rearward REAR BUMPER COVER
before front of panel can be raised high enough to
clear the trunk and release the tabs from slots (see Removal
Step 5).
1. Open saddlebag doors.
Slide panel back then 2. Remove “M” panel (page 3.31) or lift lower legs of “M”
lift if equipped with a panel up to access the two screws on the top inside
trunk. edge (A).
3. Remove (6) button head screws from cover. Protect

chrome exhaust shield when removing outer screws
4 (B) on left and right side.
3
B
5 A
5. Slide “M” panel rearward to move top tabs down in the

elongated top slot until panel is clear of trunk.
Installation
6. Lift front tabs out of slots and remove panel.
1. Align screw holes and install all screws until lightly
seated.
2. Torque to 4.0 Nm (36 lb-in).
3.31
FRAME-BODY-EXHAUST
TAIL LIGHT TAIL LIGHT HOUSING

Removal Removal
1. Remove “M” panel (page 3.31). 1. Remove trunk (if equipped - page 3.30) or street trim
panel (page 3.29).
2. Remove rear bumper cover (page 3.31).
2. Remove tail lights (page 3.32).
3. Remove five tail lamp lens screws (A).
3. Remove lower access panels (page 3.28).
4. Pull tail lamps rearward to remove.
4. Remove ten (10mm hex head) screws (B).
5. Remove two (13mm hex head) screws (C) at top of

panel.
A 4.0 Nm (36 lb-in)
B C
Installation
1. Left tail lamp overlaps the right.
2. Install all screws lightly to align lenses, then fully Installation

tighten.
3. Install parts removed for access.
2. Torque fasteners to 4.0 Nm (36 lb-in).
3.32
FRAME-BODY-EXHAUST
SADDLEBAG DOOR SADDLEBAG (INNER BAG)

Removal Removal
(Instructions below are for left saddlebag. Right bag
1. Open saddlebag door. removal similar).
2. Remove six screws that fasten two upper hinge plates Refer to illustration on page 3.40 for fastener location 3
to door. Door strut can remain attached to rear upper and torque values.
hinge plate.
1. Remove saddlebag door (page 3.33).
Installation
2. Remove lower access panels (page 3.28).
1. Install hinge screws and torque to 4.0 Nm (36 lb-in).
3. Remove tail light trim (“M”) panel (page 3.31).
4. Remove rear bumper cover (page 3.31).
5. Remove two nuts, washers, and outer grommets for

the muffler (page 3.45).
6. Remove two door latch bracket screws and bracket

with latch and cable attached (10mm socket) and set
bracket / latch assembly aside.
7. Remove diagnostic connector from clip. Pull grommet

through inner bag.
8. Remove rear shock air fitting.
9. Remove three screws along the rear edge of inner

saddlebag that fasten the bag to the tail light housing.
10. Remove two screws at rear lower corner of bag that

fasten bag to rear bumper (10mm socket).
11. Remove three bolts that fasten bag to frame and rear
tip over support (13mm socket). Leave one bolt
loosely installed to support the bag.
12. Remove single bolt inside saddlebag (13mm socket).
13. Remove two top bolts that fasten bag to rear

passenger hand grip mounting plate.
14. Support bag and remove the bolt from Step 10. Slide
bag outward to remove.
Installation
1. Align muffler grommets horizontally to match slot in

inner bag.
Refer to page 3.40 for fastener torques.
3.33
FRAME-BODY-EXHAUST
SADDLEBAG SUPPORT PLATE 6. Open both saddlebag doors.

(PASSENGER HAND GRIP AND TRIM) 7. Remove two saddlebag door latch bracket screws (A)
and bracket with latch and cable attached (10mm
Removal socket). Set bracket aside (remove both left and right).
8. Remove two mount plate bolts (B) from each side.
NOTE: Passenger hand grips and trim cover cannot
9. Remove tail lights (page 3.32) and separate harness
be removed with saddlebag support fully installed.
from darts on right side of plate. Set harness and lights
The support plate must be lifted off frame high
in the seat area so support plate can be removed.
enough to access fasteners.
10. Loosen two front bolts (C) and bolt inside bag (D)
NOTE: Only one saddlebag must be loosened and about 5 turns. (Remove these from one bag only).
moved slightly outward to remove support plate. 11. Remove four plate mounting bolts (E).
12. Pull top of loose bag outward slightly until outer tab on
plate clears slot in bag. Lift plate up and slide
2. Remove lower access panels (page 3.44). sideways to disengage opposite tab and remove.
3. Remove trunk or street panel as equipped.
Installation
4. Remove ECM ground wire screw. Note washer
placed under ECM for installation. 1. Reverse removal steps to install. Be sure bumpers
5. Slide ECM connector lock lever toward right side of are in place.
motorcycle until connector is disengaged from ECM.
Pull connector straight outward.
B C
A
Bumpers
D
E
3.34
See page 3.37 for EU
License Plate Mount
Tail Light Trim

(“M” Panel)
Street Trim Panel
TAIL TRIM “M” PANEL
ASSEMBLY VIEWS - REAR BODY

Rear Bumper Cover
FRAME-BODY-EXHAUST
3.35
3
FRAME-BODY-EXHAUST
TRUNK MOUNT AND ATTACHMENTS
3.36
FRAME-BODY-EXHAUST
LICENSE PLATE MODULE (EUROPE)
18 LB-IN.
(2 Nm) 96 LB-IN.
(10.8 Nm)
25 LB-IN.
96 LB-IN. (2.8 Nm)
(10.8 Nm)
3.37
FRAME-BODY-EXHAUST
TRUNK BASE
Some parts shown for reference only
3.38
FRAME-BODY-EXHAUST
TRUNK LID
Some parts shown for reference only

3
3.39
FRAME-BODY-EXHAUST
SADDLEBAG INNER
3.40
FRAME-BODY-EXHAUST
TAIL LIGHT / TAIL LIGHT HOUSING
3.41
FRAME-BODY-EXHAUST
FLOORBOARD / FOOT CONTROL MOUNTING
LEFT SIDE (SHIFT)
Lubricate with Multi Purpose Lubricant

P/N 2872863 96 lb-in (10.8 Nm)
Pedal position adjustment:
1) Remove screw
92.5 +/- 3mm 2) Move pedal assembly forward or rearward
until screw hole aligns with on of the other
A two threaded holes.
3) Install screw and torque to specification.
4) Adjust shift pedal height as follows:
5) Hold linkage rod end (A) with a 7/16 wrench
and loosen jam nut (B) with a 1/2 inch wrench.
6) Rotate linkage rod to set pedal height within specification.
B 7) Hold linkage rods and tighten jam nuts securely.
RIGHT SIDE (BRAKE)
96 lb-in (10.8 Nm)
3.42
FRAME-BODY-EXHAUST
PASSENGER FLOORBOARD MOUNTING
LEFT SIDE 3
RIGHT SIDE
3.43
FRAME-BODY-EXHAUST
LOWER ACCESS PANEL / PASSENGER HAND GRIP / SIDE COVER
8-Ball
3.44
3
3.45
FRAME-BODY-EXHAUST
REMOVAL: INSTALLATION:
1. Use tool PV-49955. See removal procedure. 1. Loosely assemble all parts (except shields A and B)
2. Tighten fasteners in order A - H
3. Remove all oil, grease, or lubricant before starting engine

24.5 Nm (18 lb-ft) 24.5 Nm
(18 lb-ft)
YSTEM
Torque to 24.5 Nm (18 lb-ft)

EXHAUST SYSTEM
NOTE: Rotate all muffler clamps and head pipe clamps

ASSEMBLY VIEW - EXHAUST S
so gaps are 90 degrees from slots in muffler or pipe.

FRAME-BODY-EXHAUST
ASSEMBLY VIEW - MUFFLER & HEAD PIPE SHIELDS
Muffler Shields
Locate clamp lock

on back of muffler
50mm
560mm
280mm
Catalyst not removable
Center on
head pipe
Head Pipe Shields
3.46
FRAME-BODY-EXHAUST
EXHAUST MUFFLER REMOVAL 6. Loosen both the muffler clamp and the crossover pipe
clamp on the left side, and the muffler clamp and head
NOTICE: Allow exhaust to cool completely before you pipe bolt (near the crossover pipe) on the right side.
begin work. After the exhaust has cooled, joints can be NOTE: Even if you do not plan to remove the head
sprayed with a spray lubricant to ease removal. pipes, removal of the chrome shields and loosening
both clamps (left side shown below) and head pipe 3
Removal mounting bolt (on right side) will allow more
movement of the muffler to expand the joint.
1. Remove side covers (page 3.27).
7. Slide muffler clamp(s) off joint(s) and spray joint(s)
2. Remove both left and right lower access panels with lubricant.
(below the saddlebags) (page 3.28).
3. Remove chrome shield at the front of the left and right

mufflers. Twist clamps to disconnect and remove.
Note orientation of clamps before removing.
4. Remove (2) nuts, washers, and support grommets

from the muffler mounts.
Left Side
8. Hook slot (A) of Exhaust Muffler Wrench PV-49946 on

muffler bracket (B) as shown below. Pull handle of tool
to rotate muffler until studs (C) are clear of mounting
slots on inner saddlebag.
PV-49946 A
5. Remove bolt at the rear of each muffler that fastens

the muffler to the bumper bracket.
C
B
3.47
FRAME-BODY-EXHAUST
9. Move the muffler back and forth to expand the joint and HEAD PIPE REMOVAL
allow lubricant to enter. Tap muffler with a rubber
hammer at the front (D) and slide it off the head pipe NOTICE: Allow exhaust to cool completely before you
or use Exhaust Muffler Wrench (PV-49946) to rotate begin work. After exhaust has cooled, joints can be
muffler back and forth until loose. sprayed with a spray lubricant to ease removal.
Removal
Locate pipe clamp gaps 90 degrees from
slots in pipes. 1. Remove mufflers (page 3.47).
2. Remove right leg fairing.
3. Remove right floorboard support (page 3.42).
4. Lift the tab on each oxygen sensor connector and

disconnect. DO NOT attempt to remove the wire
from the sensor! Open wire guides and remove wire
from guides in the vicinity of the sensors.
D
5. Loosen rear head pipe flange nuts about 3 turns. Do
not remove the flange nuts at this time. Leave front
head pipe flange nuts tight.
6. Loosen clamp on lower head pipe.

EXHAUST MUFFLER INSTALLATION
7. Remove oil filter and cover filter mounting area to
1. Clean all lubricant from the exhaust joints (if used for prevent debris from entering.
removal).
2. Place muffler bushing and Slide muffler onto head pipe 8. Spray lubricant on lower head pipe joint.
as far as possible until studs are aligned with slots of
inner saddlebag. 9. Move rear head pipe assembly back and forth to
expand lower pipe joint and allow lubricant to work into
3. Hook Exhaust Muffler Wrench (PV-49946) onto muffler joint.
bracket in the opposite direction as for removal, and
rotate the muffler until studs are engaged in slots. 10. Remove rear flange nuts.
4. Locate pipe clamp gaps away from pipe slots. Torque 11. Pull rear head pipe rearward and rotate it outward until
all fasteners and clamps (page 3.45). clear of engine and front head pipe.
5. Clean exhaust pipes to remove all oil, grease, or 12. Remove front head pipe flange nuts and pipe.
fingerprints before running the engine to check for
exhaust leaks. Installation
1. Clean all lubricant from exhaust joints (if used for

removal).
2. Install new head pipe gaskets.
3. Reverse removal steps to install head pipes
4. Install mufflers and shields.
5. Clean exhaust to remove all oil, grease, or fingerprints

before starting the engine to check for exhaust leaks.
3.48
LUBRICATION & COOLING
CHAPTER 4
OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
OILING SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SPECIFICATIONS - LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4
OIL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
ASSEMBLY VIEW - OIL COOLER AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
OIL COOLER INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
OIL COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
OIL COOLER / LINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
LUBRICATION OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
COOLING OIL FLOW INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
OIL PRESSURE RELIEF VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
OIL PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
4.1
OILING SYSTEM TROUBLESHOOTING
OPERATION LOW OIL PRESSURE HIGH OIL PRESSURE

The engine must be running in order to perform some of Incorrect oil being used or Incorrect oil being used
the procedures in this section. Read, understand and low oil level
follow the warnings and cautions contained in this
section. Engine temp above test Additives added to oil to
temperature range increase viscosity
The oil pump has two sets of internal gerotors. One set
provides lubrication pressure and the other provides
Damaged O-rings or Engine temp below test
cooling oil pressure. There is a separate pressure relief
leaks at pipes or fittings temperature range
valve located on the oil pump for each oiling system.
The engine must be removed from the frame and Damaged or worn oil Restricted oil passages
disassembled to access the oil pump. Use the pump or oil pump drive
troubleshooting charts contained in this chapter before
removing and disassembling the engine. Pressure relief valve Incorrect oil filter
stuck open
Check lubrication side oil pressure any time an engine is
making objectionable noises that appear to be coming Damaged engine Pressure relief valve
from rotating parts. Check oil pressure before the engine bearings/excessive stuck closed
is disassembled. Re-check oil pressure following a repair. engine wear.
Cooling oil pressure troubleshooting is accomplished by Restricted oil filter, oil filter
verifying cooling oil flow as opposed to cooling oil screen or passages
pressure. See oil pressure testing on page 4.8.
WARNING SPECIAL TOOLS

Oil Pressure Gauge PV-43531
DO NOT loosen any oil line connections with the engine
running, or within 30 minutes of operation. Oil inside the Moly Assembly Paste PN 2871460
lines could be under pressure.
5mm Ball Drive Allen Socket (commercially available)
WARNING
Never run an engine in an enclosed area. Exhaust

contains poisonous carbon monoxide gas that can
cause loss of consciousness or death. Operate the
engine in an open area or with an exhaust evacuation
system connected and functioning properly.
WARNING
The engine components, oil and exhaust system

become hot during operation and remain hot for a
period of time after the engine is shut off. Wear eye
protection and heat-resistant garments for hands and
arms if working on a hot engine or wait until the
components have cooled sufficiently before working on
the machine.
4.2
OILING SYSTEM DATA

SPECIFICATIONS - LUBRICATION
LUBRICATION & COOLING SYSTEM
Item Standard Service Limit
Engine Oil Capacity (After Disassembly) 4.75 Liters (5.0 U.S. qts) Not Applicable
Engine Oil Capacity (At Change) Fill to full line with the engine Approximately 4.25 Liters Not Applicable 4
at operating temperature. (4.5 U.S. qts)
Recommended Engine Oil Victory 20W/40 for all Not Applicable
If Victory 20W/40 is not available, use motorcycle oil suitable operating temperatures.
for wet clutches (such as those with JASO MA rating).
DO NOT use additives of any kind.
Oil Pressure @ 3000 rpm (Lubrication System) 552 kPa (80 psi) Readings should be within
Measurements must be taken with engine at operating 20% of the specifications.
temperature (82oC/180oF) and specified Victory Engine Oil Minimum Lubrication
Pressure 276 kPa (40 psi)
Oil Pressure (Cooling System) No measurement.
-
See page 4.8.
Oil Pump Clearances Rotor Tip Clearance .12 mm (.005") .18 mm (.007”)
Pump Body Clearance .10 mm (.004") .26 mm (.010")
Pump End Clearance .025 mm (.001") .10 mm (.004")
Cooling Rotor Width 14.96 mm (.5889") 14.90 mm (.5866")
Lubrication Rotor Width 9.99 mm (.3933") 9.90 mm (.3897")
Shaft End Play (Check 2.0 mm (.080") + .5 mm (.020")
assembly of pump if
excessive)
Fastener Torque Specifications - Lubrication & Cooling

Torque Torque
Description
Nm lb-ft (lb-in)
Cylinder Head Temperature Sensor - (CHT) - (Install new if removed) 13.5 10 lb-ft
Oil Cooler Lower Support Bracket 13.5 (120 lb-in)
Oil Drain Plug 20 Nm 15 lb-ft
Oil Filter - apply oil to filter O-ring 8 Nm (71 lb-in)
Approximately 3/4 turn after sealing ring
has contacted the engine case.
Oil Filter Nipple (threaded fitting to crankcase) 61 45
Oil Line to Crankcase 10 (85 lb-in)
Oil Lines to Cooler 10 (85 lb-in)
Oil Pressure Relief Valves 6 20 lb-ft
Oil Pressure Sensor Loctite™ 565 or pipe sealant 14 (125 lb-in)
Oil Pump to Crankcase / Oil Tube to Crankcase 10 (85 lb-in)
Oil Pump Sprocket 10 (85 lb-in)
4.3
OIL FLOW
DIAGRAM
Valve
Adjusters
Camshaft Journals Rocker Arm Shafts
Lower Camshaft Carrier

Cylinder
Cylinder Head Cam Chains / Sprockets
Heads
(Exhaust Valve Bridge) Right Side
RH Front Cylinder Stud
Crankcase Passage Passage In Passage in

Head Gasket Cylinders (Left side)
Stator
Crankshaft Cam Chain
Tensioner
Starter Drive Main Bearings Crankcase Passage
Rod
Bearings
UPPER HOSE
Oil Pipe
Oil Filter Oil Cooler Torque

LOWER HOSE Compensator
Gear
Oil Pipe
Oil Pressure
Switch Oil Jet
Transmission
Oil Pressure Oil Pressure
Oil Pump
Regulator Regulator
Lube Cooling
(Lubrication) (Cooling)
(+ 85 PSI) (+ 105 PSI)
Pickup
Screen
Oil Sump
Crankcase Passage Gravity & Splash Lubrication

Lubrication Circuit
Reed Valve
Air Box Cooling Circuit
Breather Hose Pressure Relief Circuit
Breather Circuit
4.4
OIL COOLER
ASSEMBLY VIEW - OIL COOLER AND LINES
Apply mild soap and water Clean from this side

to ease assembly
O-Ring Apply Victory Engine Oil To O-Rings

4
9.6 Nm (85 lb-in)

O-Ring
O-Ring Flat Washer
Flat Washer
9.6 Nm (85 lb-in)
Tightening Order - Oil Lines 9.6 Nm (85 lb-in)
Tighten second P-Clamp Detail

9.6 Nm (85 lb-in) Note orientation of text
Shift shaft
Bottom View
Retainer Detail
Install retainer
P-Clamp plate with bend in
Tighten last Bracket corner of plate facing
9.6 Nm (85 lb-in) Tighten first away from engine
9.6 Nm (85 lb-in) OUT
4.5
OIL COOLER INSPECTION / CLEANING OIL COOLER REMOVAL

1. Inspect cooler, lines, and all connections for leaks. Also refer to Illustration on page 4.5.
2. Inspect lines for proper routing. Replace if there is any 1. Place drain pan beneath oil cooler and lines.
sign of abrasion or damage.
2. Remove screws (A) and disconnect oil lines.
3. Inspect cooler surface for obstructions or debris.
3. Remove mounting screws (B).
4. Rinse from back side to front with low pressure water.
4. Slide cooler off of grommet (C).
5. Inspect oil cooler fins for deformation. Fins can be
straightened if not severely deformed and no oil leaks
are present.
B
6. Inspect cooler mounting fastener for proper torque.
Inspect mounting bracket and rubber grommets for
cracks or damage (page 4.5).
7. Replace any damaged components.
A
C
O-ring
Washer
5. Carefully remove from bracket.
4.6
OIL COOLER / LINE INSTALLATION

Refer to Illustration on page 4.5 for detail views.
Oil Lines to Engine
Oil Cooler Installation
1. Installation of lines to engine is easier with lines
If oil lines were removed from cooler and engine, install
removed at the oil cooler end. engine end first.
2. Assemble support grommet (A) with print facing UP. 1. Lubricate cooler support grommets in bracket with
Install P-clamp (B) over grommets. See P-clamp detail
on page 4.5. Do not tighten P-clamp screw.
mild soap and water solution. 4
2. Install cooler, engaging post with grommet.
3. Install new backing washers (C) on lines.
3. Install mounting screws.
4. Lubricate new O-rings (D) with engine oil and install
against backing washers. Oil Lines to Cooler
5. Clean oil line sealing surfaces on engine. Carefully
assemble lines to engine by rotating the lines to clear 1. Install new backing washers on oil lines.
primary cover or gasket surface and frame. 2. Lubricate new O-rings with engine oil and install on
6. Install retainer plate (E) with curved ends facing OUT. lines against backing washers.
7. Install screws and torque to 9.6 Nm (85 lb-in). 3. Carefully assemble lines to cooler.
8. If lines are not attached to cooler, install them before 4. Install screws and torque to 9.6 Nm (85 lb-in).
before installing P-clamp. Install P-clamp screw.
Apply mild soap and water

to ease assembly
OUT
Tighten second
9.6 Nm (85 lb-in).
D E
D C
C B
D
C
9.6 Nm (85 lb-in).
A
F
Tighten last
Tighten first
9.6 Nm (85 lb-in). 9.6 Nm (85 lb-in).
4.7
OIL PRESSURE INSPECTION COOLING OIL FLOW INSPECTION

Cooling oil inspection is accomplished by verifying oil flow
LUBRICATION OIL PRESSURE
through the cooler. The temperature of the cooler should
Use caution when working around hot engine oil. Review be close to crankcase temperature. Pressure testing
all WARNINGS on page 4.2. cannot be performed at the Cylinder Head Temperature
(CHT) port, because the sensor does not enter the
1. Warm engine to operating temperature. cooling oil passage. Cooling oil pressure changes along
various paths and designed flow restrictions located
2. Stop the engine.
inside the engine (like voltage drops across a resistive
3. Remove oil pressure sensor (A). electrical circuit). Diagnostics should be limited to
verifying that oil is flowing through the cooler, and that air
4. Install oil pressure gauge adapter.
flow through the cooler and to the engine cylinder fins is
Oil pressure gauge: PV-43531 unobstructed. Cooling oil enters the cooler on the bottom
Lubrication System Pressure line and exits (back to the engine) on the upper line.
Oil Pressure
Gauge IMPORTANT! Tip conforms to cylinder head metal when
installed. It does not contact the cooling oil passage!
Apply LoctiteTM 565
Cylinder Head DO NOT
Temp re-install
Sensor a temp sensor
(CHT) if removed!
Oil
Pressure No Thread
A Sensor Sealant at tip
(2-3 mm)
5. Check engine oil using dipstick. Add recommended
oil if necessary.
Fig. 1 Apply LoctiteTM 565 Sealant
6. Start engine and check oil pressure at 3000 rpm.
Cylinder Head Temperature Sensor (CHT)
7. If oil pressure is outside of specification, refer to the
troubleshooting on page 4.2.
TORQUE: Temperature Sensor
8. Once testing is completed clean threads with Loctite REPLACE WITH NEW IF REMOVED
Primer N, apply thread sealant to the threads in area 13.5 Nm (10 lb-ft)
indicated in Fig. 1 and install. Do Not Overtighten
Oil Pressure Sensor
TORQUE: Oil Pressure Sensor

NOTE: See Chapter 5 for temperature sensor location
14.0 Nm (125 lb-in) and installation.
Lubrication Oil Pressure @ 3000 rpm Standard ±20%

552 kPa (80 psi) MINIMUM pressure is
Measure at Oil Pressure Sensor @ 82oC/180oF 276 kPa (40 PSI)
Cooling Oil OIL FLOW -
4.8
OIL PUMP
LUBRICATION/COOLING OIL PUMP ASSEMBLY
Replace all gaskets, washers, and O-rings Pump - Check for free rotation after
installation
B Fitting (Nipple)
Install after pump and pipe (A)
62 Nm (45 lb-ft) 4
9.6 Nm (85 lb-in)
O-Ring(X2)
1/2-3/4 turn past gasket

contact (by hand)
Washer
O-Ring A
O-Ring Oil Tube Installed With Pump
Remove / install this pipe Washer and Before Nipple (B)
and oil pump as an assembly
9.6 Nm (85 lb-in)
OIL PUMP REMOVAL 4. Remove oil pump drive sprocket bolt and sprocket (C).
1. Disassemble engine to access oil pump. (Refer to 5. Remove (3) oil pump mounting bolts (D). The oil pump
Chapters 6-10) mounting bolts also hold the oil pump body together.
A D
2. Remove oil filter and oil filter nipple (fitting) (A). 6. Remove long oil tube.
NOTE: The oil filter nipple MUST be removed to remove 7. Remove oil pump and short oil tube together as a unit.
the long oil delivery tube. See photo above.
Use caution not to drop any parts when removing oil
3. Remove retaining screw for short oil tube (B). pump from crankcase.
NOTE: The washers and/or O-rings for the oil piping may
stay in the engine cases/oil pump body. Be sure to
retrieve the used O-rings and washers and discard. Use
new O-rings and washers during assembly.
4.9
OIL PRESSURE RELIEF VALVES proper location on the oil pump. The lubrication pressure
relief valve screws into the main oil pump body, and has a
The lubrication and cooling systems operate at different oil SHORTER hexagonal portion. The cooling pressure relief
pressures, regulated by pressure relief valves. The valves valve screws into the oil pump base, and has a LONGER
are not interchangeable. Be sure to install each valve in the hexagonal portion.
Lubrication Oil Pressure Relief Valve

(Shorter Hexagonal Portion - 85 PSI)
27 Nm (20 lb-ft) Long Hex
Short Hex
Pump Base
(Cooling Oil Pump)
Lubrication Pump
Cooling Oil Pressure Relief Valve
(Longer Hexagonal Portion - 105 PSI*)
27 Nm (20 lb-ft)
* See cooling oil flow inspection

on page 4.8.
1. Remove the relief valves. The lubrication relief valve

(A) has a SHORTER hexagonal portion and screws
into the pump BODY (B). The cooling pressure relief
valve (C) has a longer hexagonal portion and screws
into the pump BASE (D).
2. Visually inspect the relief valve for obstruction or
unusual wear.
A C
B
D
4.10
OIL PUMP INSPECTION 3. Measure clearance between pump body and outer
gerotor on the lubrication side.
Inspect the oil pump when lubrication oil pressure is below
specification. The oil pump contains 2 sets of inner and
outer gerotors. Follow the inspection procedure for both
sets of gerotors and both ends of the pump.
Keep gerotors together as a set, and keep them oriented

the same way (dots on each gerotor must be on the same
side upon assembly). Part not interchangeable. 4
If dots on the gerotors are not visible, mark the gerotors
upon disassembly so they can be matched and oriented
properly upon assembly.
Before disassembling pump completely, follow these
inspection steps, and compare to specifications on
page 4.3.
1. Remove the pump base (A) and lubrication side end 4. Measure clearance between pump body and outer
cap (B). gerotor on the cooling side.
2. Measure tip clearance as shown below for both cooling 5. Measure the oil pump end clearance with a feeler
(larger gerotor set) and lubrication. gauge at point “A”. Lubrication side of pump is shown
below. Cooling side is measured in the same manner.
4.11
OIL PUMP DISASSEMBLY
Oil Jet
Torque: 13 Nm (115 lb-in.) Dowel 9X26 mm
Pressure Relief Valve Assembly - 85 PSI
(Lubrication Pump) Cooling Gerotor
Shorter Hex
Torque: 27 Nm (20 lb-ft.) Pump Body
Dowel 9X10mm
Pin Pump Base
Pressure Relief Valve Assembly - 105 PSI

Lubrication Gerotor (Cooling Pump) Longer Hex
Torque: 27 Nm (20 lb-ft.)
Seal
Shaft / Body (Both Ends)
Apply Moly Lube
APPLY VICTORY ENGINE
OIL TO ALL PARTS
DURING ASSEMBLY
Lubrication Pump Cap Inlet Screen
NOTE: Keep all parts together during disassembly. Note 7. Push on opposite end of shaft to allow pin to be
orientation of dots on gerotors for assembly. Gerotors removed from lubrication gerotor. Pull lubrication rotor
must be assembled with the dots on the same side. They back to expose pin and remove pin.
do not need to be aligned with each other.
6. Remove cooling outer gerotor.
8. Push shaft back toward cooling end of pump and

remove pin from cooling gerotor.
9. Pull shaft with inner rotor from pump body.
10. Clean all parts and inspect for wear.
11. Dry with compressed air
4.12
OIL PUMP ASSEMBLY 4. Assemble lubrication gerotor on pump shaft.
Refer to Illustration on page 4.12 for assembly

view and torque values.
1. Press short dowel pins into lubrication side of pump

body using an arbor press and a 6mm allen head
screw (A).
5. Lubricate shaft with moly assembly paste PN 2871460.

6. Insert pump shaft/rotor assembly into pump body in
direction shown (B).
2. Press long dowel pins into cooling side of pump body

using same method as above.
3. Secure pump body in a soft jaw vise. Apply Victory
engine oil to threads of lubrication pressure relief valve B
and install into pump body. The lubrication relief valve
has a shorter hexagonal portion than the cooling relief
valve. torque to (20 lb-ft).
7. Lubricate and install the cooling gerotor with pin slot

(C) facing OUT.
8. Insert pin (D) into shaft on cooling side.
9. Push shaft inward while rotating to align pin and slot.
D
C
4.13
10. Install outer gerotor. 13. Install oil jet to oil pump base.
Torque to 13 Nm (115 lb-in)
14. Lubricate pressure relief valve assemblies and both

11. Push shaft toward lubrication side and hold in place. lubrication and cooling gerotors with engine oil.
Install pin for lubrication rotor. Lubricate both gerotors
with oil. 15. Install base (A) and body cap (B) to pump.
16. Install a new oil inlet seal to inlet screen (C).
17. Pre-lubricate the entire oil pump and relief valves with
Victory engine oil and assemble screen to oil pump
body, aligning groove (D) in screen to tab on pump.
A
C
12. Secure pump base in a soft jaw vise. Apply Victory

engine oil to threads of cooling pressure relief valve B
and install into pump base. The cooling relief valve has
a longer hexagonal portion than the lubrication relief
valve. Torque to 27 Nm (20 lb-ft). D
4.14
OIL PUMP INSTALLATION 6. Start the top two oil pump retaining bolts (E) and the
1. Refer to Fig. 2. Clean oil pipes and dry with rear pipe bolt (F) but do not tighten at this time.
compressed air. 7. Install new oiled O-rings (G) onto front of long oil pipe.
NOTE: After oil pump is installed, be sure the pump Install new washer (H) on end of pipe and a new
rotates freely by installing the sprocket without the O-ring (I).
chain and rotating pump a few revolutions.
8. Fit front end of long oil pipe into position at front of
2. Use new washers and O-rings upon assembly. crankcase and rear of pipe through oil filter nipple
3. Install a backing washer (A) and lightly oiled O-ring (B) opening in crankcase. Install pipe retaining bolt (J). 4
onto short oil pipe. Insert pipe into pump body with a 9. Torque all pump fasteners to specification.
twisting motion until seated.
10. Install oil filter nipple (K). Center the oil pipe to the fitting
4. Place washer (C) onto the other end of short oil pipe with a 1/4 inch pin punch as shown.
followed by a new lightly oiled O-ring (D).
11. Temporarily install pump sprocket on pump shaft
5. Install oil pump and short pipe into left crankcase. Start (without the chain) and turn oil pump over by hand.
by inserting oil pipe into rear of crankcase, then place NOTE: Turn pump shaft by hand a few revolutions to
oil pump into crankcase alignment holes. make sure it turns freely.
Use 1/4 inch pin punch 10 Nm (85 lb-in)

to align oil filter nipple to
oil pipe during installation E
G
62 Nm (45 lb-ft) K
B
H
A J
I 10 Nm (85 lb-in)
Tapered O-ring seat

faces oil pipe 10 Nm (85 lb-in)
D F
C
Fig. 2
4.15
12. Remove sprocket so chain can be installed.

13. Install chain over oil pump sprocket and balance shaft
sprocket. Align pump sprocket to shaft and install
retaining bolt (A). Torque to 9.6 Nm (85 lb-in).
NOTE: The sprocket is a floating design. A small

amount of end play is normal after tightening the
retaining bolt.
14. Refer to Chapter 10 for crankcase assembly.

15. Verify proper lubrication oil pressure after assembly.
Refer to page 4.8.
4.16
FUEL SYSTEM / FUEL INJECTION
CHAPTER 5
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FUEL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
TROUBLESHOOTING, BASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
BASICS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
THROTTLE BODY FLOW SCREW AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
IDLE STOP SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5
SERVICE PRECAUTIONS, EFI SYSTEM GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FUEL SYSTEM ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL TANK HOSE CONNECTION - 49 STATE MODELS . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL TANK HOSE CONNECTION - CALIFORNIA MODELS. . . . . . . . . . . . . . . . . . . . . 5.7
FUEL LEVEL SENSOR / FUEL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
FUEL PUMP AND FUEL TANK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
AIR INTAKE / BOX FRAME ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
IDLE AIR CONTROL ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FUEL SYSTEM DEPRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FUEL TANK VENT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FUEL PUMP REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FUEL PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FUEL TANK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FUEL PUMP CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FUEL LEVEL SENSOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FUEL LEVEL GUAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FUEL PUMP ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
FUEL PUMP SUPPLY VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
BATTERY VOLTAGE NOT REACHING FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
FUEL PUMP CURRENT DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
FUEL PUMP PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
IDLE AIR CONTROL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
EFI SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
FUEL INJECTION COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
FUEL RAIL / FUEL INJECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
FUEL RAIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
FUEL INJECTION SYSTEM TESTING AND DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . 5.24
FUEL INJECTION SYSTEM - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . 5.24
IDLE AIR CONTROL (IAC) - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . 5.24
SELF-DIAGNOSTIC FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
VIEWING AND CLEARING TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
SENSOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
SPN / FMI ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
ECM HARNESS CONNECTOR TEST PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . 5.29
ECM CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
ECM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
EFI SENSOR CIRCUIT WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
EFI SENSOR CIRCUIT WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
5.1
SENSOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32

THROTTLE POSITION SENSOR (TPS) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 5.32
TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) . . . . . . . 5.33
AIR TEMPERATURE SENSOR (ATS) DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . 5.34
CYLINDER HEAD TEMPERATURE SENSOR (CHT) DIAGNOSTICS . . . . . . . . . . . . . 5.35
IDLE AIR CONTROL (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
VEHICLE SPEED SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
MEMORY CHECK SUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
TIPOVER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
CRANKSHAFT POSITION SENSOR DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
BATTERY VOLTAGE AT ECM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
USING DIGITAL WRENCH DIAGNOSTIC SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . 5.39
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
DIAGNOSTIC SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
TPS CALIBRATION NOT REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
ECM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
DIGITAL WRENCH FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
GUIDED DIAGNOSTICS AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
DIGITAL WRENCH FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
DIGITAL WRENCH SCREEN EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
REPROGRAMMING THE ENGINE CONTROL MODULE (ECM) OVERVIEW . . . . . . 5.45
REPROGRAMMING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
REPROGRAMMING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
5.2
SAFETY PRECAUTIONS
FUEL SAFETY
Many hazards are present when working on or around the fuel injection system. Read and pay close attention to the
following warnings and cautions when working on any component in this section.
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is
stored. 5
Do not overfill the tank. Do not fill the tank neck above the fuel tank insert. Leave air space to allow for fuel
expansion.
If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately. Never try to syphon gasoline
using mouth suction.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of
consciousness and death in a short time.
Gasoline is extremely flammable and is explosive

under certain conditions. Work in a well ventilated The engine exhaust from this product
area. Open flames, sparks and cigarettes must be contains chemicals known to cause cancer,
kept away from gasoline. birth defects or other reproductive harm.
KEEP GASOLINE OUT OF REACH OF CHILDREN!
The engine and exhaust system become very hot

Careless handling of the control cables can result in during operation and remains hot for a period of time
twisting or bending of the cables. This can cause the after the engine is shut off. Wear insulated
cables to stick or bind, resulting in loss of vehicle protection for hands and arms or wait until the
control. engine and exhaust system have cooled before
performing service work.
DO NOT TAMPER WITH DO NOT TAMPER WITH

THROTTLE BODY FLOW IDLE STOP SCREW
SCREW
DO NOT TAMPER
5.3
SPECIFICATIONS TROUBLESHOOTING
FUEL SYSTEM SPECIFICATIONS BASICS TROUBLESHOOTING
NOTE: The closed-loop EFI system does not require
FUEL SYSTEM TPS calibration. Refer to Fuel System
Troubleshooting page 5.49 - 5.52.
Item Specifications
DO NOT OVERLOOK THE BASICS WHEN
Fuel Octane (Minimum) 91 Octane (R+M/2) TROUBLESHOOTING:
Fuel Pump Pressure 3.50 BAR (350 kPa) (51 psi) 1. Battery in a low state of charge can cause problems.
Be sure the battery is in good condition and fully
45 liters/hr charged.
Fuel Pump Volume 325 ml/30 seconds
11 oz./30 seconds 2. Air leaks in intake tract / air box - check for air leaks
0.165 gal/min and repair to avoid mis-diagnosing the EFI system.
Idle Speed 950 rpm ± 100 3. Contaminated or improper fuel.
Not Adjustable (Set by ECM 4. Restricted fuel flow / filters (low fuel pressure).
Fast Idle Speed
/ IAC valve)
5. Fuel tank vent line pinched or obstructed.
Throttle Grip Free-Play 2-4 mm (1/16"-5/32") 6. Faulty spark plug(s).
Fuel Pump Current 7. Corroded, disconnected, or mis-connected wiring.
5A maximum
Draw (Mis-connected wiring after recent service).
Injector Resistance 11.4 - 12.6 Ohms 8. Poor ground connections - be sure all are clean and
tight.
Recommended Octane 91 Octane Minimum
9. Exhaust system restriction or improper exhaust.
NOTE: Idle speed is continuously monitored and
adjusted by the ECM via the IAC valve. DO NOT tamper 10. Engine mechanical condition.
with or attempt to “adjust” the idle stop screw or throttle
plate flow screw! They are factory pre-set. If idle is erratic THROTTLE BODY FLOW SCREW AND
or if idle speed is incorrect, refer to troubleshooting in this IDLE STOP SCREW
section to find the cause of the problem.
DO NOT TAMPER WITH THESE SCREWS!
SPECIAL TOOLS
Throttle body flow and idle stop screws are factory pre-
FUEL SYSTEM SERVICE TOOLS set. Throttle body must be replaced if screw setting is
SPX PART changed.
TOOL DESCRIPTION
NUMBER
Diagnostic Tool Kit - with Digital Wrench
Software PU-47052-C (and license serial
PV-46085
number), Standard Interface Cable PU-
47151, and Victory Adapter PV-46085-2)
SmartLink Interface Kit*
PU-47471
*Kit Includes:
CAN Interface Cable (PU-47469)
Serial Interface Cable (PU-47470) NOT ADJUSTABLE
Fluke 73 Digital Multi Meter PV-43546
Laptop Computer (Commercially
-
Available)
5.4
SERVICE PRECAUTIONS Static electricity can damage the ECM beyond repair. The
human body can easily store enough static electricity to
EFI SYSTEM PRECAUTIONS damage sensitive electronic components. Before working
with any components of the Fuel Injection system, ground
NOTICE: While electronic fuel injection is very durable yourself to dissipate any static charge. Also take care not
and reliable, the components can be easily damaged or to touch any of terminal pins on the ECM.
problems can be introduced if the following precautions
are not observed.
Do not touch ECM connector pins
It is not advisable to “jump start” the machine with another Anti-static wrist strap PV-43541
battery. Although problems are unlikely to occur if every- NOTICE: Some tests require probing of the ECM wiring
thing is done carefully, the possibility of permanent dam- harness connector. Do not touch or probe the exposed
age to expensive electrical component exists. pins on the ECM. Static electricity from your body or the
Never disconnect the battery while the engine is running. meter can easily damage the ECM.
Pay special attention when connecting and disconnecting Always use the proper adapter from the Connector Test
the battery cables. Refer to Chapter 16 for complete Adapter Kit when probing the terminals. Most of the
battery connection and charging information. connectors are sealed and cannot be back probed. Be
extremely careful not damage the connectors by forcing
Before disconnecting or connecting electrical
meter probes into the connectors.
connections, be sure the key switch is off. An even better
practice is to disconnect the battery when disconnecting
or connecting electrical connections.
Fuses and circuit breakers protect critical electrical
components and circuits. Investigate the cause, repair the
problem, then replace the fuse. Never replace the fuse
with a larger value fuse or “jumper” the fuse with wire,
Use proper test adapters on connector pins
aluminum foil or any other means.
Connector test adapter kit PV-43536
Poor connections are the most common cause of
Electronic Fuel Injection malfunctions. Inspect connector
and wiring connections carefully during troubleshooting.
“SNAP”
The ECM is a sensitive piece of electronic equipment.
Dropping it or hitting it may cause irreparable damage.
This is also true for sensors used in the system.
Carefully inspect connections of a failed circuit before

doing any other troubleshooting steps. Wire terminals
must be corrosion free and fully seated. Connectors
should snap together and lock.
Do not drop or strike F.I. components
5.5
FUEL SYSTEM ASSEMBLY VIEWS

FUEL TANK HOSE CONNECTION - 49 STATE MODELS
Over flow Drain Hose and Fuel Tank Vent Inspection - 49 State
1. Remove covers as required (Chapter 3) and disconnect hoses from fittings at right side of fuel tank.
2. Verify hose is clear between cap basin and hose termination point. Verify the vent is clear at each fuel tank.
3. The fuel pump / tank vent line is routed down the left side tank to the evaporator.
5.6
FUEL TANK HOSE CONNECTION - CALIFORNIA MODELS
Purge Valve
(ECM controlled)
Tank Vent Inspection (California Models)

1. Remove covers as required (Chapter 3).
2. Open fuel cap.
3. Disconnect line from fitting on evaporative emissions canister marked “TANK”.
4. Pump low pressure air into canister end of vent hose. Verify air escapes from vent tube (right side). Be sure all
hose connections are secure between canister and fuel tank fitting.
Overflow Drain Inspection

1. Remove covers as required (Chapter 3).
2. Open fuel cap.
3. Disconnect drain hose. Pump low pressure air into bottom of drain hose and listen for air escaping from drain hole
on left side of fuel cap well.
4. Pump low pressure air into bottom of drain hose to check lower hose for obstruction.
5.7
FUEL LEVEL SENSOR / FUEL PUMP / GAUGE TEST
FUEL PRESSURE: 3.50 BAR (350 kPa) (51 psi)

See page 5.20 for pressure test procedure.
Fuel Level Sensor

Resistance Test is on
page 5.17.
Fuel pump connector:
Main wire harness connector pins:

2008-2009 2010
FUEL GAUGE TEST:

To test fuel gauge in the Instrument Cluster:
1. Remove windshield access panel and disconnect pump harness connector.
2. Connect a resistor with a value between 50 and 250 Ohms, across
Pin C (BK/GN) and Pin D (BK/W) of the main harness connector.
3. Turn ignition key ON. Fuel gauge should indicate a fuel level based
on the value of the resistor used.
(Example: a 50 Ohm resistor should read in the FULL range).
5.8
FUEL PUMP AND FUEL TANK ASSEMBLY VIEW
2008-2009 5
CORRECT INCORRECT
Contact
2010  Follow pump installation
procedure page 5.12.
AIR INTAKE / BOX FRAME ASSEMBLY VIEW
Air Intake Silencer - 2010 9.6 Nm

(85 lb-in)
9.6 Nm
(85 lb-in)
Seal
Crankcase
Breather Hose
Main Chassis Harness

Ground Location
Drain Plug
5.9
IDLE AIR CONTROL ASSEMBLY VIEW
Install fitting to depth of paint mark

Do not insert tube too far into tee or elbow,
or the IAC air delivery will be restricted.
9.6 Nm (85 lb-in)
Whenever IAC is disconnected, or after

ECM re-programming (re-flash), cycle the
ignition key ON and OFF a few times (with
kill switch in RUN position) to allow the IAC
valve to learn its “base” position. Wait 5-10
seconds after turning key ON or OFF.
Front
9.6 Nm (85 lb-in)
Detail of IAC Restricted “T” Fitting

Front To Air Box Plugged on 49 State
Connected to Purge Valve on California
To Throttle Body (Rear)
Do not install “T”
Paint mark fitting too deep!
To Throttle
To Throttle Body (Front) Body
Restricted side of “T” must be on purge valve

View From Left Side side (California) or plugged side on 49 State
5.10
FUEL SYSTEM SERVICE 7. WAIT until the ECM centers the IAC valve (the clicking
sound stops) and then wait an additional 10 seconds.
FUEL SYSTEM DEPRESSURIZATION or until you hear a faint single “click” from the relay.
8. Repeat Steps 4-7 about 5 times to complete the
WARNING priming procedure.
9. Turn ignition key OFF when priming is complete.
Allow engine and exhaust to cool completely before
disconnecting fuel line or removing tank. Wear eye NOTE: Fuel level in tank must be high enough to
protection. submerge pickup screen on the pump.
5. Wrap a clean shop towel around fuel line fitting.
FUEL TANK VENT INSPECTION 5
6. Squeeze both release buttons (A) (one on each side
of fitting) and hold; carefully slide fitting from fuel rail. 1. Refer to page 5.6 (49 State) or 5.7 (California) for tank
vent inspection and hose routing information.
FUEL PUMP REMOVAL
WARNING
A
Replace o-ring upon assembly. Review gasoline
warnings on page 5.3.
1. Remove right fairing, and right speaker volume box.

Refer to Chapter 3 for panel removal.
2. Lift tab (A) and separate the pump harness connector.
NOTE: The fuel line can also be removed from the

fitting at the fuel tank end. A
7. Cover fuel fittings to keep debris out of line.
B
PRIMING THE FUEL SYSTEM

Fuel pump prime procedure also serves to center the IAC
C
valve. Prime procedure should be performed:
• If a new fuel pump is installed or if tanks are run

completely dry. A
• Whenever fuel system is serviced (fuel line is
disconnected).
• Whenever battery or IAC is disconnected. 3. Remove fuel vent line from fitting (B). Note orientation
1. Fill the fuel tank. of line on fitting for reassembly.
2. Turn Engine Stop switch OFF. 4. Remove fuel supply line from fitting (C). Note
orientation of line on fitting for reassembly.
3. Turn ignition key ON.
5. Remove all flange screws.
4. Turn stop switch to RUN.
NOTE: Pump assembly is compressed. Spring
5. Allow switch to remain in RUN position until pump pressure will force pump flange up.
stops running (about 2-3 seconds).
6. Turn stop switch OFF.
5.11
6. Carefully remove the pump from the tank by lifting and FUEL PUMP INSTALLATION
turning the assembly 180 degrees, then tilt the
assembly forward and complete pump removal. 1. Prepare fuel tank for assembly by thoroughly cleaning
inside the tank and all sealing surfaces, including the
opening for the pump. Verify pump is ready for
installation with a new sealing o-ring installed. See
“FUEL SYSTEM ASSEMBLY VIEWS” on page 5.6
2. Be sure rubber o-ring (A) is installed as shown, under
the pump mount flange.
A
1
3. Carefully install the pump by compressing the pump

assembly with your hands. With the fuel pick-up and
float pointed forward, tilt the assembly and insert the
pump into the tank. Once the pick-up and float
assembly clear the inside tank wall, rotate the pump
180 degrees to it’s final position and finish pump
installation.
(Cont.)
5.12
5. Compress the pump flange against the tank and o-ring.

If the flange lays completely flat, re-verify the o-ring is
in place and install the flange screws. Torque to
specification using the torque pattern as shown. DO
NOT install or torque the flange screws until the pump
flange is seated completely flat on the tank.
3 A
4
3
5 5
1
2
4
5 68 in. lbs (7.6 Nm)
6. Install harness connector (A), vent line (B) and supply

line (C).
B A
C
4. IMPORTANT - To verify that float is free, lift pump

assembly up and move float arm with your finger inside
the tank. If arm does not move freely it may be caught
under the filter sock. Remove pump, free the float arm
and re-install.
5.13
FUEL TANK ASSEMBLY VIEW
Cap area drain

A
H
47.5 Nm
(35 lb-ft)
Vent (from pump) to canister (CAL)
or atmosphere (49 state)
7.7 Nm (68 lb-in)
D
B
Tank Mount Detail

7.7 Nm (68 lb-in)
H
47.5 Nm
E (35 lb-ft)
G
5.14
FUEL TANK REMOVAL FUEL TANK INSTALLATION

Refer to Fuel Tank Assembly View on page 5.14. 1. Assemble grommets and stepped spacers to LEFT
tank mount holes. See Mount Detail on page 5.14.
2. Install crossover hose (G) securely on LEFT tank. You
should hear an audible CLICK when hose fitting is fully
WARNING seated on fitting.
Review gasoline warnings on page 5.3. Allow engine 3. Position front wheel straight ahead to gain adequate
and exhaust to cool completely before disconnecting clearance for tank installation.
fuels line or removing tank. Drain fuel tanks as
completely as possible before performing removal. 4. Install LEFT tank. Verify spacers and grommets are
still in place on tank mounts and install all mount bolts
5
1. Draw fuel from RH tank through the cap opening using (H) with washers.
a pump designed for fuel transfer. Follow all safety 5. Torque LEFT tank mount bolts to 47.5 Nm (35 lb-ft).
precautions specified by the manufacturer and all fuel
handling precautions in this chapter. Lean motorcycle 6. Route and attach vent line (D) to LEFT tank. Be sure
toward right side to allow fuel from left tank to transfer it is secured fully onto the fitting with an audible CLICK.
to the right when draining.
7. Assemble grommets and stepped spacers to RIGHT
2. Remove fuel tank covers (page 3.21). tank mount holes. See Mount Detail on page 5.14.
8. Have mounting bolts accessible for installation. DO
3. Remove side covers (page 3.27). NOT support weight of tank with crossover hose after
connecting the hose in the next step.
4. Depressurize fuel system (page 5.11).
9. Install RIGHT tank to frame, guiding crossover hose
5. Disconnect drain hose (A) from fuel cap basin (not onto lower fitting. Push bottom of tank inward firmly
required for tank removal). until crossover hose is fully seated on fitting, listening
for an audible CLICK.
6. Disconnect fuel pump / level sensor wire harness.
10. Verify spacers and grommets are still in place on tank
7. Disconnect fuel supply line (B) and vent line (C) from mounts and install all mount bolts (H) with washers.
fuel pump. 11. Torque RIGHT tank mount bolts to 47.5 Nm (35 lb-ft).
8. Disconnect tank vent line (D) from RIGHT tank. 12. Attach vent line (D) to RIGHT tank fitting. Be sure it is
secured fully onto the fitting with an audible CLICK.
9. Remove rivet (E) and pull hose shield (F) to remove.
13. Install crossover hose shield (F), engaging clips of
10. Disconnect one end of tank-to-tank crossover line (G). shield to bar of support frame. Align hole of shield with
hole in main frame and install rivet (E).
11. Remove two of the three mounting bolts (H) from tank
to be removed. Leave one bolt loosely in place. 14. Connect wire harness to fuel pump.
15. Connect vent line (C) to fuel pump.
12. Position front wheel straight ahead to gain adequate
clearance for tank removal, remove last bolt and tank. 16. Route and connect fuel supply line (B) to pump and rail.
13. Clean up any fuel spills immediately. 17. Connect drain hose (A, if removed) to fuel cap basin.
14. Remove remaining tank. 18. Refer to Chapter 3 for tank cover, panel, and side cover
installation.
19. Add fuel to tank and check carefully for leaks.

20. Prime fuel system page 5.11.
5.15
FUEL PUMP CIRCUIT DIAGRAM

ECM Connector
(Under Seat)
RH Switch Connector
(Under Console)
(In Fuse Box)
Engine Harness Connector

(Under Left Side Cover)
Fuel Pump / Level Sensor

Connector
(Top of RH Fuel Tank)
FUEL PUMP RELAY
To test pump and wiring between tank

and relay, perform a current draw test
(page 5.19).
RIGHT SIDE FUSE BOX.

(Under Windshield Access Panel)
NOTE: Identical relays in fuse box can be swapped for test purposes.
5.16
FUEL LEVEL SENSOR RESISTANCE TEST

OVERVIEW OF OPERATION: The fuel level sensor is a
mechanical float arm located on the fuel pump inside the
fuel tank. Circuit resistance determines the reading on the
fuel gauge located on the instrument panel.
When the fuel level indicated on the fuel gauge is below

FULL: 50
1/4 tank, a LOW FUEL warning icon lights up on the
information display.
Follow the steps below to test the sensor circuit with an

ohmmeter.
5
EMPTY: 250
Main system connectors are located at the back of the
instrument cluster and on top of the right fuel tank (at the
fuel level sensor / fuel pump connector).
1. Remove the windshield access panel and right fairing

(Chapter 3).
2. Disconnect the fuel level sensor / fuel pump connector
located on top of the right fuel tank. FUEL LEVEL GUAGE
3. Set multimeter to measure resistance.
Refer to page 5.8 for Fuel Level Gauge test. Refer to
Chapter 19 for Instrument Cluster information.
4. Attach the meter leads to pin C and pin D of the 4- pin

connector out of the fuel pump. Estimate the fuel level
in the tank and compare resistance reading to the table
below.
Resistance Measured
Approximate
From Pin C to Pin D in
Resistance
4-Pin Connector
FULL (Sensor Arm Up)

Sensor Resistance 50  +/- 3 
(Room Temperature) EMPTY (Sensor Arm Down)
250  +/- 5 
5.17
FUEL PUMP ELECTRICAL DIAGNOSTICS
FUEL SYSTEM
Fuel Pump Pressure 3.50 BAR (350 kPa) (51 psi)
Fuel Pump Volume 60-80 liters/hr @ 12VDC
Fuel Pump Current Draw Less than 5 amps @ 12.0 VDC
NOTE: When ignition switch is turned ON and Engine Stop switch is in the RUN position, fuel pump will run
momentarily (about 2-3 seconds). Key or Engine Stop switch must be turned OFF for at least 5 seconds (there
may be an audible click as the relay re-sets) before fuel pump will cycle again. Fuel pump will not cycle again
if switch is turned on and off too quickly.
FUEL PUMP SUPPLY VOLTAGE TEST BATTERY VOLTAGE NOT REACHING FUEL
1. Disconnect fuel pump / level sensor
PUMP
harness.page 5.17. 1. Check fuel pump / ignition fuse. If open (blown)
2. Set meter to DCV. Connect red meter lead (+) to pin A visually inspect circuit wiring for shorts to ground and
(on wire harness side of connector) and black (-) meter then perform fuel pump current draw test on
lead to pin B (ground). page 5.19.
2. If fuse is OK, remove fuel pump relay and check for
Pin A battery voltage on the Orange wire (relay terminal 30).
(Violet/Yellow wire) If power is present, carefully connect a jumper wire
diagonally across the fuel pump relay contacts from
terminal 30 to terminal 87 (OR to VIO/Y).
CAUTION
DO NOT apply battery power to terminal 85 of the relay
(Gray wire) or ECM damage will result!
3. If pump runs when powered directly in Step 2, swap

Pin B
fuel pump relay with another identical relay, turn
(Ground wire)
Fuel Pump Connector (Main Harness Side) ignition key ON and cycle key/stop switch to test. If
pump runs when key/kill switch is cycled replace faulty
relay. Wait at least 30 seconds with key OFF before
3. Turn Engine Stop switch to RUN. repeating the test.
4. Turn ignition key ON and read DC voltage on meter 4. If pump does not run with relay swapped and key / stop
when key is first turned on. Voltage reading on pin A switch cycled (but ran in Step 2) check for battery
(Violet/Yellow) should be equal to battery voltage for voltage on Red/Black wire (terminal 86) at pump relay.
2-3 seconds after turning key ON.
5. If there is no battery voltage on terminal 86 (with
5. If low or no voltage is delivered to the fuel pump, verify ignition key ON and Engine Stop switch to RUN) refer
ground wire (Pin B, Black) has good continuity to to the wiring schematic to trace power path through
battery (-) post. If ground is OK, check Gray wire from ignition switch and Engine Stop switch (Orange to
fuel pump relay the Engine-Chassis harness Pink, and Pink to Black / Red leading to relay.
connector (under left side cover) and from there to
ECM pin #28. This Gray wire receives a momentary (Cont.)
ground from the ECM (for 2-3 seconds) and activates
the fuel pump relay which supplies power to the pump
on the VIO/Y wire. Trace the power and ground circuits
to determine fault if battery voltage is not present for
2-3 seconds.
5.18
BATTERY POWER TO FUEL PUMP (Cont.) 4. Insert one meter lead in pin socket (30) and other meter
lead in pin socket (87) of relay block. These terminals
6. If there is battery voltage on terminal 86, check are the farthest apart diagonally in the relay socket.
continuity on gray wire from fuel pump relay (terminal
85) to Engine Harness Connector pin E, and from pin
E to ECM pin 28 in ECM connector. The ECM grounds
the pump relay through ECM pin 28 for 2-3 seconds
when key switch and stop switch are first turned ON.
The ECM maintains this ground connection after
30
engine start-up. Ground Gray wire to bypass ECM
ground.
5
FUEL PUMP CURRENT DRAW TEST 87

OVERVIEW OF TEST: Fuel pump current draw is a good
indicator of fuel pump condition. Perform the following
test if fuel pump operation is suspect, or if fuel pump fuse
5. Read fuel pump current draw on meter and compare
is found to be open (blown).
to specification.
CAUTION
DO NOT apply battery power to terminal 85 of the relay
(Gray wire) or ECM damage will result!
5A
NOTE: When meter leads are inserted the pump will
run, and current draw will be displayed on the meter,
even with key and stop switch off. Fuel tank must
have enough fuel in it to cover the fuel pickup screen
for an accurate test.
1. Remove the windshield access panel and right fuse

box cover.
2. Remove fuel pump relay (A) by pulling straight upward.
6. Inspect fuel pump circuit wiring or replace fuel pump if
current draw exceeds specification.
Pump relay removed
SPECIFICATION: Fuel Pump Current Draw
Maximum: 5 DC Amps
3. Set meter to DC Amps. Be sure red meter lead is

inserted in AMP 10A jack, and black meter lead is in
common (-) jack.
5.19
FUEL PUMP PRESSURE INSPECTION Fuel Pressure Gauge: PU-43506-A
WARNING
Attach gauge to valve
GASOLINE A
Gasoline is extremely flammable and is explosive
under certain conditions. Work in a well ventilated
area. Open flames, sparks and cigarettes must be
kept away from gasoline. KEEP GASOLINE OUT OF
THE REACH OF CHILDREN! B
CAUTION
Wear safety glasses or a face shield when working
around the fuel system to protect your eyes.
1. Remove the cap from test fitting and attach fuel 2. Start engine and record fuel pressure (or cycle ignition
pressure gauge. key and Engine Stop switch to read pressure when
pump cycles for 2-3 seconds).
Fuel pressure 3.50 BAR (350 kPa) (51 psi)
3. Turn ignition switch off. Disconnect gauge and install

cap on fitting. Start engine and inspect for fuel leaks.
FUEL PRESSURE TROUBLESHOOTING
FUEL PRESSURE TOO LOW: INSPECT FUEL PRESSURE TOO HIGH: INSPECT
Low fuel level (add fuel) Plugged fuel return (in tank on pressure regulator)
Pump not running (Fuel pump or circuit malfunction) Pressure regulator malfunction (located on pump in
fuel tank).
Restricted fitting, fuel supply line, or gauge adapter hose
Fuel line kinked or restricted (from tank fitting to rail)
Fuel line leaking (leaking air in or fuel out)

Vent restriction
Plugged fuel filter (located in fuel tank)
Pressure regulator malfunction (located on pump in fuel
tank)
Fuel pump malfunction (Pump should run for about 2
seconds the instant that the key switch and Engine Stop
switch are turned ON.
5.20
IDLE AIR CONTROL REMOVAL 7. Disconnect primary wire harness from coil.
Also refer to IAC Assembly View on page 5.10.
1. Remove RH cover and IAC cover (page 3.6).

2. Remove wire dart (A).
3. Push tab (B) to disconnect IAC harness.
4. Remove (4) IAC bracket screws (C) using a 5mm ball
drive hexagonal socket.
5
C
A
B
8. Push tab on ignition switch connector and remove
bracket with switch attached.
9. Remove air supply hose from air box, the front air
delivery hose, and the rear air hose with “T” fitting from
throttle body.
NOTE: Restricted side of tee fitting faces purge valve
on California models. On 49 state models, the
5. Remove high tension leads from coils. restricted side of the tee fitting is plugged (F).
NOTE: The front HTL is routed behind the ignition
switch cover, not above it upon assembly. F
6. Remove (4) screws (E) at the corners of the bracket

with a 5mm ball drive hexagonal socket.
5.21
EFI SYSTEM COMPONENTS

FUEL INJECTION COMPONENT LOCATIONS
Idle Air Control (IAC) Fuel Pump (with pressure regulator and filter)
ECM Located inside RH fuel tank
Under IAC cover
Under seat
Throttle Body &
Fuel Injectors
Fuel Line / Fuel Rail

(pulse damper on RH side of fuel rail)
Tipover Sensor (2009 +) Crank Position Sensor

TMAP Sensor Right side under timing cover
Right side rear cylinder intake port
Throttle Position Sensor (TPS)
Left side of throttle body
Air Cleaner
Evaporative Emissions Canister

(California Models)
Battery &
40 amp Circuit Breaker
(Front of battery box)
Diagnostic Port
Engine Temperature Sensor (CHT)
In LH saddlebag
Front cylinder head, left side
5.22
FUEL RAIL / FUEL INJECTOR REMOVAL FUEL RAIL INSTALLATION

1. Remove leg fairings (page 3.12). 1. Install new O-rings on each injector and lubricate with
2. Remove ignition coil with bracket (page 17.12) and engine oil. (Note: Service O-rings are the same color
IAC bracket assembly with hoses (page 5.21). and suitable for use on bottom and top of injector).
3. Remove fuel rail screws (A) and four intake manifold 2. Install retainer clips fully onto each injector. Be sure
screws (B). clips are fully seated in the groove.
B 3. Install injectors in cylinder heads with rear connector

facing straight rearward and front facing straight
forward. Press firmly to seat. Remove protective cover.
5
Rearward Forward
A
Rear Front
4. Install fuel rail and place in position on top of injectors.

4. Remove throttle cables and cruise control cable. Press rail over each injectors evenly until retaining
5. Push throttle body and air box seal up into frame to clips “click” into place on the rail. Be sure rail is seated
provide as much clearance as possible for injector completely and clips are engaged in the groove.
removal. Align injectors carefully before
6. Remove red lock tab from each injector harness installing the fuel rail.
connector.
5. Install fuel rail retaining screws and torque to 85 in. lbs.

(10 Nm).
6. Install wire harness on each injector and then install the
lock clips. Secure wires with new tie straps where any
7. Press tab to remove harness from each injector. were removed.
8. Slide fuel rail retaining clip back until rail is released 7. Assemble remaining parts in reverse order and prime
from injector, or remove them completely. the fuel system (page 5.11).
9. Lift fuel rail off injectors and remove rail from the right
side.
10. Cover the ends of injectors and fuel rail with plastic
wrap to prevent contamination.
11. Clean the area around injectors with compressed air
to prevent foreign material from entering the engine.
Pull injectors out of cylinder heads, keeping them in
order (front and rear) for assembly.
5.23
FUEL INJECTION SYSTEM TESTING IDLE AIR CONTROL (IAC) - OVERVIEW OF

AND DIAGNOSTICS OPERATION
The Idle Air Control system consists of the Engine Control
FUEL INJECTION SYSTEM - OVERVIEW OF Module (ECM), IAC valve, air supply hose, two air delivery
OPERATION hoses, and related wiring between ECM and IAC valve.
The Electronic Fuel Injection (EFI) system functions to (See IAC Assembly View on page 5.10).
provide the engine with precisely metered fuel under The IAC valve is located behind the triangular cover on the
varying loads and conditions. right side of the throttle body. Its main function is to
stabilize the engine’s base idle speed by varying the
The Engine Control Module or “ECM”, is located under amount of air allowed to the engine when the throttle
the seat. It is programmed to provide the proper fuel and plates are closed. The air is regulated by main and trim
ignition timing based mainly on primary inputs of engine valves located inside the IAC valve body.
RPM and the Temperature and Manifold Absolute
The ECM continuously monitors engine RPM, and
Pressure (TMAP) sensor inputs. The ECM evaluates
changes the position of IAC air valves (via step motors) to
other minor sensory information received from various
maintain idle speed between (approx) 900-1000 RPM.
sensors in the EFI system, and also provides grounds or
voltage to other EFI related circuits of the electrical and Filtered air from the air box is delivered to the IAC valve
fuel delivery systems. body through a supply hose on the lower left side of the air
box, then distributed to front and rear cylinder throttle
A Throttle Position Sensor (TPS) is mounted on the left bodies through separate delivery hoses.
side of the throttle body. The TPS is not a primary input IAC CYCLING - Whenever the IAC wire harness is
for air flow information in the closed loop system. It mainly disconnected, or after ECM re-programming (re-flash)
provides “rate of change” feedback to the ECM (such as cycle the key switch on and off so the IAC valve can “learn”
rapid acceleration) and also serves as a plausibility check its position. Wait 5 seconds after turning the key ON. The
for the TMAP sensor. The MAP portion of the TMAP system requires no scheduled maintenance beyond visual
sensor is the primary air flow and load sensing device. inspection to ensure all hoses and electrical connections
are tight. NEVER attempt to “adjust” idle speed with the
An electric fuel pump, mounted inside the fuel tank
throttle stop screw or flow balance screw located on the
supplies fuel pressure to the injectors continuously when
throttle body. These screws are factory pre-set. Any
the engine is running or cranking. A pressure regulator
tampering will require throttle body replacement.
incorporated on the pump keeps fuel pressure steady at
approximately 50 PSI (3.44 Bar). The fuel pump cycles
“ON” for 2-3 seconds when the ignition key and Engine
SELF-DIAGNOSTIC FEATURE
Stop switch are turned on to pressurize the system for The ECM used on the Victory motorcycle stores trouble
start-up. codes in memory. Trouble codes are stored by the ECM
The fuel injectors inject fuel when they are grounded by when a sensor reading is outside of the normal or
drivers inside the ECM. The duration of the injector pulse “plausible” range. These codes are listed and described
(length of time the injector circuit is grounded) is on page 5.27. The ECM is located under the seat.
controlled by the ECM. Pulse duration determines the When a fault occurs, the ECM records a code in the
amount of fuel delivered to the engine (longer cycles = “Logged Faults” memory. If a fault is currently active, the
more fuel). The ECM selects the correct amount of fuel code is also recorded in the ECM “Current Faults”
injector cycle time by referencing a three dimensional fuel memory and remains until the fault is no longer occurring.
“map”. Simplified, each reference point on the map If the problem is corrected, the “Current Fault” is erased,
represents a different amount of time. but the code remains in the “Logged Faults” memory until
Although TMAP and engine RPM are the most influential it is manually deleted (cleared) using Digital Wrench
inputs for selecting a map reference point, the ECM also software. Logged faults remain even if the battery power
evaluates feedback from minor sensors in the system, to is removed from the ECM.
obtain a more accurate “picture” of the fuel needs at any
Digital Wrench diagnostic software is the tool used to
given moment.
interface with the EFI system by coupling to a diagnostic
port located under the left saddlebag door. Whenever
The locations of sensors and other EFI system related
components is shown on page 5.22. available, Digital Wrench should always be connected
to a vehicle for more accurate problem diagnosis.
5.24
ECM CONNECTOR MAP

Refer to page 5.29 to remove connector from ECM.
Slide Latch
TOP VIEW - ECM CONNECTOR (WIRE SIDE SHOWN)

5

FRONT (BOOT AND WIRE COVER REMOVED)

Note: Touch pins with probes, do not force probe into connector pin.
FUEL SYSTEM RELATED ECM CONNECTOR MAP

(System related wire color & pin number shown. Refer to wiring diagram for complete connector diagram).
Some open pin connector positions are included for clarity.
1 3 6 7 8 9 16 19 23 24 25 26 27 28
VIO/PK W / BK BU / PK BU / W BU / OR BU / R OPEN BU OPEN W / BU W / GY OPEN GY
VPWR #2 IGN IAC IAC IAC IAC CANIST INJECTOR INJECTOR FUEL PUMP
COIL PWR STEPPER STEPPER STEPPER STEPPER PURGE 1 2 RELAY GROUND
MOTOR 1 MOTOR 2 MOTOR 3 MOTOR 4 VALVE ECM CONTROLLED
BN = Brown; GN = Green; BK = Black; GY = Gray; PK = Pink; R = Red; VIO = Violet; W = White; Y=Yellow;
OR = Orange; BU = Blue
31 33 36 37 38 39 40 46 49 53 54 55 56 57 58
VIO/PK BK / W GY / R GY / BU OR / GN OR / BU OR / W BN / BU OPEN OR / Y OR / BN BN / R OPEN R BK
ECM #1 (FRONT) #2 (REAR) INTAKE CYLINDER TIPOVER SIGNAL TPS MAP +5
VPWR GROUND O2 O2 AIR TEMP HEAD SENSOR RETURN REFERENCE CPS + CPS -
SENSOR SENSOR TEMP (2009) VOLTS
VERIFY TERMINAL PINS ARE NOT LOOSE IN CONNECTOR AND WIRE CONNECTION TO TERMINAL PIN IS
SECURE.
CHASSIS TO ENGINE HARNESS CONNECTOR (14 PIN)

Some sensor tests refer to the Engine Harness Connector (A)
located behind the left side cover.
A
Read ECM CONNECTOR REMOVAL procedure on page 5.31
before attempting to remove the ECM connector.
5.25
VIEWING AND CLEARING TROUBLE CODES SENSOR DIAGNOSTICS - IMPORTANT

INFORMATION TO UNDERSTAND BEFORE
Trouble codes are logged in the ECM memory when a
sensor or other supported system fault occurs. To view
YOU BEGIN
the codes, do the following:
If a sensor fails or reads outside a “normal” range, a “pre-
programmed” (default) value is substituted by the ECM
Viewing Trouble Codes
until sensor reading returns to normal.
1. Connect the Digital Wrench™ diagnostic software and
establish communication with the ECM. Sensor values can be viewed in Digital Wrench™ on the
2. Select the icon to display loaded trouble “Sensor Data Grid Or Graphs” screen. HOWEVER, the
code(s). sensor reading may be actual feedback from the sensor,
or it may be the default value set by the ECM in the event
3. The codes are classified as Current or Historical. of a fault in the sensor or wiring.
Current codes are occurring at the moment. Historical
codes are not occurring at the moment but have The check engine (“ENG”) warning may or may not
occurred in the past. A list of codes is on page 5.27. illuminate to alert the rider of a possible problem,
Clearing Trouble Codes depending on the system fault. Following a check engine
light, perform a visual inspection to see if a cause can be
4. Click on the “Clear Trouble Codes” icon to clear trouble determined.
codes.
Connect the Digital Wrench™ to see what codes are
present in memory, and focus your diagnostics on that
sensor and the related wiring for that circuit. (Refer to
wiring diagrams for ENG light circuits.
If multiple codes are set, refer to the wiring diagram and

focus your efforts on wiring and connections common to
each of the sensors. Multiple sensor failure is extremely
unlikely.
The sensor tests described in this section are performed

at the ECM wire connector. This method ensures that the
data from a sensor is reaching the ECM. Sensor tests can
be performed at the sensor if easily accessible, but the
wiring between the sensor and the 60 pin ECM connector
should always be closely examined and tested if the
sensor itself passes the test.
Poor or corroded connections are the most common

cause of system faults. Always check the integrity of the
male pins and female receptacles of the connectors in the
affected circuit. These may include the sensor connector,
the ECM connector, and any in between the two such as
jumper harnesses or the Engine-to-Chassis harness 14
pin connector where applicable.
5.26
TROUBLE CODES
Access codes by clicking on the icon on the Digital Wrenchdiagnostic screen.

Refer to Digital Wrench guided diagnostics for detailed P-code description and
Code Access Icon troubleshooting. See page 5.28 for description of FMI / SPN codes and where they appear.
P-CODE BLINK
NUMBER SPN FMI DESCRIPTION
CODE
P0107 Manifold Absolute Pressure sensor circuit voltage low - MAP portion of TMAP sensor
45 102 4
circuit is open, or shorted to ground.
P0108 Manifold Absolute Pressure sensor circuit voltage high - MAP portion of TMAP sensor
46 102 3
circuit is shorted to battery voltage. 5
P0112 Intake Air Temperature Sensor voltage low - Temperature portion of TMAP sensor circuit is
41 105 4
shorted to ground.
P0113 Intake Air Temperature Sensor voltage high - Temperature portion of TMAP sensor circuit
41 105 3
is open, or shorted to battery voltage.
P0117 42 110 4 Cylinder Head Temperature (CHT) Sensor voltage low - circuit shorted to ground.
P0118 Cylinder Head Temperature (CHT) Sensor voltage high - circuit open, or shorted to battery
42 110 3
voltage.
P0122 22 51 4 Throttle Position Circuit voltage low - TPS open, or shorted to ground.
P0123 22 51 3 Throttle Position Circuit voltage high - TPS shorted to battery voltage.
P0171 34 520204 17 Fuel Correction - system too lean Cyl 1 (Front).
P0172 34 520204 15 Fuel Correction - system too rich Cyl 1 (Front).
P0174 35 520205 17 Fuel Correction - system too lean Cyl 2 (Rear).
P0175 35 520205 15 Fuel Correction - system too rich Cyl 2 (Rear).
P0217 - 110 16 Engine Temperature Sensor - temperature too high.
P0231 56 1347 5 Fuel Pump Driver Circuit - open or shorted to ground.
P0232 56 1347 3 Fuel Pump Driver Circuit - shorted to battery +.
P0261 51 651 5 Injector 1 (Front Cylinder) driver circuit open or shorted to ground.
P0262 51 651 3 Injector 1 (Front Cylinder) driver circuit shorted to battery voltage.
P0264 52 652 5 Injector 2 (Rear Cylinder) driver circuit open or shorted to ground.
P0265 52 652 3 Injector 2 (Rear Cylinder) driver circuit shorted to battery voltage.
P0336 Crankshaft Position Sensor fault - missing tooth signal not detected in CPS signal within the
44 636 8
correct period of time.
P0443 82 520202 3 Canister Purge Valve - driver circuit short to battery +.
P0444 82 520202 5 Canister Purge Valve - driver circuit open or grounded.
P0503 26 84 2 Vehicle Speed Sensor - data erratic, intermittent, or missing.
P0508 47 520193 5 Idle Air Control (IAC) circuit or IAC motor shorted to ground.
P0509 47 520193 11 Idle Air Control (IAC) circuit or IAC motor open or shorted to battery voltage.
Idle Air Control (IAC) position out of range. Note: Low battery or system voltage can also
P0519 47 520193 7 cause P0519 to appear as a historical code. If code appears as historical and the MIL light
is not on (and no running condition problem exists), clear the code, charge battery and re-test.
P0562 System Voltage Low - System voltage too low after the engine has been running for a specific
31 168 4
period of time.
P0563 31 168 3 System Voltage High - System voltage above allowable limit.
P0914 72 523 2 Gear Position Sensor Signal - signal fault
P0916 72 523 4 Gear Position Sensor Signal - voltage too low
P0917 72 523 3 Gear Position Sensor Signal - voltage too high
P1217 - 110 0 Engine Temperature Sensor - engine overheat shutdown. (2009 only)
TABLE CONTINUED ON FOLLOWING PAGE
5.27
P-CODE BLINK
NUMBER SPN FMI DESCRIPTION
CODE
P1351 36 1268 5 Ignition Coil Primary Driver Cyl 1 (Front) - driver circuit open or grounded
P1352 37 1269 5 Ignition Coil Primary Driver Cyl 1 (Front) - driver circuit short to battery +
P1353 36 1268 3 Ignition Coil Primary Driver Cyl 2 (Rear) - driver circuit open or grounded
P1354 37 1269 3 Ignition Coil Primary Driver Cyl 2 (Rear) - driver circuit short to battery +
P1501 64 520200 2 Tipover Sensor (Rollover) - signal fault.
P1502 64 520200 4 Tipover Sensor (Rollover) - voltage low.
P1503 64 520200 3 Tipover Sensor (Rollover) - voltage high.
P1504 64 520200 14 Tipover Sensor (Rollover) - tipover condition detected.
P1651 55 1213 5 Check Engine Lamp (MIL) - MIL lamp driver circuit open or shorted to ground.
P1653 55 1213 3 Check Engine Lamp (MIL) - MIL lamp driver circuit shorted to battery voltage.
P1710 - 2369 5 Right Turn Indicator Driver Circuit - driver circuit open / grounded. (2009/2010 only)
P1711 - 2369 3 Right Turn Indicator Driver Circuit - driver circuit shorted to battery + (2009/2010 only)
P1714 - 2367 5 Left Turn Indicator Driver Circuit - driver circuit open / grounded. (2009/2010 only)
P1715 - 2367 3 Left Turn Indicator Driver Circuit - driver circuit shorted to battery + (2009/2010 only)
SPN / FMI ERROR CODES

If the CHECK ENGINE (MIL) light is ON, an ERROR
message will appear after the normal LCD Information
Display functions (Miles, Trip 1, Trip 2, Miles per Gallon,
Average Speed, etc.). Use the MODE button to toggle
through the various normal display options and view the
ERROR message at the end.
The ERROR message will appear as a 2-part message

consisting of an FMI and SPN number.
Example: ERROR 14 - 520200 corresponds to FMI 3 /

SPN 520200 (and Trouble Code P1504) in the table
above for this combination. The best course of action is to
connect Digital Wrench to view logged codes directly and
use the guided diagnostics for that code; however, if
Digital Wrench is not available you can use the
description of the FMI / SPN code to determine which
system or component may be causing the code by
reading the description from the table.
NOTE: These “ERROR” codes are not stored in the

Information Display. The error screen will only appear
when the Check Engine light is ON*. If the key is turned
OFF, the code and message is lost, but will reappear if
the fault is still present after re-starting the engine.
*SPN 520193 / FMI 7: This code can appear on the

display if battery / system voltage falls below a set
minimum. If this code appears (due to low voltage) the
MIL light will not appear. See Description for Trouble
Code P0519 on page 5.27 and page 5.36.
5.28
ECM HARNESS CONNECTOR TEST ECM CONNECTOR REMOVAL

PRECAUTIONS
NOTICE: Tests in this section may require reading NOTICE: The lock lever also serves as an eject / install
resistance and voltages at ECM connector. Once ECM mechanism for the 60 pin connector. When removing or
connector has been removed from the ECM: installing the connector, you should pull or push lightly on
the connector while sliding the lock lever to assist the
• Do not touch pins on the ECM. Static electricity mechanism, keeping the connector perfectly straight with
from your body can damage the ECM. the ECM to prevent ECM pin or connector block damage.
• Do not attempt to perform tests on the ECM unit. 2. Be sure the connector area is dry and clean.
• Always use the appropriate test connector from the
Electrical Connector Test Adapter Kit (PV-43526).
3. To disconnect ECM 60-pin connector: 5
• Guide the connector and pull lightly with one hand
• DO NOT attempt to use a standard meter probe or while sliding the lock lever outward (toward the
other devices to probe the sockets in the ECM right side of the vehicle).
connector. Doing so could expand the terminal
socket or damage the connector case, create a • Pull the connector straight out of the ECM.
problem where none existed before, and
complicate the diagnostic process.
• Sensor tests on the following pages can often be
performed at the sensor connector itself or at the
ECM connector based on accessibility of the
connector or wiring.
• If you perform the test at the sensor and it tests
within the specified range (OK), you should then
test the circuit wiring, which usually originates at
the ECM 60-pin connector, but may include other ECM Ground
connections such as the Engine-to-Chassis
harness 14 pin connector (located under the seat).
Be sure to check all easily accessed connectors
and wiring first, to reduce diagnostic time
ECM Connector Installation

1. Carefully align the ECM connector straight with the
flange on the ECM. (Do not tip or rotate the connector
into the ECM).
2. Gently apply straight inward pressure on the connector
while sliding the lock lever inward until the lever stops
and the connector is fully seated.
ECM REMOVAL
2. Disconnect the harness from the ECM (page 5.29).
3. Remove the mounting screws. Note the washer placed
between the ECM and the support plate, and also the
location of the ground wire for installation.
5.29
EFI SENSOR CIRCUIT WIRING DIAGRAMS
NOTE: IAC diagram is on page 5.47
FUEL INJECTORS
W / BU
W / BK
VIO / PK
FUEL PUMP
OR / GN
BN / BU
INTAKE AIR TEMP

BN / R
MANIFOLD ABSOLUTE
PRESSURE (MAP)
OR / BN
GY / R
GY / BU OXYGEN SENSOR
(BK wire to sensor)

Disconnect at wire
connector not at sensor.
5.30
EFI SENSOR CIRCUIT WIRING DIAGRAMS
NOTE: IAC diagram is on page 5.47
CRANKSHAFT POSITION
SENSOR
R
5
Shield
BK
OR / BU
CYLINDER HEAD TEMP

(CHT)
BN / BU
BN / R
BN / BU THROTTLE POSITION
SENSOR (TPS)
OR / Y
BK / W
VIO
DIAGNOSTIC CONNECTOR
Y
GN
5.31
SENSOR TESTS
THROTTLE POSITION SENSOR (TPS) DIAGNOSTICS
FAIL CODE: P0122 / P0123

INDICATES INSPECT LOCATION
Voltage received at ECM from TPS is outside of Resistance readings at ECM connector. Left side throttle
parameters. This test inspects TPS and wiring. body
To view and clear trouble codes refer to page 5.26. See page 5.31 for wire colors / pin number in connector.
1. Disconnect ECM 60 pin connector (page 5.29). 4. If results are outside of specifications, disconnect TPS.
2. Attach test lead adapters to meter leads and set DMM 5. Inspect wires for continuity from ECM connector to
selector to measure resistance. TPS connector. If any wire has no continuity or high
resistance, inspect wire harness.
3. Place test leads in open side of connector (not the
ECM) as indicated in chart below. 6. If good continuity exists, test TPS separately. Compare
to chart below.
TOP VIEW - ECM CONNECTOR (Wire side is shown - perform tests on other side)
Slide Latch

(BOOT AND WIRE COVER REMOVED)

FRONT Note: Touch pins with probes, do not force probe into connector pin.
METER TEST SPECIFICATIONS

COMPONENT
SETTING CONNECTIONS (+ 10%)
TPS signal (OR / Y) to +5 VDC 1000 - 5000 Ohm +/- 1K Ohm. Resistance changes
OHMS Pin #53 to #55
reference voltage (BN/R) smoothly as throttle is opened and closed. No gaps.
TPS signal (OR / Y) to signal 1000 - 5000 Ohm +/- 1K Ohm. Resistance changes
OHMS Pin #53 to #46
return (BN/BU) smoothly as throttle is opened and closed. No gaps.
TPS +5 VDC ref wire (BN/R) to 1000 - 5000 Ohm +/- 1K Ohm.
OHMS Pin #55 to #46
signal return (BN/BU) NOTE: Reading does not change with throttle position
Red DMM lead to
Re-connect ECM 60 pin connector. Disconnect TMAP
pin 3 of TMAP
+5 VDC reference voltage (BN/R) DC Volts sensor connector at the sensor. Turn key and stop switch
sensor. Black to
ON. Verify 5 Volts DC present at pin 3 of connector.
ground.
NOTE: Resistance readings may vary slightly from vehicle to vehicle. The important thing to remember when
testing the TPS is to look for a smooth, uninterrupted sweep between closed and open throttle. Sweep can
also be checked using Digital Wrench™ diagnostic software.
5.32
TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) DIAGNOSTICS
FAIL CODE: P0107 / P0108 (MAP SENSOR COMPONENT OF TMAP SENSOR)

COMPONENT AFFECTED: Manifold Absolute Pressure Sensor
INDICATES INSPECT LOCATED
Continuity of wires from ECM connector to TMAP connector at sensor.

Voltage received Check for +5 DCV at TMAP sensor BN / R wire (ECM connector attached and On rear
at ECM from MAP Ignition key and stop switch ON.) cylinder head
sensor is outside
intake port.
5
of parameters. Connect Digital Wrench for MAP sensor test. Approximate voltage examples:
~ 0.6 V @ 30 kPa
~ 1.0 V @ 50 kPa
1. Disconnect ECM 60 pin connector (page 5.29).
2. Disconnect TMAP sensor connector (push black tab).
3. Attach test lead adapters to meter leads and set DMM to measure resistance.
4. Place test leads in open side of connector (not the ECM) and measure resistance of each wire to the TMAP sensor
connector. Verify good continuity on each wire (example: pin 53 of ECM connector to pin 4 of the TMAP connector
should have less than .5 Ohm resistance).
5. Re-connect the ECM connector.
6. Turn key ON and turn engine stop switch to RUN.
7. Set DMM to measure DC Volts.
8. Test for 5VDC reference voltage at connector (see test in table below).
9. Check the MAP Sensor Volts and pressure in Digital Wrench. Voltage should be approximately 0.6 V @ 30 kPa,
(approximately 1.0 V @ 50 kPa), etc.
TMAP Sensors
OR / GN
2008= 250 kPa
BN / BU 2009 / 2010 = 115 kPa
Do not interchange.
BN / R
OR / BN

COMPONENT
SETTING CONNECTIONS (±10%)
Re-connect ECM 60 pin connector.
Disconnect TMAP connector from
Red DMM lead to sensor. Turn key / stop switch ON. Verify
+5 VDC reference voltage (BN/R) to TMAP pin 3 of TMAP. 5 Volts DC present at pin 3 of connector.
DC Volts
connector. Black DMM lead to If Code 107 (Low voltage to MAP) code is
ground. present, jump pin 3 (5 V ref) to pin 4
(sigrtrn). Does code go out? If yes,
replace MAP Sensor. If no, check wiring.
5.33
AIR TEMPERATURE SENSOR (ATS) DIAGNOSTICS

COMPONENT AFFECTED: Air Temperature Sensor
INDICATES INSPECT LOCATED
Voltage received at ECM Resistance readings at ECM connector (ECM disconnected). On rear cylinder head
from ATS is outside of This test will inspect wiring, connectors, and Air Temperature intake port
parameters. sensor resistance. (in TMAP sensor).
1. Disconnect ECM 60 pin connector (page 5.29). 5. If reading is outside of specifications, disconnect air
temperature sensor connector and verify wires have
2. Attach test lead adapters to meter leads.
good continuity back to the 60 pin connector.
3. Set DMM to measure resistance.
6. If wiring is correct, measure the sensor resistance
4. Place meter leads in pins 38 and 46 of connector (not directly at the sensor. In addition, ATS data can be
the ECM) and compare to specification. viewed as a temperature value in Digital Wrench™
diagnostic software. The sensor should display a
NOTE: Temperature of engine / sensor must be as
temperature close to ambient room temperature.
specified.
7. Replace TMAP sensor if out of specified range.
Slide Latch


Note: Touch pins with probes, do not force probe into connector pin.

COMPONENT
AIR TEMPERATURE SENSOR signal

OHMS Pin #46 to #38 2.5 K Ohms +/- 5% at 20o C (68o F)
return (BN / BU) to OR / GN
5.34
CYLINDER HEAD TEMPERATURE SENSOR (CHT) DIAGNOSTICS

COMPONENT AFFECTED: Cylinder Head Temperature Sensor (Engine Temperature)
INDICATES INSPECT
Voltage received at ECM from CHT sensor is outside of Resistance readings through sensor and wiring at ECM
parameters. connector (ECM disconnected). This will test will inspect
the wiring, connectors, and CHT sensor resistance.
5

2. Attach test lead adapters to meter leads.
3. Set DMM to measure resistance.
4. Measure resistance between pin 46 and pin 39 of the
ECM connector and compare to specification.
5. If resistance is out of specified range, disconnect
sensor and measure the resistance through each wire
from ECM connector to the sensor connector.
Resistance should be less than 1 Ohm (good
continuity).
6. If continuity is good from Step 5, measure the
resistance through the sensor and compare to
specification. Left Side View
Slide Latch



TEST # COMPONENT
CYLINDER HEAD
TEMPERATURE SENSOR
OHMS Pin #46 to #39 30.5 K Ohms +/- 13% @ 25o C (77o F)
5.35
IDLE AIR CONTROL (IAC) be sure hoses are connected properly and securely when
Air leaks or air restrictions in the IAC air supply or delivery idle control problems exist. If an IAC code is present,
hoses will not cause a trouble code in the system, and are perform the following circuit tests.
the most common cause of idle control problems. Always

INDICATES INSPECT LOCATION
P0508 - IAC circuit or IAC motor shorted to ground.
Connector pin visual inspection.
P0509 - IAC circuit or IAC motor open or shorted to
Continuity - Verify ECM to IAC motor IAC valve - under
battery voltage.
harness connector. fuel rail cover.
P0519 - IAC position out of range. NOTE: This code
Verify battery voltage is supplied to (Upper right side
can also be due to low battery/system voltage. If there
IAC motor on VIO/PK wire triangular cover)
is no running condition problem, clear the code and be
from Engine Relay.
sure battery is fully charged and in good condition.
BU / PK
VIO / PK
BU / W
BU / OR
BU / R

COMPONENT
SETTING CONNECTIONS (+ 10%)
ECM pin 6 to IAC
IAC Circuit Resistance OHMS Less than 1 Ohm
connector pin 3.
ECM pin 7 to IAC
connector pin 1.
ECM pin 8 to IAC
connector pin 6.
ECM pin 9 to IAC
IAC Circuit Resistance OHMS motor harness Less than 1 Ohm
connector pin 4.
DMM “+” lead to
Re-connect ECM 60 pin connector. Disconnect wire
Pin 2 or pin 5 of
Voltage Supply To IAC Motor harness from IAC motor. Turn ignition key and engine kill
DCV IAC harness (VIO/
Harness Connector switch ON. Check for battery voltage at pin 2 and pin 5
PK). DMM “-” lead
of IAC motor harness connector.
to ground.
5.36
VEHICLE SPEED SENSOR TEST MEMORY CHECK SUM ERROR

To view and clear trouble codes refer to page 5.26. See To view and clear trouble codes refer to page 5.26. See
page 5.25 for wire colors / pin number in connector. page 5.25 for wire colors / pin number in connector.
1. Refer to Chapter 19 to test the speed sensor, located

on the crankcase behind the rear cylinder (A). FAIL CODE: P0601
COMPONENT AFFECTED: ECM
INDICATES INSPECT / ACTION
Module Memory Check Clear code and check to

Sum Error when installing see if code re-appears 5
new ECM.
NOTE: All new ECMs have the “Memory Check Sum

Error” at first power-up after the memory is loaded
A into the ECM. This code must be cleared at the time
the ECM is initialized. If this code appears when
using the diagnostic software, it is possible that a
new ECM was not cleared successfully. If this is the
case, the code may be present without an actual fault.
1. If Trouble Code message P0601 (Internal Control
Module Memory Check Sum Error) is present when
using the diagnostic software, first record any other
faults present, then try clearing the P0601 trouble
code.
GEAR POSITION SWITCH TEST 2. If the code reappears, further inspection is required;
1. Refer to Digital Wrench and Chapter 19 to test the however, it is more likely the code was not cleared from
gear position switch on the vehicle. The connector is memory during initialization, and will not be present
located at the top of the engine crankcase behind the after it is cleared.
side covers.
TIPOVER SENSOR
Refer to Chapter 19 and Digital Wrench for tipover sensor
information.
5.37
CRANKSHAFT POSITION SENSOR DIAGNOSTICS

See page 17.11 for CPS test procedure.
BATTERY VOLTAGE AT ECM DIAGNOSTICS

COMPONENT AFFECTED: Battery Voltage to ECM
INDICATES INSPECT
Voltage received at ECM is outside of parameters. Vehicle Battery Voltage
1. Turn the DMM selector dial to measure DC volts. Measure open circuit voltage at battery (page 18.7).
2. Battery voltage must be 12.5VDC or above. If below 12.5, charge or replace battery before proceeding.
3. Check the 15 A Engine fuse.
4. Connect red (+) DMM lead to Pin A of the Engine-to-Chassis wire harness connector (page 5.29). Connect black
(-) DMM lead to battery negative terminal.
5. Turn ignition key ON and cycle the engine stop switch from OFF to RUN. Battery voltage should appear on Pin A
for 2-3 seconds after the engine stop switch is turned ON. To repeat the test, leave key ON and turn stop switch
OFF for at least 10 seconds before repeating test.
6. Turn both ignition and engine stop switches OFF.
7. Attach test lead adapters to the DMM leads, or use Fluke accessory probes.
9. Connect a jumper wire from Pin 11 in the ECM connector to ground. Verify battery voltage is present on pins 1 and
31 when Pin 11 is grounded. If voltage is not present, test related wiring If voltage is present, go to Step 10.
10. Check for power at ECM Pin 34 (for 2-3 seconds) with ignition key ON and engine stop switch set to RUN.
Slide Latch
Connect Pin 11 to ground

Battery Voltage


5.38
DIGITAL WRENCH
USING DIGITAL WRENCH™ DIAGNOSTIC
SOFTWARE
Refer to Section 2, 3, and 4 in the Instruction Manual

provided in the Diagnostic Tool Kit PV-46085 to install
the Polaris Digital Wrench™ software on a laptop
computer. Once installed, select the HELP icon (?) for
more information.
5
TOOLS
DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER

Victory/Polaris Diagnostic Tool Kit PU-46085-A
Digital Wrench Software: PU-48731
Standard Interface Cable: PU-47151
PU-46085-A (above) INCLUDES:
Victory Adapter: PV-46085-2
SmartLink Interface Kit: PU-47471
Fluke 73 Digital Multi-Meter or Fluke 77 DMM PV-48656 (Fluke 77 - PV-43568)
Laptop Computer (Refer to diagnostic software user manual Commercially Available
or HELP section for minimum specifications
DIAGNOSTIC SOFTWARE VERSION ECM REPLACEMENT

Always be sure you are using the most current version of Although the need for ECM replacement is unlikely, a
Digital Wrench to ensure you have the latest specific replacement procedure is required to ensure that
enhancements. Reprogramming files are added to file all essential data contained within the original ECM is
sets as required for new models, new accessory kits, and transferred to the replacement ECM.
fuel/ignition map updates. For information on how to
determine if you have the latest file set download Refer to procedure and carefully follow all instructions
available, see Reprogramming Tips on page 5.45. provided in Digital Wrench.
TPS CALIBRATION NOT REQUIRED
The TPS does not require calibration in the closed loop

EFI system as in earlier systems. TPS Calibration is not a
menu option in Digital Wrench for 2008-current models.
5.39
DIGITAL WRENCH FEATURES GUIDED DIAGNOSTICS AVAILABLE

Once connected to Digital Wrench, a variety of features Guided diagnostics are available within Digital Wrench
are available for reference or to use as diagnostic tools. for all supported Trouble Codes (that is, any fault that will
turn on the CHK ENG light).
You do not have to be connected to a vehicle to use the
help feature.
In addition, guided diagnostics are also available for
many other electrical sub systems.
Diagnostic modules are added to subsequent versions of

Digital Wrench as they become available. Check your
release version often and upgrade to be sure you’re using
the most current tools available.
Status: Help
“Connected”
DIGITAL WRENCH COMMUNICATION
ERRORS
If you experience problems connecting to a vehicle or any

Digital Wrench related problem, visit the Digital Wrench
Knowledge Base for the most current troubleshooting
information, FAQs, downloads and software updates at:
Vehicle specific service reports can be saved for future http://polaris.diagsys.com/.
reference.
Victory dealers can access the Digital Wrench site by

Data grids with typical or “normal” sensor values can be visiting www.polarisdealers.com and clicking on the
saved for future reference. Some examples are shown on Digital Wrench Updates link in the Service and Warranty
the following pages. drop down menu.
5.40
DIGITAL WRENCHFEATURE MAP
5.41
DIGITAL WRENCH SCREEN EXAMPLES
Cold engine at idle

during warm up.
Throttle partially open.

TPS voltage value
has increased.
5.42
Warm engine at idle.

RPM has stabilized
Change the position of

various data items in the
table with these buttons.
5
Save data grid for future
reference
Meter Grid Display items
5.43
TPS Sweep can be

checked for smooth
transition from zero to
full throttle with engine off
Special Tests menu for

Service Reports
Saves as a .txt file
You can save a Service Report for future reference,

comparison, or for diagnostic assistance.
5.44
REPROGRAMMING THE ENGINE CONTROL 2. DEDICATED LAPTOP: Best results are obtained using
MODULE (ECM) a laptop computer that is “dedicated to Polaris/Victory
service”. A laptop that is used by a variety of people
and in several applications around the dealership is
PROCESS OVERVIEW more likely to cause a reprogramming problem than
The Digital Wrench™ Engine Controller Reprogramming one dedicated to Digital Wrench™ diagnostics only.
(or ”Reflash”) feature allows reprogramming of the ECM
fuel and ignition map. To successfully reprogram the 3. OBTAINING THE LATEST FILE SET:
ECM, an Authorization Key must be obtained by entering Reprogramming file sets are updated periodically and
a Request Code in the box provided on the Reflash contain the most recent calibrations for both Stock and
Authorization site. The Request Code is automatically Performance updates. If you have the most current
generated by Digital Wrench during the reprogramming version of Digital Wrench (version 3.1 dated 4-27-09 as 5
process. The Reflash Authorization site is located under of this printing) your file sets are current. If you attempt
the Service & Warranty drop down menu on the dealer to load a non-current reprogramming file you will be
website at www.polarisdealers.com. advised when you connect to the Reflash Authorization
Website.
The Auxiliary Controller Reprogramming feature of Digital
Wrench allows reprogramming of the main radio, CB To see what version of digital wrench you currently have
radio, or Instrument Cluster in the same manner as the installed, start Digital Wrench and look on the right side,
ECM. See Chapter 19 for Auxiliary Controller just above the icon bar.
Reprogramming.
NOTICE: Failure to follow instructions completely and

correctly can result in an engine that does not run!
Review all Reprogramming Tips below and the following Version
pages to reduce the chance of reprogramming problems.
REPROGRAMMING TIPS
The reprogramming feature is in the Special Tests menu
on the Digital Wrench™ screen. Simply start Digital
Wrench and click on the Special Tests menu icon (the red
tool box). A technician should be familiar with the process
and with computer operation in general before attempting
to reprogram an ECM.
Compare your version with the version listed in the
If you have not yet installed the software, read the Install
Downloads area at www.diagsys.com. If a later version is
Instructions in the Getting Started section of the
available, follow the instructions provide to download the
Diagnostic System Installation Guide and User Manual.
most current version of Digital Wrench which will also
Laptops that fit the System Requirements guidelines
update your file set with the most current available.
listed in the User Manual can be used for reprogramming.
Pay close attention to system requirements listed for the
Windows version on your laptop (Page 3 of User Manual).
1. BATTERY VOLTAGE: The majority of problems with

reprogramming can be attributed to a low battery. Be
sure the battery voltage (no load) is at least 13 volts
and at least 12.5 volts with the key ON. Connect a
battery charger if necessary to bring voltage level
above minimum. Fully charge the battery before you
attempt to reprogram, or leave a charger connected
during the process. If “Key ON” voltage is marginal, it
may help to remove the headlamp relay in the fuse
box (2008 Vision models).
5.45
4. CLOSE NON-ESSENTIAL PROGRAMS: 6. COMMUNICATION PROBLEMS: If you have had

Victory recommends that you DO NOT install non- problems communicating with a vehicle while
essential programs on a Service Department laptop. performing diagnostic functions, do not attempt
Camera detection software, Virus Scanners, Tool Bars, reprogramming until the cause has been identified and
etc. may clog up memory if running in the background fixed. Check all connections, and be sure battery
and make it harder for the diagnostic software to voltage is as specified in Step 1.
operate. A good “quick check” is the number of icons
in the system tray, (icons in the task bar next to the Go to www.diagsys.com for specific information and
clock). More than 4, or 5 items is a potential problem. FAQs on how to troubleshoot communication
Things to watch out for include: problems.
• Video playing software
• Automatic programs started by your ISP.
• Financial software (checking account, business
operations and accounting, tax reporting software
etc.)
• All “shareware” & “freeware” downloaded from the
internet
• Personal hand-held PC links (can prevent
diagnostic software / reprogram procedure from
working)
• Internet firewalls set to “high security mode” or virus
scanning software running in the system tray.
A good rule to follow is that if a particular piece of
software wasn’t installed when Windows was installed, it
has the potential to create problems if it’s running at the
same time as the diagnostic software. If you’re having
problems, click on the icons of non-essential programs
and close, quit, or exit them before starting the
reprogramming procedure.
7. DON’T DISTURB THE PC: when a reprogramming is
in progress. Don’t move the mouse, and don’t touch the
5. KNOW THE PROCESS: If you are not familiar with the
keyboard. The process only takes a few seconds, and
entire reprogramming process, review the HELP
is best left alone until complete.
section of the diagnostic software before you attempt
reprogramming. Click on the ? on the toolbar or press 8. You can select Vehicle Information from the Special
F11. The information in the on-line help is the most Tests menu to view the part number of the software
current and complete information available. This (map) installed when reprogramming is completed.
should be your first step until you are familiar with the
process.
5.46
REPROGRAMMING PROCESS 4. Select Engine Controller Reprogramming.
If you are not familiar with the reprogramming process,

review tips beginning on page 5.45 before you begin.
Following is an overview of the reprogramming process.
Follow the on-screen instructions as you progress
through the steps. If you encounter a problem, always
check the On-Line help for current tips and information.
1. Connect the communication cable to the diagnostic

connector (A) in the left saddlebag. On models
equipped with ABS, remove the cover panel from the
inner bag to access the diagnostic connector.
5
5. Select the file you want to load into the ECM then click
CONTINUE to proceed to the Integrity Check and
obtain a Request Code.
2. Start the Digital Wrench™ program.

6. Copy the Request Code that will be required on the
3. Select the year, product, and model from the menus, web site in the next step. DO NOT CLOSE Digital
then click the tool box icon to open the Special Tests Wrench or the Request Code will be invalid. All
menu. characters are letters; there are no numbers in a
request code.
NOTE: Request Codes, Calibration I.D. numbers (for
accessory exhaust) and Authorization Keys must be
entered EXACTLY as they appear on the screen.
Authorization Key (obtained on the web)

goes here in Step 7.
Copy the Request Code required for

the web site
5.47
7. Go to www.polarisdealers.com and click on “Re-Flash 10. In the empty box provided on the screen, enter the 9
Authorization” from the Service and Warranty drop- digit Calibration I.D number from the card enclosed
down menu. with the accessory kit, then click “Continue”.
www.polarisdealers.com main menu NOTE: Stock reprogramming files do not require a
Calibration I.D. number. An Authorization Key will
appear after clicking the Authorize button in Step 9.
Service and
Warranty
Reflash Authorization
8. Enter (or paste) the Request Code into the box. Enter the 9 digit Calibration I.D. number
from the card enclosed with the kit.
11. An 8-digit “AUTHORIZATION KEY” will be appear in

the upper left corner of the screen. Copy this number
exactly as it appears, and enter it in the Authorization
Enter Request Code Key box on the Digital Wrench™ screen. Follow
instructions provided on the screen to complete the
reprogramming procedure.
9. Select the same file type from the list that you selected
previously (e.g. Stage 1 Vision Level 1 Slip-On Pipe),
and click the Authorize button to proceed to the next
screen.
Authorize Button
Enter the Request Code and select

the SAME file you selected previously
5.48
TROUBLESHOOTING
FUEL SYSTEM TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE AFFECTED PART(s) REPAIR RECOMMENDED
Engine turns over with Compression too low See engine section
electric starter, but won’t
start No spark at spark plugs See ignition system
No fuel reaching intake Out of fuel Add Fuel

tract Blown Fuse Replace
Plugged fuel filters / lines Clean/Replace 5
Fuel pump not working Test / Replace
Fuel pressure regulator Test / Replace
Faulty fuel pump relay Test / Replace
Open wiring / connector Inspect / Repair
Faulty connection at ECM Inspect / Repair
Excessively rich or lean Fuel pump Test / Replace

fuel mixture Fuel pressure regulator Test / Replace
Crank Position Sensor Test / Replace
Low Battery Test / Replace
TMAP sensor Test / Replace
CHT sensor Test / Replace
Fuel Injector Test / Replace
Spark at wrong time or Timing Wheel or CPS Install correctly, inspect for
no spark. Fuel delivery installed incorrectly, proper air gap (gap is preset
timing incorrect. damaged, or dirty; faulty but cover, sensor, and timing
CPS wheel must be clean and in
good condition).
Poor idle Excessively rich or lean Air Leaks Inspect IAC system
fuel mixture Air restriction in IAC Inspect IAC hoses and fittings
Fuel Pump Inspect fuel pressure
Fuel injector or fuel rail Replace
obstructed or leaking
Air Filter Replace
Wrong Fuel / Old Fuel Inspect / Replace
Crank Position Sensor Inspect / Replace
Poor Running in Higher Air intake restriction Inspect

RPM Range Oil Overfilled Air filter Inspect oil level and condition
Ignition problems - Refer to ignition section.
Ignition Coil(s) / plug wires
Low Battery Voltage Battery Charge or replace
Loose, corroded, or wet ECM and wiring harness Unplug connections - inspect
connector(s)
Valve train problems Valve springs, valve, head Inspect cylinder head & valves
5.49
FUEL SYSTEM TROUBLESHOOTING (cont.)
Engine Stalls Fuel Pump Problem Low battery voltage Battery/Charging system
Faulty fuel pump Check fuel pressure
No signal from ECM Repair Wiring
Wiring problem Repair/Chk Pump Relay
Excessive rich or lean TMAP Sensor Repair / Replace

fuel/air mixture Plugged fuel filter Replace
Fuel pump (pressure) Test / Replace
Fuel pressure regulator Test / Replace Pump Assembly
Vacuum leak Repair / Replace hoses
Wiring problem Repair
Air Filter Replace
Low battery voltage Ck battery & charging system
Control Circuit/Sensors Fuel pressure regulator Test Pressure / Replace

not functioning TPS Test / Replace
correctly Engine speed sensor Test / Replace
Fuel pump relay Test / Replace
Rotor Inspect / Install correctly
Fuse Replace
ECM Relay Replace
Low battery voltage ECM Inspect Charging system
Valve train problems or Refer to chapter 7

Compression low
Backfiring Low Battery Voltage Battery, spark plug fouled, Refer to battery section
Ignition Problem poor wire connection for Replace plugs / diagnose
ignition or fuel injection, Inspect wiring connections
loose pin in multi-pin
connector for ECM or Disconnect and check pin
wiring harness connections
Air leaks Inlet and Exhaust Seal intake or exhaust leaks
Restricted air intake or Intake tract / Throttle body Clean air inlet tract and throttle
throttle body body
5.50
Poor Running in upper Control Circuit/ Engine speed sensor Test / Replace
rpm ranges Sensors not TPS Test / Replace
functioning correctly Air temperature sensor Test / Replace
Manifold Absolute Test / Replace
Pressure sensor
Intermittent wiring / Repair/Replace
connector problem ECM
Test / Replace 5
Fuel delivery incorrect Plugged or kinked fuel and/ Repair/Replace
or vent hoses
Fuel pump Test / Replace
Fuel regulator Test Pressure / Replace
Fuel filter Test / Replace
Battery/Charging System Charge/Replace
Fuel Injector plugged Clean/Replace
Contaminated fuel (water, Clean/Replace
additives, etc.)
Inadequate octane Use correct fuel
Defective throttle valve Replace throttle body
Low battery voltage Charging system
Air intake restriction Dirty Air Cleaner Clean

Intake restriction Repair
Air Leak Throttle body gasket Repair/Replace

surfaces
Intake manifold Repair/Replace
Throttle body Repair/Replace
Engine lacks power Engine component See chapter 7, 8

problems See chapter 17
Ignition problems See chapter 2
Overfilled with oil
Improper fuel delivery Plugged fuel injector Replace

TPS Inspect / Replace
Dirty air cleaner Replace
Vacuum leaks Repair / Replace
Fuel pump Test / Replace
Fuel pressure regulator Test / Replace
Air temperature sensor Test / Replace
Engine speed sensor Test / Replace
TMAP sensor Test / Replace
Plugged vent hose Charge Battery / Replace
Low battery voltage ECM Test batt./Charging system
Test / Replace
5.51
Engine overheats Internal Engine Parts Cooling System Refer to chapter 4

Lubrication & Cooling Cooling System Refer to chapter 4
system
Low or incorrect oil Engine Oil Refer to chapter 3
Brakes dragging Brake systems Refer to chapter 15
Drive belt too tight Drive Belt Refer to chapter 3
Ignition timing incorrect Ignition Coils Refer to chapter 17
Faulty coolant Replace
temperature sensor
Faulty engine Replace
speed sensor
Faulty ECM Replace
Spark plug(s) Heat range incorrect Replace
Low battery voltage Charging System Refer to charging section
Faulty Battery Replace
Faulty Wiring Repair
Lean Air/Fuel mixture Fuel pressure regulator Repair/Replace

vacuum hose kinked or
plugged
Air leak Repair
Fuel injector plugged Clean/Replace
Coolant temperature Replace
sensor
Vent hose plugged/ Repair
kinked
Air leak at throttle body to Repair
manifold seal
Won’t Accept New Non-Current Go to

Calibration Calibration File Set Dealer website (Victory Re-
Flash) and download the most
current Victory Calibration File
Set
Low Battery Voltage Attach Battery Charger

During Re-Flash, and Re-
Charge Battery When Re-Flash
Is Completed
Attempting Re-Flash Enter Authorization Code Sent

Without Proper VIN, With Accessory Kit
Calibration I.D. number,
or calibration
authorization code
5.52
ENGINE REMOVAL & INSTALLATION
CHAPTER 6
OVERVIEW - ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
ENGINE MOUNTING - AIRBOX / MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 6.4
ENGINE MOUNTING - REAR SUB FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 6.5
ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
REMOVAL PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
INJECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
PREPARATION FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6.1
OVERVIEW - ENGINE REMOVAL

GENERAL
A floor jack or commercially available motorcycle engine lift or hoist is required for engine removal. Arrange for
assistance when removing and installing the engine.
Once engine is removed from frame, an engine stand is recommended for engine disassembly and assembly.
Engine removal and installation methods may differ slightly depending on available equipment, but always be sure the
engine and chassis are securely supported and secured at all times.
REQUIRES ENGINE REMOVAL FOR SERVICE CAN BE SERVICED WITH ENGINE IN FRAME
Camshaft Alternator
Camshaft Chain / Guide / Tensioner Blade Cam Chain Tensioner
Crankcase Breather Reed Valve Clutch
Crankshaft & Crankshaft Component Service Fuel Injectors / Fuel Rail
Cylinder Heads Gearshift Linkage (External)
Valve Covers Ignition System
Oil Pump Output Shaft Seal
Oil Pump Drive / Balance Shaft Starter, Starter One-Way Clutch, Starter Torque Clutch,
Piston / Cylinder Throttle Body
Transmission / All Internal Transmission Parts Torque Compensator Assembly
SPECIFICATIONS
ENGINE WEIGHT and OIL CAPACITY
Item Specifications
Engine Dry Weight Approximately 120 Kilograms (265 lbs)
Oil Capacity Approximately 4.75 Liters (5.0 Quarts)
6.2
SPECIAL TOOLS
1.) Motorcycle table lift with wheel vise (commercially available)
2.) Engine platform jack or platform lift (commercially available)
3.) Engine stand (commercially available)
4.) Engine Mounting Plates (PV-48737)
PV-48737
ENGINE MOUNTING PLATES
(Required for engine removal)
6.3
TORQUE VALUES
ENGINE MOUNTING - AIRBOX / MAIN FRAME ASSEMBLY
ENGINE INSTALLATION
(See page 6.11 - 6.12 for procedure)
= Apply Victory All Purpose Grease 2872187 1. Install all bolts in order A-D page 6.4 and 6.5.
Do not tighten.
2. Torque bolts as specified in order 1 - 4
3. Refer to Chapter 3 for Body Panel Removal

procedures and torque specifications.
Rear Sub Frame

Attachment Point
111 Nm (82 lb-ft)

B 3 M12 x 100mm
(Torque the nut end)
111 Nm (82 lb-ft)

A 4 M12 x 100mm
6.4
ENGINE MOUNTING - REAR SUB FRAME ASSEMBLY

111 Nm (82 lb-ft)
D 1 M12 x 100mm
Airbox / Main Frame

Attachment Point
Tie Strap
48 Nm (35 lb-ft)
C 2 M10 x 70mm
6.5
ENGINE REMOVAL 5. Remove LEFT floorboard assembly (C).
PREPARATION FOR REMOVAL

A number of different methods can be used to
remove the engine depending on the equipment
available to the technician.
• Support motorcycle securely in an upright position

during engine removal. Clamp front tire securely
with lift bench wheel vise.
PRECAUTIONS C
• Clean engine thoroughly before removal. Cover
openings during and after engine removal.
6. Remove RIGHT floorboard assembly (D).
• Note routing of wires, cables and hoses. Refer to
routing diagrams in Chapter 1.
REMOVAL PROCEDURE
1. Completely drain fuel from fuel tank halves.
2. Disconnect battery cables (Chapter 2).
3. Remove front body work and seat (Chapter 3)
4. Remove bolt (A) then lever (B) from shift shaft.

D
B
7. Remove rear master cylinder assembly (E) from
floorboard mount (F) with all brake lines still attached.
Support assembly off to the side. Do not allow
A assembly to hang from brake lines.
Shift Linkage
6.6
8. Disconnect both O2 sensors at the connector (not at NOTE: If you plan to disassemble the engine
the sensor) and remove exhaust system (Chapter 3). crankcase, remove drive sprocket (Chapter 11).
11. Remove crankcase breather hose (I).
Unplug both 6
Lambda Sensors
9. Loosen rear axle nut (G) about 3 turns. Loosen belt

adjusters on each side about 2 turns. Tap wheel/axle
12. Rotate lifter arm inward and disconnect clutch pull rod
forward to remove belt tension.
(hydraulic clutch) or cable end (cable clutch).
13. Remove slave cylinder from crankcase (J).

G
Uncouple
Here
J
10. Remove reverse motor and gearbox (page 11.10),
sprocket cover, and drive belt from sprocket.
14. Slide lock lever (K) out. Pull ECM connector straight
out of ECM. Disconnect harness ground wire (L).
K L
NOTE: Do not kink or twist the drive belt.
6.7
15. Disconnect engine harness. 18. Remove the battery (page 2.20).
19. Unplug and remove regulator / rectifier (P).
NOTE: Regulator / Rectifier removal is not required,

but it is recommended during engine removal to
prevent from damaging the component.
16. Disconnect diagnostic connector (M) and push

harness and grommet (N) out of inner saddlebag to
allow harness removal.
P
M
20. Disconnect positive (red) lead from main circuit

breaker (Q) and negative (black) lead (and all other
ground wires) from engine ground (R).
17. Remove fuel tanks (page 5.15). R
6.8
21. Remove oil cooler mounting bolts (S). 26. Remove upper rear engine mount bolts and plates
(V).
22. Pull cooler out of grommet (T) for removal with engine.
V
T
6
S
23. Remove positive cable from starter motor. 27. Install Engine Mounting Plates PV-48737 in place of
24. Unbolt brake switch from front sub frame and rear original mount plates (page 6.3).
brake line bracket from rear of engine crankcase.
PV-48737
Remove
Pivot brake line here

during engine removal
28. Support bottom of engine with a platform jack or
25. Remove (2) bolts from front sub frame. Support sub platform lift (commercially available).
frame as to prevent pulling or damaging brake line(s). 29. Remove bolts (W) retaining rear sub frame to engine.
6.9
30. Remove the right-hand side cover and disconnect the 33. When all fasteners have been removed, ensure all
cables from the throttle body (dark cable is pull cable hoses, wiring, and other components have been
and located on the bottom). Lift cruise control cable disconnected or removed to allow engine removal.
out of bracket and disconnect.
34. Slowly lower engine and move it forward slightly to
release engine from rear crankcase alignment pins.
X
NOTE: Move rear brake line as needed to clear
engine during removal. Take care not to damage the
rear brake line.
35. When engine is free of rear sub frame, carefully lower

it enough to allow throttle body adaptor to clear the
airbox/frame assembly.
36. Remove engine out RIGHT side of chassis.

X
NOTE: Attach engine securely to an engine stand to
prevent damage and for ease of disassembly. Use
spacers as needed for stand you are using. If
31. Remove upper front engine mount bolts and plates. crankcases will be separated, use two left crankcase
mounts (Z) only.
32. Pull engine harness through rear portion of LEFT

fairing leg support (Y) to allow engine harness to INJECTOR REMOVAL
remain with engine.
IMPORTANT: Debris could have collected in and
around injector cavities. If injector removal is
required, clean cavity and surrounding area with
compressed air before removing injectors. If
removed, injectors must be indexed properly to the
fuel rail (aligned) to ensure proper spray pattern
(Chapter 5).
6.10
ENGINE INSTALLATION 4. Slide engine back onto dowel pins and adjust engine
height as needed to align the pins and fully seat the
PREPARATION FOR INSTALLATION throttle body into the airbox/frame seal.
Refer to page 6.4 - 6.5 for torque values and assembly

views. CAUTION
Refer to routing diagrams in Chapter 1 for locations and Be sure engine is aligned at the proper height and
electrical connectors. angle with the dowel pins. DO NOT force engine
alignment using the mounting bolts, or the rear sub
frame and dowel pins may be damaged!
CAUTION Adjust engine height and angle continuously as
required while drawing up the bolts.
Arrange for assistance when installing engine.
The engine must be held securely to prevent 5. Tighten (4) rear sub frame bolts evenly until engine is 6
damage to engine, frame, wiring, or hoses. The drawn flat against sub frame, but do not torque at this
engine is very heavy and could cause severe time.
personal injury if not handled properly. Be sure
engine is properly supported before proceeding. 6. Properly route all hoses, wiring and other components
before installing engine mounting hardware.
IMPORTANT: Be sure alignment dowel pins are in 7. Install front cylinder engine mounting plates and
place on rear sub frame or rear portion of engine loosely install bolts.
crankcase.
8. Remove Engine Mounting Plates (PV-48737).
INSTALLATION PROCEDURE
9. Install original rear cylinder engine mounting plates
1. Clean mating surfaces of rear sub frame and engine and tighten bolts evenly, but do not torque at this time.
crankcase. Grease the dowel pins.
10. Torque engine mounting bolts in following order:
2. Slide and rotate engine into frame through RIGHT 1. (4) Rear sub frame bolts (page 6.5)
side and position engine to center of frame. 2. (5) Rear cylinder engine mounting bolts (page 6.4)
3. (3) Front cylinder engine mounting bolts (page 6.4)
3. Raise engine and start throttle body adaptor into
airbox/frame assembly seal.
11. Remove platform jack or platform lift.
12. Route engine harness through rear portion of LEFT

leg fairing support.
Seal
Adaptor 13. Reinstall throttle cables onto cable bracket and adjust
free play (Chapter 2).
14. Install starter motor lead and torque to 6.8 Nm

(60 lb-in).
6.11
15. Install front sub frame. Torque upper mounting bolts 28. Adjust belt tension and tighten axle nut (page 2.24).
to 25.8 Nm (19 lb-ft).
29. Install exhaust system and connect O2 sensors
(page 3.45).
25.8 Nm
(19 lb-ft) 30. Install rear master cylinder onto brake pedal support.
Torque mounting bolts to 24.4 Nm (18 lb-ft).
31. Install right and left floorboard assemblies. Torque

cradle to sub frame bolts to 25.8 Nm (19 lb-ft) and
cradle to engine bolts to 47.5 Nm (35 lb-ft).
47.5 Nm
(35 lb-ft)
16. Install brake line to engine crankcase and brake

switch to front sub frame. Torque to 8.5 Nm (87 lb-in).
17. Install oil cooler onto sub frame and torque mounting
bolts to 9.6 Nm (85 lb-in).
25.8 Nm
18. Install regulator/rectifier to engine (if removed). (19 lb-ft)
Torque fasteners to 9.6 Nm (85 lb-in).
32. Install shift arm onto shift shaft. Install retaining bolt
19. Install ground wires to engine. Torque screw to 9.6 and torque to 9.5 Nm (7 lb-ft).
Nm (85 lb-in). Install positive regulator / rectifier wire
to circuit breaker. Torque nut to 2.8 Nm (25 lb-in). 33. Install front body work and seat (Chapter 3).
20. Install battery (page 2.20). 34. Apply dielectric grease to battery terminals and
connect battery cables. Torque terminal bolts to 4.5
21. Install fuel tanks (page 5.15). Torque (6) fuel tank Nm (40 lb-in).
mounting bolts to 47.5 Nm (35 lb-ft).
35. Install new oil filter and fill crankcase to proper level
22. Install diagnostic connector harness and connect with Victory engine oil (Chapter 2).
engine harness to main harness. 36. Inspect operation of all controls and adjust as
necessary (Chapter 2).
23. Connect engine harness to the ECM and attach ECM
ground wire. 37. Add fuel to fuel tank and prime fuel system
(page 5.11).
24. Install clutch slave cylinder or cable bracket to
crankcase. Torque screws to 8.5 Nm (87 lb-in). 38. Start engine and inspect for oil leaks.
25. Install engine breather hose and secure clamps. 39. Test brakes to be sure operation and pedal pressure
are normal.
26. Install drive sprocket (if removed). Torque to 244 Nm
(180 lb-ft). (See Chapter 11). 40. Test ride motorcycle; check all systems for proper
operation.
27. Install drive belt and sprocket cover. Torque cover
bolts to 9.6 Nm (85 lb-in). 41. When test ride is completed, check entire vehicle and
engine for fluid leaks.
NOTE: Drive belt is installed with “VICTORY”
readable from right side. Do not kink or twist the 42. Inspect oil level and adjust if necessary.
drive belt.
6.12
CYLINDER HEAD & VALVE TRAIN
CHAPTER 7
IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
DATA - CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
TORQUE VALUES AND ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
CAM DRIVE & VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
CAMSHAFT CARRIER / ROCKER ARM - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
CAMSHAFT CARRIER / ROCKER ARM - 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CAMSHAFT TIMING QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
CYLINDER HEAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
CAMSHAFT DRIVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
CAMSHAFT CHAIN & SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
ROCKER ARM REMOVAL - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
ROCKER ARM & SHAFT INSPECTION - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
CAMSHAFT INSPECTION - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
CAMSHAFT CARRIER REMOVAL - 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
ROCKER ARM & SHAFT INSPECTION - 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
CYLINDER HEAD REMOVAL - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
CYLINDER HEAD REMOVAL - 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
VALVE SPRING FREE LENGTH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
VALVE GUIDE REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
VALVE SEAT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
CYLINDER HEAD INSTALLATION - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
CAMSHAFT / ROCKER INSTALLATION - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
CYLINDER HEAD INSTALLATION - 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
CAMSHAFT TIMING - REAR CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
CAMSHAFT CHAIN GUIDE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
CAMSHAFT TIMING - FRONT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN . . . . . . . . . . . . . . . . . . 7.34
7.1
GENERAL INFORMATION
IMPORTANT NOTES
• This section covers service of the cylinder heads, camshafts, cam chains and tensioners, cam chain guides and
rocker arms. Cam chain tensioners can be serviced with the engine in the frame. Most other cylinder head
components require engine removal.
• Refer to Chapter 6 for engine removal and installation.
• If cylinder heads are removed the cylinder base gasket must be replaced also.
• Head and base gasket replacement is recommended on 2009-2010 models if camshaft carrier fasteners are
loosened or removed. The 1-piece camshaft carrier design on these engines uses common fasteners for the
carrier, the cylinder head, and the cylinder.
• Mark and store all mating parts for correct engine assembly.
• Use Moly Assembly Paste P/N 2871460 or Victory Semi-Synthetic 20W/40 Engine Oil P/N 2872176 to lubricate
parts where indicated.
• Handle and store all parts in such a way that they will not be damaged or contaminated.
• Some fasteners have a pre-applied locking agent, and must be replaced if loosened or removed. Always
replace fasteners that have a pre-applied locking agent or as directed in this service manual.
• There are some precision machining steps to be performed in this section. If you are not sure of your
capabilities in these areas, have a competent machinist perform these operations.
• Valve guide and seat reconditioning should be performed by a technician proficient in cylinder head
reconditioning techniques using high quality equipment with grinding stones or precision carbide cutters. Do not
attempt cylinder head repair without the proper equipment or experience in cylinder head reconditioning
techniques.
• The intake and exhaust valves cannot be re-faced.
• Cleanliness of parts is critical to engine life and accurate parts inspection. Use clean solvent to clean all
disassembled parts. Dry parts with compressed air and lubricate before engine inspection and engine assembly.
SPECIAL TOOLS
• Valve Spring Compressor PV-1253 or PV-4019 with adapter PV-43513-A
• Crankshaft Rotation Socket PV-48736
• 8mm or 5/16 pin punch (Commercially available)
• Engine lock Tool: PV-43502-A
7.2
DATA - CYLINDER HEAD

SPECIFICATIONS
CYLINDER HEAD - 2008 - 2010
Valve Train Single Overhead Cam / 4 valves per cyl 2
Intake valves / 2 Exhaust valves
Intake Valve Opens At 1 mm Lift 1o BTDC
Intake Valve Closes At 1 mm Lift 27o ABDC
Exhaust Valve Opens At 1 mm Lift 33o BBDC
Exhaust Valve Closes At 1 mm Lift -5 ATDC (5o BTDC)
o
Max Lobe Lift (In / Ex) 7.26 mm / 7.07mm

Max Valve Lift (In / Ex) 10 mm / 10 mm
CYLINDER HEAD & VALVE TRAIN - 2008 / 2009-2010

7
Cam Chain Tensioner (Hydraulic) - -
Cam Shaft Lobe Height IN 40.259 mm (1.5850") 40.159 mm (1.5811”)
EX 40.060 mm (1.5772") 40.02 mm (1.5732”)
Oil Clearance .036 mm to .086 mm ( .0014" to .0034" )
2008 Journal O.D. 23.96 - 23.98 mm (.943 - .944" ) 23.93 mm (.942”)
2009 - 2010 Journal O.D. (Small) 23.96 - 23.98 mm (.943 - .944" ) 23.93 mm (.942”)
2009 - 2010 Journal O.D. (Large) 48.464 - 48.484 mm (1.9080 - 1.9088") 48.434 mm (1.9068”)
Cylinder Head Warpage (Distortion) - .10 mm max. (.004”)
Rocker Arm Bore I.D. In/Ex 12.01 - 12.03 mm (.473 - .474") 12.065 mm (.475”)
Rocker Arm, Shaft, Rocker Arm Shaft O.D. In/Ex 11.974 - 11.986 mm (.471-.472") 11.944 mm (.470”)
& Lifter Rocker Arm to Rocker Arm .024 - .056 mm (.001 - .0022") .156 mm (.006”)
Shaft Clearance In/Ex
Valve Clearance Hydraulic/Self Adjusting -
Valve Guide Installed Height 12.2-12.8 mm (.480-.504") 41.40 mm (1.630”)
(See illustration on page 7.23)
Valve Stem O.D. In 6.953 - 6.973 mm (.2737 - .2745") 6.933 mm (.2729”)
Ex 6.950 - 6.970 mm (.273 - .274") 6.928 mm (.2727”)
Valve Stem Deflection - .13 mm max. (.005”)
Valve, Valve Guide, Valve Seat Width Intake 1.2 mm (.047") -
Valve Seat Valve Seat Width Exhaust 1.75 mm (.068") -
Valve Stem Runout - .13 mm max. (.005”)
Valve Head Radial Runout - .05 mm max. (.002”)
Valve Installed Height INTAKE: 49.31 - 50.31 mm --
(See illustration on page 7.23) (1.941 - 1.981")
EXHAUST: 48.78 - 49.78 mm
(1.920 - 1.960")
Valve Spring Free Length In/Ex 43.36 mm ( 1.708" ) 41.40 mm (1.630”)
Intake Valve Maximum Lift 10.0 mm ( .393" ) --
Exhaust Valve Maximum Lift 10.0 mm ( .393" ) --
Spring Installed Height 34.20 - 36.20 mm --
(See illustration on page 7.23) (1.346 - 1.425")
7.3
TORQUE VALUES AND ASSEMBLY VIEWS

CAM DRIVE & VALVE COVER
13 Nm (115 lb-in)
Repeat Torque
Sealant bead UP
14.6-19.5 Nm (10.8-14.5 lb-ft)

(New plugs - with anti-seize
compound applied to threads)
13.5 Nm (120 lb-in)
Cam Chain Tensioners

75 Nm (55 lb-ft)
11.3 Nm (100 lb-in)
Sealant bead
toward cover
13 Nm (115 lb-in)
Repeat Torque
11.3 Nm
(100 lb-in)
Clean with isopropyl alcohol 23 Nm (17 lb-ft)

Align slot with tab on cover
Apply firm pressure (40-60 psi) for 30 seconds
Allow 24 hour cure
7.4
CAMSHAFT CARRIER / ROCKER ARM: 2008
NOTES
Apply Moly Assembly Paste
1 (PN 2871460)
Upper carrier half must be loose to allow upward movement when
cylinder head nuts are torqued. (See Cylinder Head Installation on page 7.25)
After cylinder head nuts have been torqued, torque upper cam carrier as follows:
 Lubricate nuts and washers with engine oil
 Tighten slowly and evenly or cam holder assembly may crack
 Follow sequence shown below
 Torque to 24.5 Nm (18 lb-ft) to seat upper carrier Camshaft - Install w/
 Torque to 27 Nm (20 lb-ft) final torque lobes down. Refer to
page 7.26 for
camshaft installation.
After assembly, rotate cams back and

20 Nm (15 ft. lbs.)
forth slightly to verify free rotation.
Allow time for lifters to bleed down
before performing this inspection
CAM CARRIER TORQUE SEQUENCE
7.5
CAMSHAFT CARRIER / ROCKER ARM - 2009 - 2010

After assembly, rotate cams back and forth slightly to verify free rotation. Allow time for lifters to bleed
FRONT down before performing this inspection.
2009-2010 6.8 Nm
(60 lb-in).
Solid pin - install
chamfered end first.
“F” (FRONT)
Camshaft - Install with  Tighten head nuts slowly and evenly

lobes down. Refer to to allow lifters to bleed off pressure
page 7.28 for
camshaft installation.  Tighten only enough to seat carrier.
Follow cylinder head torque procedure
on page 7.28 - 7.29.
Solid pin - install

REAR chamfered end first.
2009-2010 Camshaft - Install with
lobes down. Refer to
6.8 Nm page 7.28 for
(60 lb-in). camshaft installation.
“R” (REAR)
 Tighten all head nuts slowly and evenly to allow lifters to bleed off pressure
 Tighten only enough to seat carrier. Follow cylinder head
torque procedure on page 7.26.
7.6
CYLINDER HEAD
See page 7.26 (2008) or 7.29 for Temp Sensor

cylinder head torque procedure. (Front Cylinder Head Left Side)
IMPORTANT! Gaskets and gasket 13.5 Nm (10 lb-ft)
surfaces must be oil free. Loctite 565 or Pipe Sealant
(Replace sensor if removed)
20 Nm
(15 lb-ft)
Damper on front
tensioner only 7
“R”
75 Nm (55 ft. lbs.) Studs 8/9 mm

20 Nm (15 lb-ft)
Studs 10/11 mm
34 Nm (25 lb-ft)
Apply Loctite 598 to crankcase parting line below

base gasket. Assemble immediately.
7.7
CAMSHAFT TIMING QUICK REFERENCE

Use this page as a reference ONLY if you are familiar with the cam timing procedure.
Refer to Page 7.30 for complete camshaft timing procedure
The illustration below shows final cam timing configuration.
_
The rear cylinder has been timed and the crankshaft rotated 410 from rear TDC.
Twin marks indicate the crankshaft has been

rotated 410_ from rear TDC cam timing.
Rear Cylinder Front Cylinder
Gasket Surface
Rear Camshaft Sprocket Marks Parallel

To Gasket Surface Front Camshaft
NOTES
1 Rear camshaft must be timed first.
Install rear tensioner (marked “R”).
2 Rotate crankshaft CLOCKWISE

(viewed from right side) 410
to FRONT cylinder TDC,
then time front camshaft Key way aligned with front cylinder
crankshaft/camshaft centerline
as shown above
Front cylinder TDC hole Rear cylinder TDC hole
Ill. 1
7.8
VALVE COVER REMOVAL

CYLINDER HEAD SERVICE
1. Engine removal is required. Refer to Chapter 6.
CAMSHAFT DRIVE COVER
2. Remove all valve cover screws.
1. Remove cam drive cover.
3. Tap cover with a soft faced hammer until loose.
2. Remove CPS timing wheel.
4. Remove cover and gasket.
VALVE COVER INSTALLATION

1. Install gasket with sealant bead UP (toward cover) on
clean, dry surfaces.
2. Install all screws and tighten evenly in a cross pattern.

7
13 Nm (115 lb-in)
3. Place shop towel in cavity below cam drive sprocket to

prevent objects from falling into crankcase.
CAM CHAIN TENSIONER REMOVAL
CAUTION
Do not rotate engine with tensioner(s) removed.
1. Remove tensioner body (A), sealing washer (B) and

damper sleeve (C) (damper on FRONT cylinder only).
2. Inspect tensioner parts.
4. Rotate engine to front or rear TDC using Crankshaft

Front Cam Chain Tensioner
Rotation Tool PV-48736.
5. Insert 8mm (5/16) pin at front or rear cylinder TDC to
prevent engine rotation. See page 7.8
Front tensioner only
CAUTION
Do not rotate engine with cam chain tensioner(s) A

removed.
B
C
7.9
CAM CHAIN TENSIONER INSPECTION CAM CHAIN TENSIONER INSTALLATION

1. Visually inspect inner plunger (A) for damage, scoring, 1. Lubricate all parts with engine oil.
or burrs.
2. Lubricate inner plunger with engine oil. Move plunger 2. Install damper (C) squarely into tensioner bore in
in and out of outer plunger (B) to check for smooth cylinder, and push it past the first 4 or 5 threads.
movement without binding.
3. Inspect damper (C) on FRONT tensioner. It should slip
over inner plunger with noticeable drag, not a loose fit.
4. Replace tensioner assembly or damper if worn or
damaged.
A B
3. Install tensioner body with a new sealing washer.

C
4. Torque tensioner body to 75 Nm (55 lb-ft).
7.10
CAMSHAFT CHAIN & SPROCKET REMOVAL 7. Remove tensioner blade bolt (C) and guide bolt (D).
1. Remove engine from frame (Chapter 6).
2. Remove camshaft drive cover and CPS timing wheel C D

(page 7.9).
3. Rotate crankshaft clockwise, past TDC on the

compression stroke for front cylinder until bottom
sprocket bolt (A) is accessible and remove it.
Crankshaft Rotation Socket: PV-48736
A 7
8. Remove cam chain and sprocket from camshaft and
lower it between tensioner blade and guide, then
remove chain from drive sprocket on crankshaft.
9. Lift chain, sprocket, tensioner blade, and guide out of

engine.
2008 Shown (2009-2010 similar)
10. Repeat steps for rear cylinder.
4. Rotate crankshaft clockwise back to front cylinder TDC

(camshaft marks aligned with cylinder head surface)
and remove top sprocket bolt (B).
5. Remove front cam chain tensioner (page 7.9).
6. Remove lower cam chain guide (below drive sprocket).
7.11
ROCKER ARM REMOVAL: 2008 ROCKER ARM & SHAFT INSPECTION: 2008
NOTE: Keep mated rocker arm shafts and rocker 1. Separate top and bottom half of rocker carrier. Tap
arms together. Do not interchange mated parts. shaft out of top carrier until hole in shaft is exposed on
Rocker arm carrier is marked “F” for front cylinder. the other end.
Mark parts as required to keep them in order.
1. Remove or loosen rocker arm carrier nuts (A) 1/2 turn

at a time using a cross pattern until loose.
A
C
B 2. Remove shafts with a twisting motion.
2. Remove carrier nuts and washers.
3. Remove upper cam carrier and camshaft.
4. If cylinder head will be removed, camshaft upper and

lower carrier can be removed as an assembly together
with camshaft. To do this, loosen nuts (A) evenly in a
cross pattern about 3 full turns, then loosen all (6)
cylinder head nuts evenly and remove nuts and
washers. Lift camshaft and carrier out as an assembly.
5. Note markings on end of front and rear camshafts.

Front and rear cylinder heads use different camshafts.
Camshafts are marked at drive end.
3. Visually inspect rocker arms and rocker arm shafts for
excessive wear, scoring or damage.
4. Inspect all oil passages and clean thoroughly. Use only

clean solvent. Do not allow dirt to contaminate the
hydraulic adjuster on rocker arm.
5. Rotate rocker arm on shaft. The rocker arm should fit

the shaft tightly without excessive play, and rotate
smoothly on the shaft without binding.
7.12
6. Measure O.D. of each rocker arm shaft (A) and CAMSHAFT INSPECTION: 2008
compare to specification.
1. Visually inspect camshaft journal surfaces (C) for
7. Measure I.D. of each rocker arm (B). scoring or signs of insufficient lubrication. Replace
camshaft if heavy scoring or damage is noted.
8. Subtract rocker arm shaft O.D. from its matching
rocker arm I.D. to determine rocker arm shaft-to-rocker
arm clearance. Compare to specification on page 7.3.
C C
B
2. Measure O.D. of each camshaft journal.
9. Replace parts worn beyond service limits.
3. Inspect height of each cam lobe.
7.13
CAMSHAFT CARRIER REMOVAL: 2009-2010 ROCKER ARM & SHAFT INSPECTION:

NOTE: Base and head gasket seal is released when 2009-2010
removing camshaft carrier. Replacement of both head
1. Remove button head screw (C) and pin (D). Slide
and base gasket is recommended to prevent oil
camshaft out of carrier.
leaks. Keep mated parts together.
1. Remove M8 nuts (A) with washers. Loosen camshaft 2. Remove dog point screws (E) and tap rocker shafts out
carrier/cylinder head nuts (B) 1/2 turn at a time using of carrier.
a cross pattern until loose. 3. Visually inspect rocker arms and rocker arm shafts for
wear, scoring, or damage.
B 4. Inspect all oil passages and clean thoroughly. Use only
A
clean solvent. Do not allow debris to contaminate
hydraulic lifters on rocker arms.
5. Rocker arm should fit tightly on shaft without excessive
play, and rotate smoothly on shaft without binding.
6. Check roller for radial movement. Roller should have
no noticeable radial movement (F).
7. Apply light pressure to roller with a flat piece of bar
stock and draw the stock over the roller while observing
movement. Roller should not stop, drag, or bind.
Bar stock
2. Remove carrier nuts and washers, then remove carrier
with camshaft and rocker arms as an assembly.
8. Measure O.D. of each rocker arm shaft (G) and

compare to specification.
9. Measure I.D. of each rocker arm (H).
10. Subtract rocker arm shaft O.D. from its matching
rocker arm I.D. to determine clearance. Compare to
specification on page 7.3.
3. Note markings “F” or “R” on drive end of camshafts. F H

Front and Rear cylinder heads use different camshafts.
C
G
D
11. Replace parts worn beyond service limits.
7.14
CAMSHAFT INSPECTION (ALL - TYPICAL)

1. Visually inspect camshaft journal surfaces (A) for
scoring or signs of insufficient lubrication. Replace
camshaft if heavy scoring or damage is noted.
A
7
2009-2010 Shown (2008 similar)
2. Measure O.D. of each camshaft journal.
3. Inspect height of each cam lobe.
7.15
CYLINDER HEAD REMOVAL: 2008 CYLINDER HEAD REMOVAL: 2009-2010

1. Remove engine (Chapter 6). 1. Remove engine (Chapter 6), valve covers (page 7.9),
and camshaft sprockets (page 7.11).
2. Remove camshafts (page 7.11).
2. Remove camshafts (page 7.14).
3. Loosen cylinder nuts (A) completely.
3. Remove cylinder head nuts and washers (A).
4. Loosen nuts (B) 1/4 turn at a time using a cross pattern
until all four are loose. 4. Remove cylinder head (B) head gasket (C) and
alignment pins (D).
B
A
5. Remove all nuts and washers, along with lower

camshaft carrier.
6. Remove cylinder head and gasket. B
7.16
CYLINDER HEAD DISASSEMBLY 2. Remove upper valve spring retainers (B), springs (C),
and valves (E).
CAUTION 3. Remove and discard valve guide seals (D). 7

4. Clean carbon deposits from combustion chamber.
Wear eye protection while removing valve springs.
NOTE: Keep mated parts together for assembly. It is

important to put cylinder head parts back in the same
location.
Valve Spring Compressor: PV-1253 (or PV-4019 with

adapter PV-43513-A)
1. Remove the valve keepers (A) using a valve spring
compressor tool. Use a pencil magnet to remove valve
keepers.
5. Clean gasket surfaces.
7.17
CYLINDER HEAD INSPECTION VALVE SPRING FREE LENGTH INSPECTION

1. Visually inspect cylinder head for cracks or damage. 1. Measure free length of valve springs. Replace springs
Pay close attention to the areas around spark plug that do not meet specification on page 7.3.
and valve seats.
2. Be sure oil passage (A) in cylinder head is
unobstructed.
NOTE: Intake and exhaust springs are identical.

VALVE INSPECTION
Specification are on page 7.3.
3. Inspect cylinder head for distortion with a straight edge

and feeler gauge. Check in different directions and
locations on the cylinder head as shown. Compare to
specification on page 7.3.
1. Place valves on V-blocks as shown and measure

valve stem runout.
2. Inspect the valve face for damage from burning, pitting
or uneven contact.
3. Place valves in V-block as shown in and inspect valve
head radial runout.
4. Insert valves into their original locations in cylinder

head.
7.18
5. Inspect that each valve moves up and down smoothly

without binding in guide.
6. Measure valve stem deflection for each valve to
determine if valve or valve guide requires replacement.
A. Raise valve 10mm (0.400") off of seat.
B. Position dial indicator as shown. Measure deflection
in two directions perpendicular to each other (X & Y
axis).
7. If valve deflection exceeds service limit measure valve

stem.
8. Replace valve and repeat step 6 if valve stem O.D.
measures outside standard range. If valve stem
deflection exceeds service limits with a new valve
installed, valve guide must be replaced.
Measure valve stem in several places.
9. Installation of new valve guides and/or new valves

requires valve seat reconditioning. This work should
be performed by a technician experienced in cylinder
head reconditioning and properly equipped.
7.19
VALVE INSPECTION
VALVE INSPECTION
CONDITION ILLUSTRATION POSSIBLE CAUSE CORRECTIVE ACTION
Uneven seat width Bent valve stem, worn Replace valve and reface
valve guide seat
Damaged valve face Burnt, pitted, foreign Replace valve and reface
material damage seat
Contact area too high Wear, settling of valve seat Lower with 30o stone
Contact area too low Wear, settling of valve seat Raise with 60o stone
Contact area too wide Wear, settling of valve seat Narrow with both 30o
stone and 60o stone
Contact area too narrow Use 45o stone
Contact area free of pitting Correct None

and damage, centered in
seat, proper width.
7.20
VALVE GUIDE REMOVAL / INSTALLATION 4. Drive or press new guides from camshaft side of head.
Drive or press guides in until circlip (A) seats against
head surface (B).
CAUTION A
B
Replacement of valve guides requires an oven,
special equipment and experience to do the job
correctly. If you are unsure of your ability to do the
repair professionally it is best to sublet the labor to a
competent machinist. Valve seat reconditioning is
required when valve guides are replaced.
5. Measure valve guide height from spring seat:

GUIDE INSTALLED HEIGHT: 12.20-12.80 mm
7
6. Ream new valve guides to size to obtain specified
stem-to-guide clearance. Ream from combustion
chamber side of head.
1. Support cylinder head and place valve guide remover

into valve guide from the combustion chamber side.
2. Drive or press old valve guides out of cylinder head.
CAUTION
The cylinder head can be easily damaged if the

procedure is done carelessly.
3. Apply 90 weight oil to outside of new valve guides.

CAUTION
Do not tilt the reamer while reaming the guide.

Always rotate the reamer in a clockwise direction.
7. Clean cylinder head thoroughly with clean solvent.
8. Inspect and recondition valve seats.
7.21
VALVE SEAT INSPECTION VALVE SEAT RECONDITIONING

1. Remove carbon deposits from valves and seats. NOTE: Valve seat reconditioning should be performed
by a technician proficient in cylinder head reconditioning
2. Inspect valve face for burning, pitting or uneven
techniques using grinding stones. The use of carbide
contact. (Fig. 1)
cutters is not recommended. Follow recommendations of
the manufacturer of the valve seat reconditioning
Valve Seat Centered. No Pitting or Damage. equipment being used. Do not grind seats more than
Refer to width specifications. necessary to provide proper seat width and contact point
on valve face.
Valve Seat
Width
Fig. 1
NOTE: Valves cannot be ground. If valve face is

burned or badly worn, replace the valve.
3. Apply a light coating of machinist’s layout fluid or paste
to valve face.
4. Install valve into valve guide.
5. Tap valve several times to make a clear impression on
the valve face. Do not rotate valve.
6. Remove valve and measure contact area (valve seat
width).
7. If valve seat is incorrect, recondition as needed.
7.22
CYLINDER HEAD ASSEMBLY
B A. Keeper
C B. Spring Retainer
D C. Spring
D. Seal
E. Valve
Valve Installed Height

(From Head Surface, Seal Removed)
Valve Spring Installed Height

(Measure with Seal Installed)
Valve Guide Installed Height

(From Head Surface, Seal Removed)
INSTALLED HEIGHT MEASUREMENT

REFER TO PAGE 7.3 FOR SPECIFICATIONS
7.23
CYLINDER HEAD ASSEMBLY 6. Compress valve springs using a valve spring

compressor and adapter.
CAUTION
Wear eye protection during assembly.
7. Apply a small amount of grease to both sides of a valve

keeper.
1. Lubricate valve stems with assembly lube.

Moly assembly paste PN: 2871460
2. Install valve in head before installing seal. Hold valve
against seat wipe off the portion that extends above the
guide.
3. Apply Victory engine oil to valve guide seal and install
seal on valve, rotating the seal as you install it.
4. Press seal firmly in place on top of guide. Be careful
not to dislodge spring from seal.
5. Install valve spring and upper retainer.
CAUTION 8. Insert both valve keepers in place on valve.

9. Remove spring compressor.
Support cylinder head so valves will not be dam- 10. Repeat previous steps for remaining valves.
aged.
Do not compress valve springs more than 11. Be sure all keepers are fully seated in groove.
necessary to install keepers.
7.24
CYLINDER HEAD INSTALLATION: 2008 4. Install cylinder head onto cylinder.
NOTE: Base gasket seal is broken upon cylinder head

removal and must be replaced at this time. Refer to CAUTION
Chapter 8 for cylinder base gasket replacement.
The camshaft carrier can be installed as an assembly,
1. Thoroughly clean cylinder and cylinder head gasket with camshaft. However, all nuts (C) on upper half of
surfaces. Both surfaces and gasket must be free of oil carrier must be removed or loosened to allow upper half
or grease. to move upward when cylinder head / lower carrier nuts
are tightened. Lower holder may crack if installed with
IMPORTANT: Gaskets and gasket sealing surfaces
upper carrier nuts tight. Installation procedure below
(A) must be free of oil and grease during assembly.
describes individual assembly of components.
AA A
A
A
7
A BB
C
C
5. Camshaft carriers are matched. Carriers are marked

2. Install dowel pins (B). FRONT or REAR for installation in their respective
3. Install a new head gasket. cylinders (D).
7.25
6. Install (E) on cylinder head. 10. Follow torque procedure below to ensure accurate final
torque:
F CYLINDER HEAD TORQUE PROCEDURE: 2008
Step 1 Apply engine oil to nut thread and nut bases.
Step 2 Follow torque pattern shown.
Step 3 Tighten 10 mm nuts (1-4) to 30 Nm (22 lb. ft.)
Step 3 Back off completely
E Step 4 Tighten 10 mm nuts (1-4) to 54 Nm (40 lb. ft.)
Step 5 Repeat the 54 Nm (40 lb-ft) torque on 1-4.

7. Install (F) over dowel pins and tap lightly to seat in Step 6 Torque 8mm nuts (5-6) to 24.5 Nm (18 lb-ft).
place.
8. Apply engine oil to nut threads and nut bases. CAMSHAFT / ROCKER INSTALLATION: 2008
1. Camshafts are marked F (front) or R (rear) on drive
9. Install washers and nuts on cylinder studs. Tighten
end for installation in their respective cylinders. Align
finger tight.
mark on cam and sprocket to ensure proper
orientation. Mount cam chain sprocket onto camshaft
4 2 temporarily with one bolt finger tight.
6
5 1 3
FRONT CYLINDER HEAD 2. Apply moly paste to camshaft journals (A) cam lobes
(View from front of engine) (B) and ends of all valve stems (C). Install camshaft
into lower carrier.
4 2
6
B
A A
5
1 3
C
REAR CYLINDER HEAD C

(View from front of engine)
7.26
3. Turn cam until lobes are pointing down. CYLINDER HEAD INSTALLATION: 2009-2010
4. Inspect each rocker arm and position flat side of
NOTE: Base gasket seal is broken upon cylinder head
hydraulic adjuster down as shown at right (D).
removal and must be replaced at this time. Refer to
Chapter 8 for cylinder base gasket replacement.
D
1. Thoroughly clean cylinder and cylinder head gasket
surfaces. Both surfaces and gasket must be free of oil
or grease.
IMPORTANT: Gaskets and gasket sealing surfaces
(A) must be free of oil and grease during assembly.
2. Install dowel pins (B).
5. Apply engine oil to rocker arms. AA A

A
6. Install rocker arm assembly over lower carrier studs.
7
A
A BB
3. Install a new head gasket.
7. Apply engine oil and Install washers and nuts.

8. Tighten nuts evenly in a cross pattern 1/2 turn at a time
until rocker assembly is seated.
9. Torque rocker arm carrier to specification in 3 steps
following the torque pattern shown below.
CAM CARRIER TORQUE SEQUENCE

27 NM (20 LB-FT.)
4. Clean gasket surface on cylinder head and set cylinder

head in place on cylinder.
10. Rotate cams back and forth slightly to verify free

rotation. Allow sufficient time (up to 5 minutes) for lifters
to bleed down before performing this inspection.
7.27
5. Camshaft carriers are marked “F” (FRONT) or “R” 13. Install washers and nuts on cylinder studs. Tighten
(REAR) for installation in their respective cylinder finger tight.
heads (C).
Lobes Down
2009-2010
2009-2010
14. Slowly and evenly tighten cylinder head nuts following
torque sequence in Fig. 2. This allows hydraulic lifters
6. Apply Moly Assembly Paste (P/N 2871460) to lobes to bleed off pressure. Tighten only enough to seat cam
and main journals of camshaft. carrier on head.
7. Install camshaft marked “R” into rear cam carrier and

camshaft marked “F” into front cam carrier.
8. Be sure alignment pins (D) are in place and fully seated

in cylinder head. 3 1 5
2 4 6
FRONT CYLINDER HEAD - 2009

C Front of
Engine
3 1 5
2009
2 4 6
9. Turn camshaft until lobes are pointing down (away
from cam follower rollers).
10. Inspect each rocker arm and position flat side of
hydraulic lifter DOWN. REAR CYLINDER HEAD - 2009
Fig. 2
11. Set camshaft carrier on cylinder head.
12. Apply engine oil to 10mm studs, nut threads, nut bases
and washers.
7.28
15. Fully torque cylinder head following the procedure

below to ensure accurate final torque:
CYLINDER HEAD TORQUE PROCEDURE

2009-2010
(Camshaft carriers installed and seated in head)
Step 1 Lubricate 8mm studs, washers, and nuts with

engine oil and install hand tight.
Step 2 Follow torque pattern shown in Fig. 2.
Step 3 Back off completely
Step 5 Repeat the 54 Nm (40 lb-ft) torque on 1-4. 7

Step 6 Torque 8mm nuts (5-6) to 24.5 Nm (18 lb-ft).
Step 7 Verify that camshaft rotates freely in carrier

after hydraulic lifters have had time to
bleed down.
Step 8 Repeat Steps 1-7 for other cylinder head.
7.29
CAMSHAFT TIMING - REAR CYLINDER 5. Be sure rear camshaft lobes are pointing down. The
single mark on cam (D) must be facing UP as shown
NOTE: Rear cam chain must be installed first. below.
1. Rotate crankshaft clockwise to TDC (rear cylinder) 6. Inspect marks before installing sprocket on camshaft.
using crankshaft rotation tool PV-48736. Mark on sprocket (E) must align with camshaft “R”
mark (D). Outer marks (F) must be parallel with valve
Crank Rotation Socket PV-48736 cover gasket surface.
2. Hold crankshaft at rear TDC by inserting an 8 mm (or F

5/16) locating pin through crankcase hole (A) into
crankshaft.
R
E
D
Parallel
7. Align camshaft with sprocket hole and install top

A sprocket bolt finger tight.
8. Apply engine oil to rear cam chain tensioner.
Tensioners are not interchangeable due to the length
of the tensioner body. The rear tensioner is stamped
CAMSHAFT CHAIN GUIDE INSTALLATION
with a “R”.
1. Place cam chain around rear camshaft sprocket and
lower it into chain cavity along with the cam chain
guide (B).
2. Seat upper pins of guide in the cylinder head recess,
and install cam chain over innermost sprocket on “R” = Rear Tensioner
crankshaft.
3. Install rear tensioner blade (C).
4. Torque guide and tensioner blade bolts to
specification.
9. Install tensioner with a new sealing washer. Torque to

75 Nm (55 lb-ft.).
C 10. Torque top sprocket bolt to 13.5 Nm (120 lb-in).
11.3 Nm (100 lb-in)
7.30
CAMSHAFT TIMING - REAR CYLINDER 15. Insert an 8 mm (5/16) pin through crankcase hole to
(cont.) hold the crankshaft in position at front cylinder TDC.
Timing sprocket key (A) will be aligned with pin and
11. Check carefully to be sure rear cylinder camshaft front cylinder centerline.
timing is correct before proceeding:
• Crankshaft secured by pin and locked in the rear

cylinder TDC position.
A
• Rear camshaft lobes facing down (”R” mark on cam
aligned with “F/R” mark on sprocket).
• Rear tensioner (stamped “R”) is installed and tight.
• Outer marks on camshaft sprocket are parallel to

valve cover gasket surface.
12. Remove locating pin from crankshaft and proceed to

Step 13.
7
CAMSHAFT TIMING - FRONT CYLINDER 16. Install cam chain guide with front cylinder cam chain
and sprocket. Insert pins (B) on upper end of guide into
NOTE: Rear camshaft must be properly timed as
recess in cylinder head.
shown in Step 6 on page 7.30 before you begin the
front cylinder camshaft timing procedure.
13. Rotate crankshaft clockwise 410o to TDC on the front
cylinder (exactly one full turn, plus an additional 50o).
B
2. Rotate another 50
1. Rotate 360
17. Install front cam chain over crankshaft sprocket.

18. Install front tensioner blade (C).
14. Rear camshaft double marks are now at the top. Install
cam sprocket finger tight.
C
7.31
19. Torque guide and tensioner blade bolts to 24. Apply engine oil to front cam chain tensioner and
specification. damper. Push damper (F) squarely into tensioner bore
in cylinder, and push it past the first 4 or 5 threads.
11.3 Nm (100 lb-in)
20. After pin is installed, torque the rear cam sprocket

bolt (installed in Step 14) to 13.5 Nm (120 lb-in.)
25. Install tensioner with a new sealing washer. Torque to
21. Rotate front camshaft slightly so lobes are pointing 75 Nm (55 lb-ft).
DOWN.
22. Install sprocket on camshaft with two lines on sprocket

(D) parallel to valve cover gasket surface (E).
E 26. Torque sprocket bolt to 13.5 Nm (120 lb-in.).
27. Verify camshaft timing by comparing to Ill. 1 on

page 7.8.
23. Install top camshaft sprocket bolt finger tight. Do
not torque the bolt until front tensioner is installed. 28. Remove TDC locating pin from crankcase and rotate
engine clockwise until the remaining front camshaft
sprocket bolt hole is accessible.
29. Install sprocket bolt. Torque to 13.5 Nm (120 lb-in.).
NOTE: Be sure all camshaft sprocket bolts have been

installed and properly tightened.
7.32
30. Fill cam carrier area of both front and rear cylinders
with Victory engine oil.
31. Rotate crankshaft clockwise approximately three

complete revolutions and stop on front cylinder TDC on
the compression stroke.
32. Again compare camshaft timing to Ill. 1 on page 7.8 to

verify the timing is correct.
33. Install valve covers (page 7.9).
34. Install bottom cam chain guide. Torque screws to 11.3

Nm (100 lb-in).
11.3 Nm (100 lb-in)
35. Clean threads of crankshaft and retaining bolt with

Loctite Primer N.
36. Apply 2 drops of Loctite 262 (red) to bolt threads (not
required if using a new bolt which has a pre-applied
locking agent).
37. Install ignition timing wheel and torque bolt to
specification. Allow adequate cure time for Loctite 262
as directed on container.
23 Nm (17 lb-ft)
7.33
TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN

Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test. Other
problems associated with this area of the engine are external fluid leaks, excessive use of oil or abnormal noises.
Troubleshooting involves the use of:
• Leak down (cylinder leakage test) or a compression gauge
• Visual inspection for the source and cause of a fluid leak
• Listening to the engine with a stethoscope to determine source of abnormal noise
The troubleshooting table below lists problems and possible causes, parts affected, and repair suggestions. Thoroughly
investigate the problem and possible solution before disassembling the engine to replace suspect parts.
PROBLEM POSSIBLE CAUSE PART(s) AFFECTED REPAIR RECOMMENDED
Hard Starting Low Compression Lifter(s) locked Replace lifter(s)
Won’t Start Collapsed Hydraulic Lifter(s). Bleed Lifter
Excessive Lifter Noise Lifter Extremely Noisy. Noise will typically stop after 10-
15 minutes of high idle
operation. If lifter will not bleed,
replace lifter.
Worn Valve Guide(s) Replace Valve Guide(s).
Poor Seating of Valve(s) Repair or Replace
Broken Valve Springs Replace
Spark Plug Not Seated Torque to Specifications
Incorrect Valve Timing Repair
Valve Stuck Open Repair
Cylinder Head Gasket Leak Repair
Slow Starter Motor See Electrical Section
Worn Rings, Piston, or See Cylinder/Piston Section
Cylinder
Ignition Problem See Ignition Section
Fuel Problem See F.I. Section
Electric Starter High Compression Excessive carbon build-up in Use “Carbon Clean” fuel
Straining to Turn combustion chamber. system additive or disassemble
Engine Over engine to de-carbon
combustion chamber.
Excessive Starter Load Internal Engine / Drive Determine Cause of Seizure or

Components Seized or Binding Binding
Abnormal Pre-ignition
Poor Idle Quality Low Compression Collapsed Hydraulic Lifter(s). Air trapped in lifter. Noise will
Lifter Extremely Noisy. stop after 10-15 minutes of high
idle operation. If air will not
bleed, replace lifter.
Poor Seating of Valve(s) Repair or Replace
(Continued on next page)
7.34

Poor Idle Quality Air leak Mounting Surfaces, Hoses Repair Air Leak
IAC System Fault Inspect IAC System Hoses Repair Air Leak or restriction
in IAC System
Fuel Mixture Rich F.I. System Refer to Chapter 5
Fuel Mixture Lean F.I. System / Inlet Tract Refer to Chapter 5
Ignition Misfire Ignition System Refer to Chapter 17
Excessive Oil in Valve guides Replace
Combustion
Chamber
Excessive Oil in Worn Rings, Cylinder, or Refer to Chapter 8
Combustion Piston
Chamber Engine Oil Overfilled Correct
Valves Not Opening Fully Worn Cam Shaft or Rocker Arms Replace
Engine Noise Valve Train Area Collapsed Hydraulic Lifter(s). Air trapped in lifter. Noise will
Lifter Extremely Noisy. stop after 10-15 minutes of 7
high idle operation. If lifter will
not bleed, replace lifter.
Lifter(s) Locked Replace Lifter(s)
Broken or Weak Valve Springs Replace
Worn Camshaft or Rocker Arm Replace
Rocker Arm Roller Bearing Replace
Damage
Cam Journal Worn or Damaged Replace
Piston/Cylinder Area Worn Pistons and/or Cylinders Replace
Excessive Carbon Build-up in Clean
Combustion Chamber
Worn Piston Pin, Piston Pin Bore Replace
and/or Small End of Connecting
Rod
Worn Piston Rings or Piston Ring Replace
Lands.
Engine Noise General (May apply to all
Exhaust leak Remove exhaust and seal
areas below)
Timing Chain Area Stretched Chain Replace
Worn Sprockets Replace
Tensioner Not Working Replace
Primary Cover Area Clutch Refer to Chapter 9
Flywheel Refer to Chapter 9
Starter System Refer to Chapter 18
Torque Compensator Refer to Chapter 9
Bottom End Area Main Bearings Refer to Chapter 10
Rod Bearings Refer to Chapter 10
Loose Side Clearance Refer to Chapter 10
Transmission Area Bearings Refer to Chapter 10
Misplaced Circlips Refer to Chapter 10
Incorrect Side Clearance Refer to Chapter 10
7.35

Poor high speed running Air Intake Problem Refer to Chapter 5
F.I. System Problem Refer to Chapter 5
Ignition Problem Refer to Chapter 17
Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft/Rocker Arms Replace
Valves Opening & Closing Incorrect Valve Timing Correct
at Wrong Time
Lack of power in all RPM Low Compression Worn Piston, Rings, Cylinder Replace
ranges Low Compression Poor Valve Seating Repair/Replace
Valves Opening & Closing Valve Timing Incorrect Correct
at Wrong Time
Incorrect Valve Clearance Hydraulic Lifter Bleeding Down Replace
Lifter(s) Locked Debris in Lifter Replace lifter(s)
Collapsed Hydraulic Air Trapped in Lifter. Noise will Replace Lifter
Lifter(s). stop after 10-15 minutes of high
Lifter Extremely Noisy. idle operation. If lifter will not
bleed, replace lifter.
Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft/Rocker Arms Replace
F.I. Problem Refer to Chapter 5
Air Intake Problem Refer to Chapter 5
Oiling Problem Oil Overfilled Correct
Vacuum Leak Mounting Surfaces, Hoses Correct
Using/Burning Oil Oil in Combustion Chamber Oil Overfilled Correct
Oil Past Rings Worn or Damaged Piston, Rings, Replace
Cylinder
Oil Past Valve Guides Worn Valve Guides Replace
Worn Valve Guide Seals Replace
7.36
CYLINDER & PISTON
CHAPTER 8
CYLINDER & PISTON
CYLINDER & PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
BASE GASKET SEALING & CYLINDER STUD TORQUE . . . . . . . . . . . . . . . . . . . . . . . 8.2
PISTON RING PROFILE AND ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CYLINDER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
PISTON TO CYLINDER CLEARANCE WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CYLINDER WARPAGE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
PISTON & PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
PISTON & PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
PISTON PIN / PIN BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
CYLINDER STUD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 8
TROUBLESHOOTING, CYLINDER & PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
TROUBLESHOOTING (CONT.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.1
CYLINDER & PISTON
CYLINDER & PISTON

GENERAL
NOTE: Clean the machine thoroughly before removing engine from frame.
• This section covers service of the cylinder, piston and rings. The engine must be removed from the frame to
perform the procedures in this section. Refer to Chapter 6 for engine removal and installation.
• Mark and store all mated parts for assembly. Assemble engine by putting used parts that pass inspection back
in the same location.
• Machined and mated surfaces are very delicate. Handle and store all parts in such a way that the mating
surfaces will not be damaged.
• Many parts require assembly lubrication. Follow the assembly lubrication procedures carefully.
• There are many precision measuring steps in this section. If you are not sure of your capabilities in these areas,
have a competent machinist perform the precision part inspection operations.
• Cleanliness of parts is critical to engine life and proper parts inspection. Use clean solvent and hot, soapy water
to clean parts. Dry with compressed air before inspection and engine assembly. Coat parts with fresh lubricant
to prevent oxidation after cleaning.
BASE GASKET SEALING & CYLINDER STUD TORQUE M10x1.5 mm Studs 34 Nm (25 lb-ft)
(M11x1.50 thread to case)
Apply sealant to
case parting line
before installing
base gasket
M9x1.25 thread to case
M8x1.25 mm Studs
(M9x1.25 mm to case) 20 Nm (15 lb-ft)
PISTON RING PROFILE AND ORIENTATION

Cylinder Wall Piston
Mark
“CTOP”
UP Oil control ring
top rail gap
location Top
Locate circlip end gap
at top
Second ring gap
Second
Oil control ring
expander gap
location Oil Control
Arrow points to
FRONT of engine
Top ring gap Piston Ring Profile
Oil control ring bottom rail gap
8.2
CYLINDER & PISTON
SPECIFICATIONS
CYLINDER & PISTON
I.D. 100.987 - 101.013 Check taper and
( 3.9759" - 3.9769”) out-of-round
Cylinder Out of Round Measure 66mm up from base 0.05 mm ( .002" )
Taper gasket surface 0.05 mm ( .002" )
Gasket Surface Warpage  .1mm max. ( .0039")
Piston Mark Direction Piston orientation is determined by arrow on piston crown.
Position BOTH pistons so arrows point to front of engine.
Piston O.D. (Nominal) 100.946 - 100.964mm Replace if piston-to-
(Measured 10mm up from (3.9742 - 3.9750") cylinder clearance is
bottom of skirt, 90 degrees excessive with good cylinder
Piston to pin)
Piston Pin Hole I.D. 22.006 - 22.012 mm 22.047 mm
(.8664 - .8666") (.8680")
Piston Pin O.D. 21.995 - 22.000 mm 21.96 mm
(.8659 - .8661") (.864")
Piston to Cylinder .023 - .067 mm .15 mm 8
(.0009 - .0026") (.006")
Piston to Piston Pin .006 - .017 mm .035 mm
(.0002 - .0007") (.0014")
Piston Ring Clearances Ring End Gap - Top .15 - .40 mm .80 mm
(Installed) (.006 - .016") (.031")
Ring End Gap - 2nd .33 - .53 mm 1.11 mm
(Installed) (.013 - .021") (.043")
Ring End Gap - 3rd .15 - .35 mm .80 mm
(Installed) (.006 - .014") (.031")
Piston Ring Marks -- “CTOP” mark must face UP on
all rings. page 8.2
Piston Ring to Ring Land
Top Ring .02 - .060 mm
.11 mm (.0043")
(1.2mm ring thickness) (.0008 - .0024")
2nd Ring .02 - .060 mm
.11 mm (.0043")
(1.2mm ring thickness) (.0008 - .0024")
.03 - .17 mm
Oil Control Ring .26 mm (.010")
(.001 - .0067")
SPECIAL TOOLS
Piston ring compressor pliers: PV-43570-1
Piston ring compressor band: PV-43570-2
Cylinder bore gauge: PV-3017
Straightedge, feeler gauge, precision measuring instruments: Refer to Chapter 1 or Commercially available
Protective sleeves for pistons / studs: Commercially available
8.3
CYLINDER & PISTON
CYLINDER REMOVAL CYLINDER INSPECTION

1. Remove engine from frame (Chapter 6). 1. Visually inspect cylinder bores for scratches and wear.
2. Remove cylinder head(s) (Chapter 7). 2. Inspect gasket surfaces for scratches or other damage
that may cause an oil leak.
CYLINDER BORE MEASUREMENT

1. Measure each cylinder bore in 6 places to determine:
• Cylinder Bore Inside Diameter

• Cylinder Taper and Out of Round
3. Remove cylinder(s). Support pistons while removing

cylinders so they do not fall into the cylinder studs. Use
a section of hose (A) to protect piston rings from
contact with the studs.
4. Clean gasket surfaces of cylinders thoroughly.
A 2. Use maximum measurement to determine wear.

3. Use the worksheet provided on page 8.5 to record
measurements and calculate the clearance.
Cylinder Measurement
X Y
Top
Y
CAUTION 66mm up
X
from base
gasket surface
Careless handling of cylinder, pistons or rings may cause
irreparable damage. Do not damage gasket surfaces Bottom Y
during cleaning. X
8.4
CYLINDER & PISTON
PISTON TO CYLINDER CLEARANCE WORKSHEET

Front Cylinder Recorded Measurement Specification
Top “X”
Middle “X”
Bottom “X”
Top “Y”
Middle “Y”
Bottom “Y”
Difference between largest “Y” Taper for “Y” axis: Taper Service Limit: .05mm (.002")
measurement and smallest “Y”
measurement
Difference between largest “X” Taper for “X” axis:
measurement and smallest “X”
measurement
Largest difference between any “X” axis Cylinder Out-of-Round: Out-of-Round Service Limit:
measurement and “Y” axis measurement .05mm (.002")
Piston Skirt Measurement (page 8.6)
Difference between largest “X” axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service 8
measurement and piston measurement Limit: .15 mm (.006")
Rear Cylinder Recorded Measurement Specification

Top “X”
Middle “X”
Bottom “X”
Top “Y”
Middle “Y”
Bottom “Y”
Difference between largest “Y” Taper for “Y” axis: Taper Service Limit: .05mm (.002")
measurement and smallest “Y”
measurement
Difference between largest “X” Taper for “X” axis:
measurement and smallest “X”
measurement
Largest difference between any “X” Cylinder Out-of-Round: Out-of-Round Service Limit:
axis measurement and “Y” axis .05mm (.002")
measurement
Piston Skirt Measurement (page 8.6)
Difference between largest “X” axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service
measurement and piston Limit: .15 mm (.006")
measurement
Compare recorded measurement to specifications. If • If the piston-to-cylinder clearance exceeds the

measured value exceeds service limit replace the service limit, measure a new piston and re-
appropriate part. calculate the clearance. If the piston-to-cylinder
clearance exceeds the service limits with a new
NOTE: The cylinders are Ni-SiC plated and cannot be
piston, the cylinder must be replaced.
reconditioned by boring or honing. If excessive surface
damage, taper or out-of-round exists, the cylinder must
be replaced.
8.5
CYLINDER & PISTON
CYLINDER WARPAGE MEASUREMENT 6. Spread rings only wide enough to remove them from
piston. Spreading rings too wide will damage them.
1. Inspect cylinder for warpage at cylinder head surface
and base gasket surface. 7. Clean piston ring grooves. Break or cut a piston ring in
half. File or grind one edge square and remove all
burrs. Use this piston ring to carefully clean piston ring
grooves.
NOTE: A soft wire brush is permissible to clean top of
piston. Do not use a wire brush to clean sides of piston or
the piston ring groves.
PISTON & PISTON RING INSPECTION
10 mm Piston O.D. Measurement
2. Place a straight edge diagonally across cylinder

mating surfaces in several positions. Attempt to slide
a .05mm (.002") feeler gauge under the straight edge
in each position.
3. Replace cylinder is warped beyond the service limit.
Piston Pin
1. Visually inspect piston for cracks, excessive wear,

PISTON & PISTON RING REMOVAL scoring, etc.
1. Cover crankcase with a clean shop towel to prevent 2. Measure piston skirt O.D. (90 to pin and 10 mm from
piston clip from falling into the crankcase. bottom of piston skirt). Compare to specifications on
2. Remove the left piston pin circlip. page 8.3. Replace piston if worn beyond the service
limit.
3. Push piston pin out to left side of engine and remove
the piston. 3. Calculate Piston to Cylinder Clearance. Subtract
piston O.D. from cylinder bore I.D. and compare to
specification listed on page 8.3.
Piston to Cylinder Clearance Calculation
Cylinder I.D.
- Piston O.D.
= Piston to Cylinder Clearance
4. Replace parts that do not meet specification.
NOTE: If piston-to-cylinder clearance exceeds service

4. Rotate rings in piston groves. Rings should rotate limit, measure a new piston and re-calculate
freely in grooves. clearance. If piston-to-cylinder clearance exceeds
service limits with a new piston, cylinder must be
5. Clean carbon deposits from piston. replaced.
8.6
CYLINDER & PISTON
5. Use a piston to push each ring squarely into cylinder PISTON PIN / PIN BORE INSPECTION
bore from bottom (push rings 25-50mm into cylinder).
1. Measure piston pin hole I.D. in four locations with a
telescoping gauge. Record the smallest.
Cylinder
25-50 mm
Piston Ring
2. Measure piston pin O.D. at three locations. Record

6. Measure installed ring end gap with a feeler gauge and largest measurement.
compare to specification listed on page 8.3. If either
ring exceeds the service limit, replace ring set.
8
End Gap
Feeler Gauge
End Gap
Cylinder
25-50 mm
3. Calculate piston pin-to-piston clearance. Subtract pin

O.D. from pin hole I.D.
4. Measure connecting rod small end I.D. at two
Piston Ring locations.
5. Calculate connecting rod-to-piston pin clearance by
7. Install rings onto a clean piston. Push rings in until they subtracting pin O.D from rod hole I.D.
are flush with piston. Using a feeler gauge (A),
measure side clearances for the 1st & 2nd rings. If any
of clearances exceed limit, replace piston and piston
rings.
Connecting Rod Hole I.D.

- Piston Pin O.D.
A = Connecting Rod to Piston Pin Clearance
6. Compare measurements to specifications listed on

page 8.3 and replace any worn parts.
8.7
CYLINDER & PISTON
CYLINDER STUD REPLACEMENT PISTON RING INSTALLATION

1. Use a stud remover to remove 10mm studs (A) and
8mm studs (B).
CAUTION
10 mm Studs A Rings may be damaged if expanded more than necessary
34 Nm (25 lb-ft)
to install them.
1. Carefully install oil control ring assembly (bottom ring)

with “CTOP” mark facing up. The oil control ring
consists of a backing spring and one rail component.
2. Install first and second rings with “CTOP” mark facing

UP.
Mark
B “CTop”
8 mm Studs
20 Nm (15 lb-ft)
8 mm stud - thread to crankcase is M9x1.25mm

10 mm stud - thread to crankcase is M11x1.50mm
Piston Ring
Profile
2. Clean threads in cases thoroughly.
Cylinder Wall
3. Apply engine oil to stud threads.
4. Install studs and torque them to specification. 3. Make sure that rings rotate freely in grooves.
4. Locate ring end gaps as shown below in relation to

arrow on piston crown.
Pin bore centerline Oil ring top

Second ring gap rail gap
Oil control ring

expander gap
location
Arrow points to
FRONT of engine
Top ring gap

Oil ring bottom rail gap
8.8
CYLINDER & PISTON
PISTON INSTALLATION 5. Push piston pin through rod and piston pin hole until it
is stopped by circlip.
The pistons are marked with an arrow on the crown. Install
pistons on connecting rods with arrow (A) facing the 6. Install remaining circlip with end gap facing up (12:00
FRONT of the engine. position.)
7. Make sure both piston circlips are seated properly in
the groove.
1. Place a clean shop towel over crankcase to prevent

foreign material from entering crankcase. 8
2. Install a new circlip on one side of the piston with end
gap facing UP (12:00 position.)
CAUTION
Never reuse piston pin circlips.
3. Apply assembly lube piston pin and I.D. of connecting

rod small end.
4. Install piston over connecting rod with arrow on piston

crown facing FRONT of engine.
(View from RH side)
Gap At Top
(12:00 Position)
Notch faces front
of engine
8.9
CYLINDER & PISTON
CYLINDER INSTALLATION 7. Place a small amount of engine oil to inside surfaces

of a piston ring compressor band.
NOTE: Be sure all top end parts are ready for assembly.
Sealant on crankcase parting line must not be allowed to
Piston Ring Compressor Band:PV-43570-2
dry before top end is assembled and torqued.
Piston Ring Compressor Pliers PV-43570-1
1. Wash cylinders with clean solvent first, then with hot
soapy water. 8. Install piston ring compressor over rings and compress
rings into ring grooves.
2. Rinse cylinders with clear water and dry immediately
with compressed air. Wipe cylinder bore with a clean
white shop towel and engine oil.
CAUTION
3. Apply a light coat of engine oil to piston and rings. Be sure compressor band end gap does not align
with any ring end gap when compressing the rings.
4. Ensure cylinder alignment dowel pins are in place and
gasket surfaces are clean and oil-free. NOTE: Install cylinders in their original locations.
5. Apply a small amount of crankcase sealant to the 9. Remove protective covering from crankcase.
crankcase parting lines on base gasket surface (A).
10. Carefully install cylinder(s) over piston/ring assembly.
Do not force cylinder over piston. Monitor rings
A carefully. If a piston ring becomes dislodged from the
ring compressor; remove cylinder, inspect ring
carefully for damage.
6. Install new cylinder base gaskets onto crankcase.

NOTE: Inspect all sealing surfaces carefully for
scratches or imperfections. DO NOT allow oil or grease
to contact gaskets or sealing surfaces during the
assembly process.
11. Remove piston ring compressor when rings are fully
captive in cylinder.
12. Slide cylinder down over piston until seated to base

gasket and crankcase surface.
13. Repeat for other cylinder.
14. Install cylinder head(s). (Chapter 7).
8.10
CYLINDER & PISTON
TROUBLESHOOTING, CYLINDER & PISTON

Engine Hard Starting (or) Low Compression Lifter(s) Locked Refer to Chapter 7
Engine Will Not Start Collapsed Hydraulic Refer to Chapter 7
Lifter(s). Lifter Extremely
Noisy.
Worn Valve Guide(s) Refer to Chapter 7
Poor Seating of Valve(s) Refer to Chapter 7
Broken Valve Springs Refer to Chapter 7
Poor High Speed Valve Float Weak Valve Springs Refer to Chapter 7
Performance Insufficient Valve Travel Worn Camshaft/Rocker Refer to Chapter 7
Arms
Valves Opening & Closing at Valve Timing Incorrect Refer to Chapter 7
Wrong Time
F.I. System Problem Refer to Chapter 5
Air Intake Problem Refer to Chapter 5
Lack of Power in all RPM Incorrect Valve Clearance Hydraulic Lifter Bleeding Refer to Chapter 7 8
Ranges Down
Collapsed Hydraulic Air trapped in lifter. Noise will Refer to Chapter 7
Lifter(s). Lifter Extremely stop after 10-15 minutes of
Noisy. high idle operation. If air will
not bleed, replace lifter.
Valve Float Weak Valve Springs Refer to Chapter 7
Valves Opening & Closing at Valve Timing Incorrect Refer to Chapter 7
Wrong Time
Engine Hard Starting Fuel Delivery Problem Low Fuel Pressure Refer to Chapter 5
Ignition Problem No Spark or Weak Spark Refer to Chapter 17
Engine Hard Starting (or) Low Compression Spark Plug Not Seated Torque Spark Plug
Engine Will Not Start Incorrect Valve Timing Refer to Chapter 7
Valve Stuck Open Refer to Chapter 7
Leaking Cylinder Head Repair
Gasket
Slow Starter Motor Refer to Chapter 18
Worn cylinder, Pistons and/ Replace parts that do not
or Rings meet specification
Fuel Problem Refer to Chapter 5
8.11
CYLINDER & PISTON
TROUBLESHOOTING (Cont.)
Engine Idles Poorly Fuel Management Air leaks intake tract Refer to Chapter 5
Incorrect IAC system malfunction, air Refer to Chapter 5
leak, or restriction
Low Compression Collapsed Hydraulic Refer to Chapter 7
Lifter(s). Lifter Extremely
Noisy
Lifter(s) Locked Refer to Chapter 7
Poor Seating of Valve(s) Refer to Chapter 7
Worn Cylinder, Pistons and/ Replace parts that do not meet
or Rings specification
Lack of Power in all RPM Insufficient Valve travel Worn Camshaft/Rocker Refer to Chapter 7
Ranges arms
Lack of Power in all RPM Low Compression Worn Piston, Rings, Replace parts that are worn
Ranges Cylinder beyond the service limit
Leaks Improper Assembly Cylinder, Gaskets, Gasket Perform white powder test to
Surfaces determine leak path.
Incorrect Fastener Torque Assemble parts clean and free

of oil, grease, or debris.
Torque fasteners properly
Damaged gasket sealing Cylinder/Crankcase Repair surface or replace part
surface(s)
Noise Excessive piston to Piston / Cylinder Replace parts that are worn
cylinder clearance beyond the service limit
Excessive piston pin Piston / Pin / Connecting Replace parts that are worn
clearance (to piston or Rod beyond the service limit
connecting rod)
Exhaust Leak - Inspect seal of exhaust system
at cylinder head
8.12
CLUTCH, PRIMARY, & SHIFT LINKAGE
CHAPTER 9
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SERVICE / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
ASSEMBLY VIEWS & TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
HYDRAULIC CLUTCH HOSE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
HYDRAULIC CLUTCH SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
CLUTCH (CABLE) ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SHIFT LINKAGE / FOOTREST - FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
PRIMARY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
SHIFT MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CAP PLATE & CAP PLATE SEAL REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . 9.9
CLUTCH PINION SHAFT REMOVAL / BEARING INSPECTION . . . . . . . . . . . . . . . . . . 9.9
CLUTCH PINION SHAFT SEAL REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . 9.10
CLUTCH PINION SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PRIMARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 9
SHIFT RATCHET REMOVAL & INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
SHIFT RATCHET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
SHIFT SHAFT BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PRIMARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
LOCKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CLUTCH ASSEMBLY VIEW & TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CLUTCH REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
PRIMARY DRIVE ASSEMBLY VIEW & TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
TORQUE COMPENSATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
TORQUE COMPENSATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
TORQUE COMPENSATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
ROTOR (FLYWHEEL) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
ROTOR (FLYWHEEL) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
SPLIT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
SPLIT GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
SPLIT GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
STARTER DRIVE REMOVAL / STARTER GEAR INSPECTION. . . . . . . . . . . . . . . . . . 9.29
STARTER CLUTCH REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
PRIMARY DRIVE GEAR REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
STARTER TORQUE LIMIT CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
PRIMARY DRIVE GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
STARTER GEAR / STARTER CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9.32
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
9.1
GENERAL
SERVICE INFORMATION
• Clutch and external transmission shift linkage service can be accomplished with the engine in the frame.
• Internal transmission or internal shifting mechanism service requires engine removal and crankcase separation.
• Oil additives of any kind are not recommended by Victory. Using oil additives or oil of the wrong viscosity can
have a detrimental affect on clutch performance, operation, and service life.
• Burnt clutch plates are not an indication of a defect. Burnt clutch plates can indicate that the plate service life
has been exceeded, that a problem exists within the clutch system, that the clutch has been used improperly, or
that the plates were contaminated by improper oil or additives.
• Victory 20W/40 motorcycle oil is recommended for all operating temperatures. If Victory 20W/40 oil is not
available, a high quality 20W/40 motorcycle oil suitable for use in wet clutch transmissions can be used.
• Lubricate parts during assembly as described in the procedures.
• Corroded or sticking shift linkage pivot points can cause abnormal shifting. Replace any linkage components
that are damaged or do not move freely, and lubricate at regular intervals.
SPECIFICATIONS
GENERAL
Item Specifications
Clutch, Gear Shift, and Linkage Clutch Type Wet, Multi-Disk
Clutch Operating Mechanism Hydraulic
Clutch Master Cylinder I.D. 12.7mm
Torque Compensator Belleville Spring Loaded Cam Assembly
Primary Reduction Ratio 1.5 : 1
Transmission Shift Mechanism Manually Operated, Spring Centered
Gearshift Pattern 1-N-2-3-4-5-6
Clutch Spring (Diaphragm Type) 145 lb. (Green Paint Mark)
SERVICE / MAINTENANCE
CLUTCH / GEARSHIFT / LINKAGE
Clutch Fluid Type DOT 4 Hydraulic Brake Fluid -
Clutch Fluid Maintenance Flush Every 2 Years Refer to Periodic Maintenance Ch2
Clutch Lever and Pivots Lubricate Refer to Periodic Maintenance Ch2
Clutch Master Cylinder I.D. 12.7mm 12.743mm
Clutch Master Cylinder Piston O.D. - 12.55mm
SPECIAL TOOLS
PRIMARY DRIVE SPECIAL TOOLS
Crankshaft Rotation Socket 2008: PV-48736
Clutch Shaft Holder: PV-45028
Clutch Spring Compressor: PV-45032
Engine Lock Tool: PV-43502-A
Rotor (Flywheel) Puller: PV-43533
1/4 inch (or 6mm) and 5/16 (or 8mm) Pin Punch or Flat Punch: Commercially available
Moly Assembly Paste (P/N 2871460)
9.2
ASSEMBLY VIEWS & TORQUE VALUES

HYDRAULIC CLUTCH HOSE ROUTING
1.6 Nm (14 lb-in)
Torque rear
screw first
10.8 Nm (96 lb-in)
Torque front
screw last
Tie strap hose to 10.8 Nm (96 lb-in)
wire harness
Install New
24.5 Nm (18 lb-ft)
9
Route
Route
Do not route clutch hose through 10.8 Nm (96 lb-in)

the wire harness tie here
P-Clamp
Slave Banjo
Orientation
2.5 Nm (22 lb-in)

Fully Support
6 Nm (54 lb-in)
Slave Cylinder
Clutch line secured with wire To Prevent
Install
harness here Bending Pull Rod New
Route clutch hose over top triple-

clamp and back under as shown
8.5 Nm (87 lb-in)
9.3
HYDRAULIC CLUTCH SYSTEM COMPONENTS

See page 15.20 for clutch master cylinder service. The slave cylinder is not serviceable.
SPECIAL GREASE (009-Z00-115)

Application: External: Lever pivot screw, 1.6 Nm (14 lb-in)
contact surface of lever to pushrod, end of pushrod
to piston.
Brake
Torque first
10.8 Nm (96 lb-in)
Torque second
10.8 Nm (96 lb-in)
Install
new
6.1 Nm (54 lb-in)
1.0 Nm (9 lb-in)
24.5 Nm
(18 lb-ft)
2.5 Nm (22 lb-in)*

6 Nm (54 lb-in)*
Install new
* Fully support slave cylinder
to prevent bending pull rod
8.5 Nm
(87 lb-in)
Slave Cylinder Not Serviceable
9.4
CLUTCH (CABLE) ROUTING
Route through lower

handlebar tie strap
Cable
clamp
9
Torque rear
screw first 0.2 Nm (1.8 lb-in)
5.4 Nm (48 lb-in) 9.0 Nm (80 lb-in)
6.0 Nm (53 lb-in)
Strap
5.4 Nm
(48 lb-in)
9.5
SHIFT LINKAGE / FOOTREST - FASTENER TORQUE
Lubricate with mild soap and water to install
9.5 Nm (84 lb-in)
9.5 Nm (84 lb-in)
47.5 Nm (35 lb-ft.)
9.5 Nm (84 lb-in)
92.5mm (3.65)
92+/- 3
Adjustment:
1. Loosen lock nuts (A)
2. Rotate linkage rod until pedal height is within
specified range.
3. Tighten lock nuts to 11 Nm (96 lb-in).
11 Nm (96 lb-in)
9.6
PRIMARY COVER
7
Sealant bead faces cover
6
2 2 Nm (15 lb-in.)
5
3 4 5.7 Nm (50 lb-in.)
8 9 10 11 12
1
13
5.7 Nm
(50 lb-in.)
14 15 5 6 5 Nm (40 lb-in.)
13 Nm (115 lb-in.)
15  5
Stator Wire Detail 9
(Stator removed for clarity)
Cover
Route wires installed
between ribs
18
5.6 Nm
(50 lb-in.)
16
19
11.3 Nm (100 lb-in.) 17
Loctite 242 (Blue)
1. Sensor, Oil Pressure 11. Cap Plate
2. Gasket, Primary Cover 12. Screw (2) 6x14 Tapered
3. Asm, Primary Cover (Incl. 4, 5, 6) 13. Screw, Dog Point (1) 8x16
4. Bearing, Needle (1)
14. Screw, (16) 6x40
5. Bearing, Needle (2)
15. Screw (1) 6x30
6. Seal (2)
16. Bracket, Stator Wire
7. Pinion, Clutch
8. O-Ring 17. Screw, (2) 5x8
CAUTION
The rotor contains powerful magnets. Use caution when installing primary cover to avoid personal injury.
Refer to page 9.14.
9.7
SHIFT MECHANISM
Hold detent arm away until

shift star is installed and
screw (# 5) is torqued.
1
Straight end of spring in slot on crankcase.
Hooked end on arm.
2
Hold clutch shaft with PV-45028
Install new bolt upon assembly 3
34 Nm (25 lb-ft) 4
5
10
11
9.6 Nm (85 lb-in.)

Loctite 242 (Blue)
Apply Lithium Grease

9 6 7 8
1. Spring 7. Shift Ratchet Assembly
2. Roller Arm, Detent 8. Retaining Ring
3. Screw, Flanged 9. Adapter, Shift Shaft
4. Shift Star
10. Washer (Install new)
5. Screw, 6x20
9.8
SERVICE PROCEDURES CLUTCH PINION SHAFT REMOVAL

1. Protect finish of pinion shaft (E). Use an adjustable
CAP PLATE & CAP PLATE SEAL REMOVAL
wrench to rotate arm toward clutch slave cylinder and
1. Remove screws (A) and cap plate. remove slave cylinder pull rod pinion shaft.
2. Remove three screws (B), cover (C), and O-ring (D).
D
C
2. Remove primary cover cap plate, cover plate, and O-
B A ring (page 9.9).
3. Remove dog point screw (F).
9
4. Pull clutch pinion shaft out of primary cover.
CAP PLATE & CAP PLATE SEAL Cover installed

INSTALLATION 15o 5
1. Install new O-ring (D). F

2. Install cover (C).
3. Torque screws (B) to 5.6 Nm (50 in.-lb.).
4. Install cap plate with screws (A) and torque to 1.7 Nm G

(15 in.-lb.).
5. Inspect pinion shaft gear teeth (G) for cracks, broken

teeth, or wear.
CLUTCH PINION SHAFT BEARING

INSPECTION
1. Apply engine oil to the bearings.
2. Temporarily install pinion shaft into primary cover.
3. Turn shaft by hand. Replace bearings that feel rough,

notched, or loose.
9.9
CLUTCH PINION SHAFT SEAL REMOVAL & CLUTCH PINION SHAFT INSTALLATION
INSTALLATION
1. Lubricate and install clutch pinion shaft. Rotate
release rack with screwdriver until flat side of rack is
1. Remove clutch pinion shaft (page 9.9).
UP and rack teeth align with teeth of pinion shaft.
2. Push pinion shaft into cover until seated.
2. Carefully pry seal (A) out of primary cover.
3. Lubricate outer edge of new seal with engine oil and

sealing lip with grease. 3. Push lightly inward by hand on the clutch arm until it
stops. The arm must be positioned at a 15o±5o angle
4. Drive seal into place with a suitable driver (B). to primary cover parting line when it stops. If angle is
not correct, lift arm, rotate as needed, and re-install
until angle is correct.
4. Install dog-point screw (C) to 4.5 Nm (40 lb-in).
15o
9.10
PRIMARY COVER REMOVAL 8. Remove primary cover screws.
1. Refer to exploded view on page 9.7. NOTE: Note position of shorter screw (A) in the hole just
to the rear of the shift shaft.
2. Remove shift linkage and footrest as an assembly
(page 9.6). Note dots on arm and shaft must be aligned
for assembly
Pull Rod / Cable Removal From Release Arm
3. Protect finish of pinion shaft release arm and use an

adjustable wrench to rotate arm toward primary cover.
4. Remove pull rod or cable end from release arm. Do not

bend pull rod or kink cable.
9. Tap cover with a soft face hammer to loosen.

9
10. Pull primary cover outward evenly at front and rear of
cover to remove.
5. Remove cap plate and cap plate seal (page 9.9).
6. Remove clutch pinion shaft (page 9.9).

NOTE: Pinion shaft removal is not required for
primary cover removal unless pinion shaft service is
required.
7. Drain engine oil into suitable container.
NOTE: Primary cover can be removed without

draining engine oil by safely leaning and supporting
motorcycle at an angle to the right.
9.11
SHIFT RATCHET REMOVAL & INSPECTION 7. Inspect compression spring (D) for tension. The spring
should apply enough tension on the shift ratchet
1. Shift transmission into neutral. mechanism to keep it extended.
8. Inspect fit of rivet (E) on shift ratchet assembly. It

should allow for free movement, but not be excessively
loose.
A
9. Inspect fit of locating retainer clip (F) and all parts of
ratchet for cracks or damage.
C B
2. Remove primary cover (page 9.11).
3. Pull straight outward on shaft to remove the shift

ratchet assembly (A) with return spring (B) attached.
4. Inspect shift shaft adapter (C) on crankcase for wear

and verify it is tight. 10. Inspect cases around shift shaft adapter for cracks.
5. Inspect shift shaft return spring for cracks or loss of 11. Use a pin punch to hold detent roller away and remove
tension. The spring should have enough tension to shift star (G) from shift drum.
keep the shift shaft centered.
12. Inspect shift star.
13. Inspect detent roller arm (H) for wear or damage.
14. Inspect spring (I) for proper tension.
15. Remove detent roller arm and spring.
6. Inspect shift shaft for wear or damage.
9.6 Nm
(85 lb-in)
9.12
SHIFT RATCHET INSTALLATION SHIFT SHAFT BEARING & SEAL

Refer to Shift Mechanism Assembly View on page 9.8.
REPLACEMENT
1. Apply Loctite 242 (Blue) to clean threads of detent 1. Remove primary cover (page 9.11). Carefully pry shift
roller screw. Install detent roller arm (A) with spring shaft seal from cover.
and torque screw to 9.6 Nm (85 lb-in).
2. Be sure balance gear oiler pin (B) is tight in crankcase.
3. Torque shift shaft adapter (C) and apply a small
amount of lithium grease to shift shaft bore.
4. Clean threads of shift star screw with Loctite Primer N
and apply a few drops of Loctite 242 (Blue) to threads.
5. Hold detent roller away with a pin punch and install shift
star. Torque screw to 9.6 Nm (85 lb-in).
B A
2. Using a suitable arbor and arbor press, press bearing
from inside of cover to outside.
3. Apply assembly lube to inner & outer surfaces of new

bearing.
9
4. Press bearing into place with numbered side out until

fully seated.
C 34 Nm
(25 lb-ft)
6. Install shift ratchet into shift shaft adapter with

centering spring (D) attached. Slide ratchet fork (E)
away from shift star and hold. Center the legs of ratchet
return spring on pin and push ratchet in until seated.
Seal Driver
5. Apply a small amount of grease to lip of seal and apply

engine oil to outside of seal.
6. Drive seal into place with a seal driver slightly smaller

E than the O.D. of seal.
7. Install primary cover (page 9.14).
7. Release ratchet fork to engage ratchet with shift star. 8. After installing primary cover, be sure shift shaft returns
8. Install clutch (page 9.22). freely to the centered position after rotating up or down.
9.13
PRIMARY COVER INSTALLATION 7. Install pinion shaft (page 9.10).
1. Clean gasket surfaces of crankcases and cover. 8. Install cap plate with seal (page 9.9).
2. Verify alignment pins (A) are in position and pinion 9. Install slave cylinder pull rod on pinion shaft arm.
shaft is removed from cover. 10. Lubricate clutch lever (page 2.11).
3. Place new primary cover gasket on crankcase with 11. Install shift linkage arm on shift shaft with dots aligned
sealant bead (B) out (toward cover). Loctite 534 can and install left footrest assembly. Torque linkage arm
be used to hold gasket in place. pinch bolt to 9.5 Nm (84 lb-in).
15o
B
A
4. Install cover keeping it parallel to crankcase to prevent 12. Check engine oil and fill to proper level (Chapter 2).
binding on shift shaft.
LOCKING THE CRANKSHAFT
CAUTION Service procedures described in this chapter require
The rotor magnets have considerable energy. DO NOT locking of the gears or shafts to prevent rotation while
place fingers between primary cover gasket surface and removing or installing the retaining nuts. Engine Lock Tool
other parts or they may be pinched. PV-43502-A is described in most procedures; however, in
some cases it is preferable to lock the engine crankshaft
5. Install primary cover screws. (shown below) or the clutch shaft using tool PV-45028.
NOTE: Short screw (C) is placed in hole just behind shift • Remove RH lower engine cover.
shaft.
• Remove crankshaft position timing wheel.
• Rotate engine to front or rear cylinder TDC with tool
PV-48736 until 8mm (5/16 inch) pin punch can be
inserted into the crankshaft TDC location hole.
C
6. Torque screws in two steps to 13 Nm (115 lb-in).
Repeat torque on all screws.
9.14
CLUTCH SERVICE
CLUTCH ASSEMBLY VIEW & TORQUE
15 16
Friction Washer
Install new
170 Nm (125 lb-ft)
Install New
17
18 19
9.6 Nm (85 lb-in)
9.15
CLUTCH REMOVAL 4. Remove clutch nut, lock washer, and flat washer.
Discard lock washer and nut.
2. Using an internal snap ring pliers, remove clutch rack.
5. Remove clutch assembly from clutch shaft.

3. Install engine lock tool (A) between crankcase and split
6. Remove friction washer (B) from clutch shaft (2010)
gear as shown below to prevent gear rotation and
and discard. A new washer must be installed upon
loosen clutch nut (rotor / starter gear removal is not
assembly.
required).
NOTE: 2010 models were equipped with this washer.
NOTE: An alternate method of preventing gear
Installation of the washer is recommended for 2008 /
rotation is to lock the crankshaft as shown on
2009 models upon assembly.
page 9.14.
Special tool: Engine lock tool PV-43502-A
B
A
CAUTION
Use caution when removing nut and keep hands and
body clear in case tool slips off gears.
9.16
CLUTCH DISASSEMBLY 4. Remove retaining ring seat (B) (stepped washer).
Special tool: Clutch spring compressor PV-45032
B
CAUTION
Clutch is under spring pressure. WEAR EYE
PROTECTION.
1. Install clutch spring compressor threaded rod and

secure it with the snap ring (A).
5. Remove tool from clutch.

A 6. Refer to exploded view on page 9.15.
7. Disassemble clutch, laying parts out in order of

removal and keep them in order.
8. Remove clutch spring (C) and pressure plate (D).

9
9. Remove (1) special friction plate (E) that is placed
outermost against pressure plate.
2. Install compressor bridge, bearing, and T-handle over

threaded post.
3. Compress clutch spring and remove snap ring. C
E D
10. The outermost plate can be identified by the wider pads

on the friction material.
9.17
11. Remove (9) identical steel plates that separate the (8) 5. Rotate hub bearing. Check for smooth rotation. Inner
identical friction plates. race should no detectable radial movement (C).
12. Remove judder friction plate, judder spring, and judder 6. Lubricate bearing with engine oil.
spring seat.
Clutch Hub
13. Note difference between judder plate (F) and next
friction plate (G). The judder plate is the innermost 7. Inspect spline teeth (D) for wear, cracks or damage.
friction plate on the clutch hub.
D
E
F
8. Inspect surface of steel plate guides (E) on outer edge

of hub for wear, grooves, or damage. Check all posts
(F) for cracks or damage. Check the snap ring groove
for wear.
CLUTCH INSPECTION 9. Visually inspect friction and steel plates for wear or
damage on both surfaces. Replace plates as a set if
1. Clean clutch plates, inner hub, and outer basket.
any plate is worn or damaged.
Clutch Basket
2. Inspect clutch gear teeth (A) for wear, cracks or
damage.
3. Inspect inside surfaces (B) of basket for cracks or wear
(grooves) from clutch plates.
A
C
B
4. Replace parts that fail inspection
9.18
10. Replace steel plates if grooved, distorted or discolored. Diaphragm Spring

Inspect plates for distortion by placing each plate on a
precision flat surface. Insert a feeler gauge (G) 14. Inspect clutch diaphragm spring (I) for cracks or
between plate and flat surface in several places. distortion.
15. Inspect inner and outer edges of spring carefully for

unusual wear or damage. Outer edge should lay flat
against a surface plate and inner tabs should be even
G in height (J).
J
Clutch Steel Plate Warp Service Limit: .20mm (.008in)
11. Measure thickness of friction plates in several places.
Thickness should be the same at each place. Replace
plates that fail inspection.
Clutch Release Rack and Bearing

9
16. Inspect clutch rack for broken or damaged teeth.
Friction Plate Thickness Minimum): 2.00 mm (.078 in)
Clutch Pressure Plate
12. Inspect pressure plate for cracks, scoring, or wear on

friction surface. 17. Remove retaining ring and disassemble.
13. Inspect lifter retaining ring groove (H) for cracks or 18. Inspect lifter bearing visually for any signs or wear or
chips. Replace pressure plate if it fails inspection. discoloration. Rotate bearing inner race with your
finger and check for smooth movement and no play.
9.19
19. If bearing (K) fails inspection, remove it from housing CLUTCH ASSEMBLY
(L) using an arbor press. Support housing evenly in
areas (M) during bearing removal. 1. Refer to exploded views on page 9.15. Apply engine
oil to judder spring seat (A) and spring (B).
K L
A
M
B
O
M
20. Press new bearing into housing until seated and past
snap ring groove (N). Press only on outer race of 2. Install judder spring seat (flat ring), then judder spring.
bearing.
NOTE: Judder spring must be installed with concave
21. Install rack into bearing as shown. side facing UP (toward outside of clutch). The tallest edge
of spring will be outermost.
22. Install retaining ring (O) with sharp (machined) edge
away from bearing (toward rack teeth). Be sure it is fully 3. Apply engine oil to judder friction plate and install.
seated.
NOTE: This plate has a thinner profile (C) than the rest of
the friction plates.
9.20
NOTE: Feel the edge of steel plates and friction plates 7. Install clutch diaphragm spring (D) with concave side
with your finger. One side of plate is machined at the down on top of pressure plate.
edges and the other side is a rolled edge (rounded).
8. Place retaining ring seat (E) and retaining ring over
Install steel plates with machined edge facing UP. Install
clutch assembly before installing clutch spring
friction plates with rolled edge facing UP.
compressor tool. Flange on inner edge of seat faces
UP as shown.
Clutch Plate Direction
Sharp Edge up
D
Steel Plate
Rolled Edge up
E
Friction Plate
Clutch Basket
4. Place an oiled steel plate into clutch basket with

machined edge UP.
NOTE: If friction plates are new, soak them in clean CAUTION

9
engine oil for a few minutes before installing.
Tool will be under spring pressure.
5. Continue stacking oiled clutch plates into clutch basket WEAR EYE PROTECTION.
alternating friction and steel plates until all are
installed, ending with the special friction plate. 9. Install compressor tool and compress spring so ring
seat can be positioned and retaining ring installed.
NOTE: Be sure to install special friction plate last
(against pressure plate). As noted in Disassembly, Special Tool: Clutch Spring Compressor PV-45032
the friction material on this plate has wider pads than 10. Install retaining ring with machined (sharp) edge up.
the other (8) common friction plates. See illustrations Position retaining ring so one end of retainer is located
on page 9.15 and photo below. on one of the posts (F).
6. Install clutch pressure plate on top of clutch packing.
Wide tabs =
Outer plate
F
Pressure plate
11. After retaining ring is installed, slowly release pressure

from tool and guide flange into position under the
retaining ring.
12. Remove spring compressor tool. Inspect retaining ring
to be sure it is fully expanded and seated in groove.
9.21
CLUTCH INSTALLATION
Replace with new

A
Replace with new

170 Nm (125 lb-ft)
C
E
D
B Replace with new
F G
1. Install a NEW friction washer (A) on clutch shaft. DO 5. Install lock tool under split gear or lock crankshaft as
NOT re-use this washer. shown on page 9.14. Torque nut to specification.
NOTE: This washer is installed on 2010 models and is
recommended for installation on all 2008 and 2009 when Engine lock tool PV-43502-A
clutch is removed for service.
6. Install clutch lifter assembly (F) and retaining ring (G).
2. Pry back split gear (B) to align teeth and push clutch Be sure retaining ring is seated in groove.
assembly onto clutch shaft until gear is fully engaged
with torque compensator gear.
8. Check engine oil and fill to proper level.
3. Clean clutch shaft threads with Loctite™ Primer N to
remove all grease, oil, or old locking agent.
4. Install washer (C), a new lock washer (D) and a new

nut (E).
9.22
PRIMARY DRIVE ASSEMBLY VIEW & TORQUE
Replace nut if loosened or removed.

Align timing marks during assembly (Pre-applied locking agent, M20x1.5)
170 Nm (125 lb-ft)
Moly Lube
102 Nm (75 lb-ft)

25* 24 9
See NOTE: below
Replace screws if loosened

57T or removed. 41 Nm (30 lb-ft)
11T 27 28 30
29 Puller Thread M20 x 1.5
9.6 Nm (85 lb-in)
26
25* NOTE: Lay idler gear in crankcase before
removing / installing primary drive gear.
IMPORTANT: Torque compensator (items 6-13) must be assembled with engine upright to prevent dislocation of
washer (item 6) from sleeve (item 8) when items 9-13 are installed. See procedure page 9.23.
1. Gear, Split, 37T 16. Rotor
2. Spring, Split Gear (4) 17. Key, Rotor
3. Gear, Split, Backlash 18. Retaining Ring
4. Retaining Ring 19. Flat Washer
5. Assembly, Split Gear (incl. items 1-4) 20. Starter Drive Gear, Crankshaft
6. Thrust Washer, Compensator 21. Starter Drive Clutch
7. Compensator Gear 22. Screw, Special (6) (Replace if removed or loosened)
8. Compensator Sleeve 23. Crankshaft Gear (Primary Drive Gear)
9. Compensator Slider 24. Shaft, Idler Gear
10. Compensator Spring, Belleville (4) 25. Idler Gear, Starter (See NOTE: #25 in illustration above)
11. Compensator Retainer 26. Torque Limit Clutch, Starter
12. Lock Washer, Split 27. Bearing
13. Nut, Special (Replace if removed or loosened) 28. O-Ring
14. Bolt, Oil Jet 29. Cover, Limit Clutch
15. Washer, Flat 30. Screw, Socket Head, M6 x 15
9.23
TORQUE COMPENSATOR REMOVAL 6. Remove gear (A) with compensator sleeve (B), and
washer (C). The washer must be positioned correctly
See Torque Compensator Assembly View (page 9.23). If upon assembly. See assembly procedure page 9.25.
split gear removal is required, see page 9.27 after
compensator is removed. A
2. Lock the engine to prevent rotation with the lock tool
or lock the crankshaft as described on page 9.14.
Engine lock tool PV-43502-A B
3. Remove torque compensator nut and lock washer and
discard. C
4. Remove retainer plate and Belleville springs.
Note orientation of washers (concave edges of
washers face each other) for installation.
TORQUE COMPENSATOR INSPECTION

1. Inspect all parts for excessive galling or damage.
NOTE: Some polishing will be evident between the
compensator gear and the compensator slider and is a
normal condition. Replace assembly if ramps are worn.
2. Measure free length of torque compensator spring
stack.
5. Remove outer ramp.
Surface Plate
Specification: Compensator Spring Stack Height

Standard: 17.68-18.08mm
(.696 - .712 inch)
Service Limit: 16mm

(.630 inch)
9.24
TORQUE COMPENSATOR INSTALLATION 7. Install sleeve (E) into gear and place washer (F) over
the protruding end of the sleeve on back side of gear.
NOTE: Engine must be upright for this procedure. It
is very important that washer (A) does not fall off the
sleeve (B) during assembly. Perform all steps to
ensure washer is in place before installing springs
and retainer plate.
Install New
E
A F
Ill. 1 8. Slide assembly onto balance shaft and seat it firmly

against split gear, using care not to dislodge the
1. Push split gear (B) fully inward to be sure it is seated. washer from the sleeve.
2. Place sleeve (C) on balance shaft and hold it in against 9. Grease the peaks and valleys gear, sliding ramp, and
split gear. splines of sleeve.
3. Pull balance shaft (D) fully outward.
9
4. Measure and record the distance from sleeve to end
of shaft.
D
B
10. Install sliding ramp.
5. Remove sleeve from balance shaft.

6. Apply Moly Assembly Paste 2871460 shaft splines,
sleeve, back side of gear, and washer.
Moly Assembly Paste: 2871460
11. Repeat measurement, pushing sleeve inward and

pulling shaft outward. Measurement should be the
same as recorded in Step 4. Disassemble and inspect
washer placement if measurement is not the same.
9.25
12. Grease edges of springs and retainer plate. Illustration ROTOR (FLYWHEEL) REMOVAL
below shows correctly assembled springs, with
concave edge facing each other. The assembled sets 1. Remove primary cover (page 9.11) and rotor retaining
of two spring washers are stacked back to back. bolt (counterclockwise). Lock the engine to prevent
rotation with the lock tool (insert at point A) or lock the
crankshaft as described on page 9.14.
13. Install retainer plate and Belleville spring assembly, Engine lock tool PV-43502-A
pushing it onto splines as far as possible.
14. Clean balance shaft threads thoroughly to remove CAUTION
all old locking agent, oil, or grease.
Use caution when removing nut and keep hands and
15. Install a new lock washer, and nut. The nut has a pre- body clear in case tool slips off gear.
applied locking agent.
2. Remove lock tool.
3. Cover crankcase cavity under rotor with a clean shop
towel to prevent parts from falling into case.
Install new parts B
102 Nm (75 lb-ft)
16. Hold shaft by inserting lock tool or pin the crankshaft.

17. Torque nut to 170 Nm (125 lb-ft.).
4. Install puller (B). Install lock tool (C) on bottom of gear
TORQUE: Compensator Nut and rotate puller clockwise to remove rotor.
170 Nm (125 lb-ft) Rotor Puller PV-43533
5. Remove rotor and key.
18. Install primary cover (refer to page 9.14).
19. Fill engine oil to proper level.
9.26
ROTOR (FLYWHEEL) INSTALLATION 8. Insert a 1/4” pin punch in gear alignment hole (B) to
relieve spring pressure on gear teeth.
1. Clean taper of rotor and crankshaft thoroughly.
2. Install key in key way on crankshaft.
B
3. Align rotor key-way and install rotor on crankshaft. B
4. Position the lock tool as for rotor removal (C, previous
photo) or lock the crankshaft as described on
page 9.14.
5. Install washer & bolt. Torque to 102 Nm (75 lb-ft).
9. Pull split gear off balancer shaft.
102 Nm (75 lb-ft)

SPLIT GEAR INSPECTION
9
1. Remove retaining ring (C) from split gear hub and
separate outer gear from inner gear. Visually inspect
SPLIT GEAR REMOVAL contact surfaces of gears, springs, spring channels,
1. Remove primary cover (page 9.11). and gear teeth.
2. Remove rotor (page 9.26).
3. Remove clutch assembly (page 9.16).
4. Remove torque compensator (page 9.24).
5. Remove starter gear retaining ring (A) with a flat-billed
external ring pliers. Remove any burrs from crankshaft
ring groove before removing starter gear, or starter
C
gear bushing may be damaged when gear is removed.
NOTE: Some normal polishing may be evident in the

spring channels of gears. Replace the gear assembly if
wear is evident.
2. After assembly, outer gear must rotate and return freely
6. Remove torque compensator (page 9.24). without binding on inner gear.
7. Temporarily install rotor to rotate engine until key is
pointing up, and timing marks on split gear are aligned
with mark on crankshaft gear.
9.27
SPLIT GEAR INSTALLATION 7. Push split gear inward until fully seated and flush with
1. Rotate balance shaft until “boss” spline (D) (double crankshaft gear. Verify proper balance shaft timing.
wide spline) is at 12:00 o’clock position.
2. Apply grease to balance shaft and back of split gear

assembly.
3. Line up teeth of split gear assembly with 1/4" straight
pin in hole (E). Leave pin in place.
4. Do not allow pin to protrude out the back of the split
gear assembly.
8. Install torque compensator (page 9.25), starter gear

(page 9.32), rotor (page 9.27), clutch (page 9.22), and
primary cover (page 9.14).
5. Place split gear on balance shaft with alignment dots

at the 9:00 o’clock position.
6. Align “boss” splines of balance shaft and split gear
while engaging crankshaft gear with split gear. Dot on
crankshaft gear (F) must be between the 2 dots on
balance gear (G).
F G
9.28
STARTER DRIVE STARTER GEAR INSPECTION

1. Inspect gear teeth for chips, cracks or excessive wear.
STARTER DRIVE REMOVAL
NOTE: The starter gear and primary drive (crankshaft)
gear must be removed before the starter idler gear or
starter torque limiter clutch and shaft can be removed 33.350 +/- 0.025
from crankcase.

2. Remove rotor (page 9.26). 49.7215
B +/- 0.0065
Rotor Puller PV-43534
3. Place a shop towel in the crankcase cavity.
4. Remove starter gear retaining ring (A) with a flat- billed
external ring pliers. Remove any burrs from crankshaft
ring groove before removing starter gear, or starter
C
gear bushing may be damaged when gear is removed.
2. Inspect bushing (B) for excessive wear and scoring.
3. Inspect one-way clutch hub (C) for wear, scoring or
rough surface.
4. Measure I.D. of bushing and O.D. of one-way clutch
hub and compare to specification. 9
5. Replace gear if wear or damage is evident.
A
STARTER CLUTCH REMOVAL / INSPECTION
1. Remove one-way clutch from primary drive gear.
2. Note direction of one-way clutch with flanged side (D)
inward (toward engine) for reassembly.
D
5. Remove flat washer and gear.
3. Inspect cage for cracks. Check band springs for

tension and proper function.
4. Inspect clutch lobes for wear, galling, or rough surface.
5. See “STARTER GEAR / STARTER CLUTCH
INSTALLATION” on page 9.32
9.29
PRIMARY DRIVE GEAR 9. Pull torque limiter clutch shaft out through cover
opening with washer.
PRIMARY DRIVE GEAR REMOVAL / NOTE: Stepped side of washer faces out (toward gear)
INSPECTION and flat side of washer is against limiter clutch (inset).
1. Install engine lock tool in position (A) to hold 10. Remove torque limit clutch.
crankshaft gear stationary while removing bolts.
2. Remove primary gear screws. NOTE: Install new
screws with pre-applied locking agent upon assembly. STARTER TORQUE LIMIT CLUTCH
3. Use a primary cover screw to pull idler gear shaft (B). INSPECTION
1. Mount torque limit clutch in a soft jawed vise across
A entire gear face (D). Clamp only tight enough to
prevent gear rotation.
Place gear here
B
B D
F
E
IMPORTANT! Position idler gear as shown for primary
gear removal. If removed from the case, place idler gear
back in this position BEFORE installing primary gear.
4. Pull primary drive gear off crankshaft. 2. Install shaft with spacer (E).
5. Remove idler gear from crankcase. 3. Use a 19mm 12 point socket on gear (F).
6. Inspect clutch hub surface (C) inside primary drive 4. Read torque at point of clutch slip.
gear for wear, scoring, nicks, or rough surface.
Limit Clutch Break-Away Torque:
Standard: 46-61 Nm (35-45 lb.-ft.)
Service Limit: 40 Nm (30 lb.-ft.)
7. Inspect gear teeth on idler and primary drive gear for

chips, cracks or excessive wear.
8. Remove starter drive cover.
9.30
PRIMARY DRIVE GEAR INSTALLATION 8. Install drive gear. If split gear is installed, rotate drive
gear clockwise against spring pressure until split gear
1. Clean mating surfaces of crankshaft and gear. teeth align. Push gear in and rotate until pin on
2. Clean screw threads in crankshaft to remove all locking crankshaft aligns with hole on the back of drive gear.
agent, oil, and grease with Loctite™ Primer N and dry Primary and split gear teeth will be flush if fully seated.
with low pressure air.
NOTE: Starter torque limit clutch (A) and idler gear (B) 41 Nm (30 lb-ft.)
MUST be placed in the case before the primary drive
gear is installed.
A Clean all holes
Use all NEW screws
B
9. Install new primary drive gear screws. These screws
have a pre-applied locking agent. Always replace
these screws if loosened or removed.
10. Install screws and torque in 2 steps following a star 9
pattern to 41 Nm (30 lb-ft.). Repeat final torque on all
3. Place idler gear in crankcase but do not install shaft. screws.
4. Temporarily install rotor to rotate engine until key is 11. Install idler gear and shaft (C).
pointing UP. Remove rotor.
5. Install primary gear on crankshaft with dot on gear at
the 3:00 position (90 degrees to the rear).
C
12. Install starter clutch and gear (page 9.32).

6. Engage teeth of primary gear and split gear, with dot
on primary gear between two dots on split gear.
7. Place engine lock tool between bottom of inner split
gear and crankcase.
9.31
STARTER GEAR / STARTER CLUTCH 4. Install retaining ring (D).

INSTALLATION
1. Install one-way clutch with raised edge (A) inward
(toward primary gear).
D
5. Install rotor (page 9.27).
2. Install starter gear (B). When properly installed, the 7. Check engine oil and fill to proper level.
starter gear should rotate smoothly in a clockwise
direction and lock to the primary gear when you
attempt to rotate it counterclockwise.
3. Install washer (C).
9.32
TROUBLESHOOTING
TROUBLESHOOTING
Clutch Lever Pulls Clutch lever pivot, bushings,
Clutch Lever Pivot Point Lubricate
Excessively Hard ferrules need lubrication
Master cylinder or Slave
Contaminated hydraulic system Inspect
cylinder
Drive plates catching on primary Clutch Primary Driven Gear/
Replace Necessary Parts
driven gear basket Clutch Plates
Clutch lifter plate bearing damage Clutch Plate Bearing Lifter Replace
Damaged clutch lifter Clutch Release Mechanism Repair as Necessary
mechanism or Slave Cylinder
Clutch Slips Clutch Spring Weak Clutch Spring Replace
Contaminated hydraulic system Master or Slave cylinder Inspect
Clutch Spring Snap ring Loose or Clutch Spring Snap ring Repair or Replace as
Broken Necessary
Pressure Plate Worn or Warped / Pressure Plate Replace
Distorted
Clutch Plate(s) Worn or Warped/ Driven Plates (possibly drive Replace
Distorted plates) 9
Clutch Lifter Mechanism Sticking Clutch Lifter Mechanism Repair
Engine Oil Level Low Oil Level Correct
Oil Additives Present in Oil or Oil Quality Replace oil & filter
Used Previously (clutch plates may need to
be replaced)
Dragging Clutch Clutch Lever, master cylinder or Lever, Master or Slave Inspect
(doesn’t disengage slave cylinder sticking cylinder
completely, creeping, Air in hydraulic system Master or Slave cylinder Inspect / Bleed (Ch15)
hard to find Neutral) Oil Additives Present in Oil or Oil Quality Replace oil & filter (clutch
Used Previously plates may need to be
replaced)
OIl Level Too High Oil Level Correct
Oil Viscosity Too High Oil Quality Replace Oil & Filter
Pressure Plate Worn or Warped/ Pressure Plate Replace
Distorted
Clutch Plate(s) Warped / Distorted Driven Plates (possibly drive Replace
plates)
Weak Clutch Spring(s) Clutch Springs Replace All
9.33

Transmission Will Not Broken Shift Drum Shift Drum Replace shift drum
Shift Bent Shift Forks Shift Fork Replace shift forks
Worn Shift Drum Shift Drum Replace shift drum
Broken Gears Transmission Gears Replace broken gear(s)
Damaged/Broken Bearings Transmission, Shift Cam Replace bearings that fail
Bearings inspection
Worn Gear Shift Pawl Ratchet Shift Pawl Mechanism Replace parts that fail
Mechanism inspection
Broken or dislodged shift shaft Shift Shaft Return Spring Repair or Replace
return spring
Roller Detent Arm Seized Roller Detent Arm Repair or replace parts
Bent Shift Shaft (internal) Shift Shaft Repair or Replace
External Shift Linkage External Shift Linkage Repair or Replace as
Binding or Damaged
Bent or Distorted Shift Forks Shift Forks Replace
Bent or Distorted Shift Fork Rails Shift Fork Rails Replace
Broken Transmission Transmission Components Repair or Replace
Components
Transmission Hard to Improper Clutch Operation Clutch Inspect, Repair
Shift Incorrect Oil Viscosity Oil Quality Replace Engine Oil
Incorrect Clutch Clutch Adjustment Adjust
Adjustment
Shift Shaft Damaged Shift Shaft Components Repair or Replace
Sticking Pivot Point, Bent External Shift Linkage Repair or Replace
External Shift Linkage
Bent or Distorted Shift Forks Shift Forks Replace
Damaged Shift Drum Grooves Shift Drum Repair or Replace
Shift Detent Plunger Stuck Shift Detent Plunger Repair or Replace
Bent/Binding Shift Fork Rails Shift Fork Rails Repair or Replace
Transmission Jumps Out Broken / Loose Stop Pin Shift Stop Pin Replace
of Gear Worn Shift Drum or Shift Drum Shift Drum or Shift Linkage Replace as Necessary
Ratchet
Broken Shift Return Spring Shift Return Spring Replace
Damaged Shift Drum Grooves Shift Drum Repair or Replace
Bent or Worn Shift Forks Shift Forks Repair or Replace
Bent/Binding Shift Fork Rails Shift Fork Rails Repair or Replace
Worn Engagement Dogs on Transmission Gears Repair or Replace
Transmission Gears
Transmission Noise Drive Belt Tension Incorrect Drive Belt Adjust or Replace
Clutch Plates Bind or Drag Clutch Plates Adjust / Repair / Replace
(When Clutch is Disengaged)
Gear/Bearing Wear/Damage Transmission Components Inspect / Repair / Replace
9.34
TRANSMISSION & CRANKSHAFT
CHAPTER 10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
CRANKCASE / CRANKSHAFT / CONNECTING ROD SPECIAL TOOLS. . . . . . . . . . . 10.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
CONNECTING ROD AND CRANKSHAFT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 10.3
ASSEMBLY VIEWS & TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
CRANKCASE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
CRANKSHAFT / CONNECTING ROD / CRANKCASE TORQUE PATTERN . . . . . . . . 10.5
CRANKCASE BOLT LENGTH AND TORQUE PATTERN. . . . . . . . . . . . . . . . . . . . . . . 10.5
SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
TRANSMISSION ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
MAINSHAFT / CLUTCH SHAFT ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
COUNTERSHAFT ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
SHIFT DRUM AND SHIFT FORK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
POWER DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
CLUTCH SHAFT INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
CONNECTING ROD SIDE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 10.16
CONNECTING ROD REMOVAL / IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
10
CONNECTING ROD INSPECTION (BIG END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
CONNECTING ROD BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
CONNECTING ROD BEARING CLEARANCE INSPECTION (TYPICAL) . . . . . . . . . . 10.18
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
CRANKSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
CRANKSHAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
MAIN BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
MAIN BEARING OIL CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
LEFT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
RIGHT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CRANKCASE REED VALVE ASSEMBLY REMOVAL & INSPECTION. . . . . . . . . . . . 10.22
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
BALANCE SHAFT REMOVAL & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
CRANKCASE ASSEMBLY & SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
10.1
GENERAL
SERVICE INFORMATION
• Remove engine from frame to service internal transmission and/or crankshaft components (Chapter 6).
• The crankcase must be separated to access internal transmission components and crankshaft. Remove:
•Cylinder heads
•Cylinders & pistons
•Gear shift linkage
•Primary cover and components (as required depending on needed access to other components).
•Regulator / Rectifier and Bracket.
•Starter motor
• Label and store parts neatly to speed the assembly process and ensure that matched parts like connecting
rods, camshaft carriers, and bearings can be installed in their original location.
• Crankshaft main bearing replacement requires line boring. This procedure requires full machine shop
capabilities and specialized knowledge. It is recommended that a qualified machine shop perform this
procedure if it becomes necessary or replace the crankcase assembly.
• Crankshafts and connecting rods are color coded for manufacturing tolerances with a white or red paint mark (or
stamped “R” or W”). See page 10.18.
• All torque specifications are "dry" unless specified for oil or locking agent. Refer to exploded views.
• When locking agents are required, use Loctite Primer N to clean fastener before applying locking agent.
Primer N reduces cure time of thread locking agent in addition to preparing the surfaces.
SPECIAL TOOLS
CRANKCASE / CRANKSHAFT / CONNECTING ROD SPECIAL TOOLS
Crankshaft Main Bearing Protector: PV-47207
Crankcase Separator: PV-47332
Crankcase Assembly Tools:
Base Tool: PV-45030
Collar: PV-46299 (M36 x 1.50 thread for use with PV-45030
Assembly Adapter: PVX-47429 (for use with PV-45030)
Drive Sprocket Seal Installer: PV-43505A
Clutch Shaft Installation Tool: PV-47331
SPECIFICATIONS
DRIVE TRAIN
Item Specifications
Drive Train (General) Transmission 6 Speed (Overdrive)
Primary Reduction Ratio 1.50: 1
Final Reduction Ratio 2.12: 1
Drive Train (Gear Ratios) Gear Ratio: 1st Gear 3.15: 1

Gear Ratio: 2nd Gear 2.03: 1
Gear Ratio: 3rd Gear 1.53: 1
Gear Ratio: 4th Gear 1.24: 1
Gear Ratio: 5th Gear 1.00: 1
Gear Ratio: 6th Gear (Overdrive) 0.84: 1
10.2
CONNECTING ROD AND CRANKSHAFT SPECIFICATIONS

CRANKSHAFT and COMPONENTS
Part Part Specific Standard Service Limit
Connecting Rod Connecting Rod to .22 - .42 mm .65 mm
Crankshaft Side Clearance (.0087 - .0165") (.025")
Connecting Rod Bearing to .0254 - .0635 mm .11 mm
Crankshaft Oil Clearance (.001 - .0025") (.0043")
Connecting Rod Small End 22.01 - 22.02 mm 22.09 mm
I.D. (.8665 - .8670") (.8694")
Connecting Rod Width 20.28 - 20.34 mm 20.03 mm
(.798 - .801") (.788")
Connecting Rod Big End I.D. 50.84 - 50.85 mm 50.89 mm
(White) (2.0016 - 2.0020") (2.0031")
Connecting Rod Big End I.D. 50.85 - 50.86 mm 50.89 mm
(Red) (2.0019 - 2.0024") (2.0034")
Crankshaft Main Bearing Connecting Rod Journal 40.00 - 40.58 mm 41.35 mm
/ Rod Journals Width (1.5748 - 1.5976") (1.627")
Crankshaft Rod Journal O.D. 47.970 - 47.978 mm 47.94 mm
(White) (1.888 - 1.889") (1.8871")
Crankshaft Rod Journal O.D. 47.978 - 47.986 mm 47.95 mm
(Red) (1.8888 - 1.8891") (1.8875")
Main Bearing Oil Clearance Left .013 - .060 mm .10 mm
(.0005 - .0023") (.004") 10
Right .014 - .061mm .10 mm
(.0005 - .0024") (.004")
Left Main Bearing Journal 64.952 - 64.973 mm 64.93 mm
O.D. (2.5571 - 2.5579") (2.556")
Right Main Bearing Journal 59.952 - 59.973 mm 59.93 mm
O.D. (2.3603 - 2.3611") (2.359")
.05 - .30 mm
Crankshaft End Play -
(.0019 - .0118")
Balance Shaft Journal O.D., Left (Primary 29.980 - 29.992 mm
Side) Journal O.D., Right (Oil 29.969 - 29.979 mm -
Pump Drive Side)
Transmission
Shift Fork Shift Fork I.D. (Dimension A, 12.00 - 12.026 mm 12.05 mm
page 10.11) (.4725 - .4732") (.4744")
Shift Fork Pin O.D. 6.036 - 6.136 mm 6.02 mm
(Dimension B, page 10.11) (.2376 - .2416") (.2370")
Shift Fork Width (Dimension 5.10 - 5.30 mm 5.05 mm
D, page 10.11) (.2008 - .2086") (.1988")
Shift Fork Rail Shift Fork Rail O.D. 11.948 - 11.972 mm 11.92 mm
(Dimension C, page 10.11) (.4704 - .4713") (.4693")
Shift Fork Rail Runout - .025 mm
(.001")
Shift Drum Shift Drum Groove - Replace drum if any wear is
evident
10.3

CRANKCASE COMPONENTS
Press until seated Install with chamfer side to bore.

Press until seated. Center reed valve
13x10 over hole in case
Replace bearing retainer plate screws if removed!
Press bearings by outer race only!

85 lb-in. (9.6 Nm)
Apply Lithium grease to bearing bores.
Press flush with surface.
Apply Lithium grease to bearing bores.
Press until completely seated.
Install with chamfer side
65 lb-in. to bore.
(7.3 Nm) Press until seated.
Loctite 262 13x10
65 lb-in.
(7.3 Nm)
25 lb-in.
(2.8 Nm)
115 lb-in.
(13 Nm)
Install with chamfer side to bore.
Press until seated.
11x10
Oiler Dowel
Apply Lithium grease to bearing bores. See details below
Press until completely seated.
Oil Jet Orientation
Section AA
Pressed in
LH Case with flat surface
facing DOWN
10.4
CRANKSHAFT / CONNECTING ROD / CRANKCASE TORQUE PATTERN

Arrow on piston crown or circlip access notch
faces FRONT of engine Place gap of circlip at 12 O’clock position (UP)
LEFT connecting rod to rear cylinder

“OUT” on LH rod faces left end of crank
Torque connecting rod caps:

1) Evenly to 7 Nm (5 lb-ft) to seat cap
2) To 54 Nm (40 lb-ft) final torque
Plug: 20 Nm (15 lb-ft.)
RIGHT connecting rod Loctite 609 (Green)
to front cylinder Press until bottomed in hole
“OUT” on RH rod faces
right end of crank
See page 10.18 for bearing color 10

codes, size chart, and part numbers
CRANKCASE BOLT LENGTH AND TORQUE PATTERN

Crankcase Bolt Torque: Torque bolts in order 1-14 (shown below) in two steps to 30 Nm (22 lb-ft.).
Repeat 30 Nm (22 lb ft. torque.
B A Crankcase Bolt Length:

A = 8 x 135
P clamps B = 8 x 110
for wiring NOTE: Install starter motor
with bolts #3 & #4
B
Crankcase Bolt #2 (CPS wire guide):
bolt torque Orient guide as shown below
- END
B Dot faces
Crankcase bolt torque - START OUT
P clamp
RH Case faces case
Flat edge
10.5
SERVICE PROCEDURES 9. Loosen remaining crankcase bolts evenly and remove

from case. Note the two different bolt lengths and the
CRANKCASE SEPARATION locations of each (page 10.5).
10. Install the crankshaft bearing protector over the cam
1. Drain engine oil. chain drive gear on the crankshaft.
2. Remove drive sprocket (Chapter 11). Special Tool: Crankshaft Bearing Protector PV-47207
3. Remove regulator / rectifier to avoid damage. 11. Install crankcase separator tool on crankcase over the
main shaft and tighten screws. Tighten the center
4. Remove engine and mount securely on an engine screw while tapping with a soft faced mallet.
stand. (Chapter 6). Special Tool: Crankcase Separator PV-47332A
5. Remove primary cover (Chapter 9). NOTE: PV-47332 can be modified for use on 2008
6. Remove cylinder heads (Chapter 7), cylinders, and crankcase. Drill an additional hole in the location
pistons (Chapter 8). shown (see bottom photo).
7. Remove shift ratchet and clutch (Chapter 9).

NOTE: For transmission service only, remove:
PV-47332A
• Clutch
• Shift drum star (A).
• Countershaft retaining bolt (C).
This allows transmission removal after cases are split.
PV-47207
PV-47332A
A Additional hole is
required to use
early PV-47332
B C
.200 in.
5.08 mm
NOTE: For complete engine disassembly, refer to
Chapter 9 to remove:
• Flywheel
• Torque compensator
• Starter gear & one way clutch
• Primary drive gear Drill new hole here
• Starter idler gear and shaft to modify PV-47332
.900in.
22.9 mm
8. Remove starter motor.
PV-47332 Modification Detail for 2008 Case
10.6
12. Lift crankcase off and remove bearing protector from

cam chain drive sprocket.
NOTE: Components such as the crankshaft, oil pump,
balance shaft, transmission, and shift drum can be
removed individually for service.
Refer to the following pages as required:

• Crankshaft Service: Page 10.15
• Oil Pump Service: Page 4.9
• Balance Shaft: Page 10.24
10
• Shift Drum / Transmission: Page 10.13
10.7
TRANSMISSION ASSEMBLY VIEW

13
15 11
12
16 18
12 18
17 10
12
18
14 18
8
18
1
3
9 2
7
9
1 2
4
9 2
1
5 2
9
2
6
19
20
21
22
36T
10.8
MAINSHAFT / CLUTCH SHAFT ASSEMBLY VIEW
MAINSHAFT / CLUTCH SHAFT
10
10.9
COUNTERSHAFT ASSEMBLY VIEW
A
B
A: Outside Diameter: 27.976-27.986mm

E
B: Outside Diameter: 27.990-28.000mm
C: Outside Diameter: 24.982-24.995mm
D: Inside Diameter: 32.005-32.021mm
E: Inside Diameter: 32.005-32.021mm
5
4
3
2
6
5 4 3 2 6 1 1
10.10
SHIFT DRUM AND SHIFT FORK ASSEMBLY VIEW
10
(Left End)
10.11
POWER DELIVERY
VIEWED FROM FRONT OF ENGINE
Indicates movement of sliding gear for engagement
Idle in Neutral
Output Shaft Clutch Shaft
Neutral Counter Shaft 1st Gear
2nd Gear 3rd Gear
4th Gear 5th Gear
Sixth Gear (O/D)
10.12
TRANSMISSION REMOVAL 5. Remove shift forks, shift drum, mainshaft and

countershaft from crankcase.
1. If not removed previously, remove countershaft
6. Carefully lift crankshaft out of left case.
locating bolt and washer (A). Use clutch shaft older
PV-45028 to prevent shaft rotation. 7. Remove oil pump sprocket, chain, oil pipes, and pump
(Chapter 4).
8. Pull balance shaft from left case.
A
2. Remove shift drum star (B).
CLUTCH SHAFT INSPECTION / REMOVAL
B 1. The clutch shaft (D) (Mainshaft 5th) is press-fit in the 10

bearing inner race. Inspect shaft and bearing with
clutch shaft in the crankcase. Rotate gear and check
for smooth movement and no play. Inspect gear,
bearings, and shaft splines for wear or damage.
Remove clutch shaft if bearing or gear service is
required (Step 2).
3. Remove shift fork shafts (C).

4. Disengage shift forks from grooves in the shift drum. D
C 2. Use an arbor press to push clutch shaft out of bearing

from clutch side. Support crankcase and protect case
mating surface during press operation. Replace
bearing if clutch shaft is removed.
10.13
TRANSMISSION INSPECTION
Refer to exploded views on page 10.8. Standard
specifications for shaft and gears are on page 10.9 (main
and clutch shaft) and page 10.10 (countershaft).
Shafts
1. Measure outside diameter of shafts in bearing areas
for wear and concentricity as shown on page 10.9 and
10.10. Look closely at splines and retaining ring
grooves of shafts for wear. Inspect ends of shafts for
signs of wear:
• Dull finish Shift Forks, Shift Fork Rails
• Discoloration Refer to specifications listed on page 10.3 and
• Rough or uneven surface page 10.11.
• Measurement outside of specification 3. Inspect all contact surfaces (A) of each shift fork.
Gears Replace a shift fork if any part is discolored
1. Visually inspect: (overheated), unusually scored, warped, or worn
beyond service limit.
• Gear internal splines (A)
4. Inspect each shift fork pin (B) for wear or damage and
• Gear teeth (B) compare to specifications.
• Gear dogs (C) for rounding, cracks, chips
• Gear dog slots (D) for rounding
B
• Bearing surfaces (E)
• Shift fork grooves (F)
C B
A
A
D
5. Inspect shift fork rails (C) for wear, scoring, or runout.
E C
F
Check each gear for damage, cracks, wear (rounding of
dogs or surfaces), or discoloration.
Clutch Shaft Bearings
1. Inspect clutch shaft needle bearings (inside) that
support the mainshaft. The clutch shaft should spin
freely and smoothly on the mainshaft. The bearings 6. Measure shift fork rail O.D. for wear in 3 or 4 places
should support the shaft firmly with little or no along the length. The rail O.D. should be consistent
detectable lateral movement. over the entire length.
2. Replace clutch shaft assembly if bearings are worn or 7. Slide rails into crankcase holes and check for a good
damaged. snug fit.
10.14
8. Visually inspect the shift drum bearing (D) in the left 13. Inspect right side shift drum bearing (G).
crankcase for wear or damage. The bearing must be
14. Temporarily install shift drum in right hand case
fully seated in the case and held in position by the
bearing and inspect fit. Spin drum to check for smooth
retaining plate. Replace the bearing if it is loose in the
bearing operation.
bore, or if any side play is detected.
9. Temporarily install shift drum into bearing and rotate,

checking for smooth bearing operation. Also, inspect CRANKSHAFT REMOVAL
shift drum bearing pin in the right crankcase to ensure
it is not loose or worn. 1. Separate RH crankcase from LH case (page 10.6).
SHIFT DRUM INSPECTION 2. Rotate balance shaft (A) until counterweights are clear
of crankshaft. 10
10. Inspect shift drum grooves (E) for wear. Pay close
attention to corners of grooves where forks change
direction.
11. Inspect shift drum star alignment pin (F). It should fit
tightly in drum and shift star. A
E F
3. Lift crankshaft straight up until clear of case.

NOTE: Connecting rod bearings and main bearings are
12. Inspect surface of shift drum star for excessive wear easily damaged. Be careful not to cause damage to these
or damage. parts when servicing items within the crankcase.
10.15
CONNECTING ROD SIDE CLEARANCE 2. Remove connecting rod bolts and connecting rod
INSPECTION bearing caps.
1. Move connecting rods to one side of crankshaft. Insert NOTE: It may be necessary to lightly tap the caps with a
a feeler gauge between one connecting rod and the plastic mallet to loosen them.
crankshaft. Compare measurement to specification
on page 10.3. CAUTION
2. If clearance recorded exceeds service limit, the
crankshaft, connecting rod or both must be inspected The mating surface of connecting rod and cap is rough
and worn parts replaced. Refer to crankshaft in appearance, which is a normal condition due to the
inspection on page 10.19 and specifications on manufacturing process. If rod caps are installed
page 10.3 to determine which part(s) are outside of incorrectly and tightened, the precision mating
specifications. surfaces will be damaged. Replace the connecting rod
assembly if mating surfaces are damaged.
CONNECTING ROD REMOVAL /

IDENTIFICATION NOTE: Rods are marked OUT as shown in photo.
NOTE: The connecting rod caps are marked from the "OUT" must face toward the left for the left connecting
factory, however it is recommended that an additional rod and must face toward the right for the right
reference mark be added for clarity. Caps are matched to connecting rod (outside of the engine).
rods and must be installed with the proper orientation. DO
NOT strike or stamp the connecting rod.
1. Use a permanent marker to mark orientation of

connecting rods and rod bearing caps. These parts
must be installed in their original locations. EXAMPLE:
Right connecting rod must be assembled to the right
with the bearing cap that was removed from it. The
bearing cap and connecting rod must be assembled in
the same direction as it was removed using the same
bolt.
Label Connecting Rod, Rod Cap & Bolt
10.16
CONNECTING ROD INSPECTION (Big end) 4. Measure I.D. of connecting rod big end for size and out
of round. Compare to specifications on page 10.3.
1. Refer to page 8.7 for connecting rod small end
inspection.
CAUTION
Be sure to match connecting rod caps with their

respective rod and orient the cap properly before
installing the cap. Secure the big end of rods in a vise
equipped with soft, protective jaws before torquing rod
bolts.
5. Visually inspect connecting rod upper and lower ends

for scoring, damage, or excessive wear.
CONNECTING ROD BEARING INSPECTION

1. Inspect bearing inserts for unusual wear, peeling,
scoring, damage etc. Replace as a set if damage is
noted. Inspect bearing clearance and refer to Bearing
Selection Chart (page 10.18). 10
2. Remove bearings and install caps on connecting rods.
Be sure mating surfaces (A) of rod and cap are clean.
3. Apply Victory engine oil to threads of rod bolts and
nuts. Torque evenly in 2 steps to specification
(page 10.19).
10.17
CONNECTING ROD BEARING CLEARANCE CONNECTING ROD BEARING SELECTION

INSPECTION (Typical) 1. There are 3 sizes of connecting rod bearings
available: Black, Orange and Blue (see chart below).
1. Assemble the connecting rod cap with bearings and
torque to specification below. 2. To determine which bearing to use, look at the color
code on RH end of crankshaft...
TORQUE: Connecting Rod Cap
7 Nm (5 lb-ft) (To Seat Bearing)
55 Nm (40 lb-ft) (Final Torque)
“R” or “W”
2. Measure the connecting rod big end bearing I.D. with
a dial bore gauge and record.
3. ...and the color code on the connecting rod.
3. Measure the connecting rod journal on crankshaft and

record.
4. Subtract the journal diameter from the connecting rod
bearing diameter to calculate oil clearance and
compare to specification (page 10.3).
5. If service limits are exceeded, install new rod bearings
and recheck oil clearance.
6. If service limits are still exceeded, determine if 4. Refer to the chart below to select the proper bearing
crankshaft or connecting rods need to be replaced. insert.
FOR EXAMPLE: If the CONNECTING ROD paint mark is
RED and the CRANKSHAFT stamp is W (white) (or not
stamped), use BLUE bearing inserts.
Connecting Rod Bearing Selection Chart

CON ROD COLOR / CRANKSHAFT BEARING COLOR BEARING
(P/N 3514390-xxx) THICKNESS
WHITE Connecting Rod with RED (“R” Stamp) on Crankshaft Black ( - 067 ) 1.409- 1.415 mm
WHITE Connecting Rod with WHITE Crankshaft (or not stamped) Orange ( - 159 ) 1.413- 1.419 mm
RED Connecting Rod with RED Crankshaft Orange ( - 159 )
RED Connecting Rod with WHITE Crankshaft (or not stamped) Blue ( - 027 ) 1.417- 1.423 mm
10.18
CRANKSHAFT INSPECTION 5. Measure O.D. of main bearing journals.
Record all measurements and compare to specifications

on page 10.3. Replace crankshaft if any measurement is
worn beyond the service limit.
1. Measure the width of the rod bearing journal. Right

Left
CONNECTING ROD INSTALLATION

1. Make sure proper bearing clearance is achieved by
using the correct colored bearing insert for a given
color combination of connecting rod and crankshaft.
2. Clean all oil off connecting rod, connecting rod cap and
bearing inserts.
2. Measure width of connecting rods at big end.
3. Install bearing inserts into connecting rods and caps.
First, install bearing tab into groove, then press the rest
of the bearing into place.
NOTE: Procedure during disassembly called for marking
of connecting rods and caps. Ensure that each part is 10
installed in original location including rod cap bolts.
4. Apply assembly lube to connecting rod bearings and
crank pin.
Moly Assembly Paste PN: 2871460
5. Install rods and caps onto the crankshaft, observing
3. Visually inspect all bearing journals for scoring, the "OUT" mark on the connecting rods. "OUT" must
damage or excessive wear. face toward the left for the left connecting rod and
must face toward the right for the right connecting rod
4. Crankshaft and connecting rods are identified by color. (outside end of crankshaft). Be sure the I.D. marks
Be sure to compare measurements to specification on made previously are aligned.
page 10.3 for the proper color (or non-marked)
connecting rod or crankshaft.
Measure O.D. of crankshaft rod journal in four places and
compare to specifications.
10.19
6. Tighten rod cap bolts: 2. After cleaning passages, apply LoctiteTM 262 to blind
plug threads and install plugs into crankshaft to
• To 7 Nm (5 lb-ft) to seat caps and bearings. specified torque. Plug should be flush with surface of
• Tighten to specification in two steps. crankshaft.
3. Install woodruff key(s). Install drive and alignment pins.
TORQUE: Connecting Rod Cap
7 Nm (5 lb-ft) (To Seat Bearing) MAIN BEARING INSPECTION
55 Nm (40 lb-ft) (Final Torque)
1. Inspect crankcase main bearing surfaces for wear,
peeling, scoring, or damage.
7. Check that the connecting rods rotate smoothly and
freely on crankshaft journal. 2. Inspect alignment of bearing lubrication hole (A) in left
crankcase half or (B) in right case half. Holes must be
8. If a connecting rod or crankshaft was replaced, re- aligned with their respective oil passage in crankcase.
measure side clearance (A) to be sure it is within
specification listed on page 10.3 before assembly.
A
B
MAIN BEARING OIL CLEARANCE

INSPECTION
1. Measure main bearing I.D. and concentricity with a
CRANKSHAFT CLEANING dial bore gauge for right and left side. Compare to
specification (page 10.3). Subtract crankshaft main
1. Remove blind plugs from crankshaft to ensure that all journal diameter from main bearing diameter to
passages are clear. calculate oil clearance.
CAUTION
Blind plugs are installed with LoctiteTM 262. Use

localized heat (such as a soldering gun) when
removing blind plugs.
Plug: LoctiteTM 262

20 Nm (15 lb-ft.)
2. If crankshaft dimensions are within tolerances and oil

clearances are incorrect, the crankcase set must be
replaced or new main bearings installed and line-
honed by a competent machinist.
NOTE: Replace crankcase halves as a set.
10.20
LEFT CRANKCASE ASSEMBLY 2. Press balance shaft bearing from the primary side
using an arbor press (B).
Prepare LEFT crankcase for assembly:
Refer to exploded view on page 10.4 for torque values,
bearing press depth, and locking agent. B
1. Clean crankcase and oil passages (A) thoroughly.
Rinse and dry with compressed air.
CLUTCH SHAFT INSTALLATION

3. Place clutch shaft support tool press plate on clutch
side of crankcase to support inner race of bearing.
Clutch shaft is a firm press-fit in bearing, and bearing
damage may result if inner race is not supported during
• Install new bearings in crankcase as required. the press operation.
• Apply a film of lithium grease to outer race of Special tool:
bearings to prevent galling upon installation.
Clutch Shaft Bearing Support: PV-47331
• Press on outer race of bearings using an arbor 10
press and a suitable arbor that is slightly smaller 4. Press clutch shaft until fully seated using an arbor
than bearing outside diameter. press (A). Check for smooth, quiet operation after shaft
is installed.
• DO NOT press on inner race of ball bearings.
A
10.21
RIGHT CRANKCASE ASSEMBLY CRANKCASE REED VALVE ASSEMBLY

REMOVAL & INSPECTION
Prepare RIGHT crankcase for assembly:
Refer to exploded view on page 10.4 for torque values, 1. Separate engine cases (page 10.6).
bearing press depth, and locking agent. 2. Remove the retaining screws for the reed valve
1. Clean crankcase oil passages (B) thoroughly. Rinse assembly. Remove breather valve assembly.
and dry with compressed air. 3. Inspect the reed valve for bending, pitting, or other
damage at the sealing surface that would prevent a
good seal.
4. Replace the reed valve as necessary.
B
Plate
Screws
Loctite 262
7.5 Nm (65 lb-in.)
Crankcase
Breather
• Install new bearings in crankcase as required. Reed
• Apply a film of lithium grease to outer race of Left Crankcase
bearings to prevent galling upon installation.
• Press on outer race of bearings using an arbor
press and a suitable arbor that is slightly smaller CRANKSHAFT INSTALLATION
than bearing outside diameter.
• DO NOT press on inner race of ball bearings. NOTE: Install left engine case onto an engine stand.
1. Apply assembly paste to main bearings.
Moly Assembly Paste PN: 2871460
2. Hold crankshaft over left crankcase and position rods so
that left side rod is in cutout for rear cylinder and right
side rod is in cutout for the front cylinder.
3. Place crankshaft into left crankcase half.
2. If main bearings are replaced, they must be line-honed

with the left side crankcase to proper finished size.
Press operation and fitting must be performed by a
qualified machinist.
10.22
TRANSMISSION INSTALLATION At this point, test the transmission by shifting through the
gears while rotating the shafts. Test operation in each gear
1. Be sure all bearing retainer plate screws are installed to ensure transmission works properly before proceeding.
and tightened to specification (page 10.4).
NOTE: Shift transmission into 5Th gear for
2. Be sure clutch shaft (A) is fully seated in bearing. crankcase assembly
3. Lubricate parts with Victory engine oil. Apply Moly

10. Install balance shaft, oil pump with pipes (Chapter 4),
Assembly Paste (PN 2871460) to ends of transmission
and crankshaft (page 10.22) if removed.
shafts.
11. Refer to Crankcase Assembly on page 10.25.
4. Install shift drum, countershaft, and mainshaft into the
left crankcase. Hold mainshaft 4th gear on shaft during 10
assembly. Make certain both shafts are fully seated
and rotate freely.
5. Install shift forks in grooves of sliding gears. The two
mainshaft forks are identical.
6. Install shift rails through forks.
7. Rotate shift drum to align proper grooves with forks.
8. Move shift fork pins into drum grooves and seat rails.
9. Photo shows transmission installed and shift forks
engaged; shift rails seated.
10.23
BALANCE SHAFT 4. Install chain and sprocket onto oil pump shaft. Align
flats to seat sprocket.
BALANCE SHAFT REMOVAL & INSPECTION
1. Remove bolt (A) from oil pump drive sprocket. Use
engine lock tool between balance shaft weight and
crankcase to hold shaft.
A
5. Install engine lock tool between balance shaft weight
and crankcase (A) to lock balance shaft.
6. Install oil pump sprocket bolt and torque to
specification.
TORQUE:
2. Remove sprocket & chain from oil pump. 9.6 Nm (85 in-lb)
3. Remove chain from balance shaft sprocket.
4. Rotate balance shaft until counterweights are clear of
crankshaft. Grasp balance shaft and remove it from
case.
5. Inspect sprocket teeth for wear or damage.
6. Check shaft for runout, or twisting.
7. Rotate right and left balance shaft bearings by hand
while observing bearing rotation. Bearings should run
smooth and quiet and shaft should be a snug fit in
bearing.
8. Visually inspect bearings for damage.
BALANCE SHAFT INSTALLATION

1. Lubricate balance shaft bearings with engine oil.
2. Insert threaded end of shaft into left crankcase bearing.
3. Install oil pump drive chain onto balance shaft.
10.24
CRANKCASE 6. Install crankshaft bearing protector over the cam chain

drive sprocket
CRANKCASE ASSEMBLY & SEALING Special Tool: Crankcase Bearing Protector PV-47207
NOTE: Place transmission is in 5th gear prior to
crankcase assembly.
1. Clean crankcase mating surfaces to remove all

grease, oil, and old sealant.
2. Check to be sure all shafts are seated, and that all
(new) O-rings, alignment dowel pins, oil pipes, etc. are
in place.
3. Install the clutch shaft holding tool PV-45028.
7. Assemble the Crankcase Installation Tool as shown at

right. PVX-47429 is required if seal sleeve is not
installed on output shaft.
PVX-47429 PV-45030 PV-46299
10
4. Apply an even bead of LoctiteTM Ultra Black 598 to

entire case sealing surface.
Tool Assembled
5. Spread out sealer into a thin even layer on entire case
mating surface. Be sure all areas are covered. DO
NOT ALLOW SEALANT TO DRY. CONTINUE
ASSEMBLY UNTIL CASES ARE SEALED AND ALL
BOLTS ARE TIGHT.
10.25
8. Install crankcase installation tool onto the output shaft. 11. Install crankcase bolts with starter motor as shown
below.
9. Pull crankcase together by tightening nut and tapping
on crankcase with a soft mallet.
NOTE: The cases will mate before the mainshaft is

drawn fully into bearing. IMPORTANT! Continue to
turn nut and tap case and apply approximately 102-
136 Nm (75-100 lb-ft.) torque to the nut).
10. Remove the tool.
12. Tighten crankcase bolts in two steps following the

sequence shown below. Repeat the final torque.
TORQUE: Crankcase Bolts

(2 steps) 20 / 30 Nm (15 / 22 lb-ft) then repeat the 30 Nm (22 lb-ft.) torque
B A Crankcase Bolt Length:

A = 8 x 135
B = 8 x 110
NOTE: Install starter motor
with bolts #3 & #4
B
Crankcase
bolt torque
- END
A
Bolt #2 (CPS wire guide):
B Orient guide as shown below
P clamp Crankcase bolt torque - START

RH Case faces case
Dot faces
OUT
Flat edge
10.26
13. Clean threads of countershaft and bolt with LoctiteTM NOTE: Use an 8mm or a 5/16 diameter pin punch in
Primer N. Apply 2 drops of LoctiteTM 262 to threads of timing hole and shift transmission into 1st gear to hold
countershaft bolt or use a new bolt with pre-applied crankshaft while tightening sprocket nut.
locking agent. Install bolt with washer (A) and tighten
to specified torque. TORQUE: Drive Sprocket Nut
244 Nm (180 lb-ft.)
TORQUE: Countershaft Bolt Loctite 262
34 Nm (25 lb-ft.)
10 Nm (85 in-lb.)
10
14. Remove tool from shaft and assemble shift
mechanism, primary drive, and primary cover. Refer to
Chapter 9.
15. Install a new mainshaft (output) seal in RH crankcase
using seal installer.
Special tool: 244 Nm (180 lb-ft.)

Final Drive Seal Installer PV-43505
16. Inspect output shaft seal sleeve for burrs, nicks, or 18. Install lock plate screws.
surface wear. The surfaces that contact bearing race
and drive sprocket must be smooth and flat to prevent NOTE: The lock plate can be installed in many positions
loosening of the drive sprocket. and either side of the plate can be used. If you cannot find
a position that will work, flip the plate over and again try to
17. Install O-ring (B), seal sleeve (C) with tapered edge install it. If the plate still does not align, tighten the
toward O-ring, and drive sprocket. sprocket nut slightly and try to fit the lock plate again.
19. Rotate the plate CLOCKWISE until it stops and hold it
firmly against the nut.
20. Tighten the lock plate screws to specified torque.
21. Install CPS timing wheel.
23 Nm (17 lb-ft)
10.27
TROUBLESHOOTING
TROUBLESHOOTING

Transmission Will Not Shift Broken Shift Cam Shift Cam Replace shift cam
Bent Shift Forks Shift Fork Replace shift fork(s)
Worn Gearshift Pawl Shift Cam Replace shift cam
Broken Gears Transmission Gears Replace necessary parts
Damaged/Broken Bearings Transmission, Shift Cam Replace necessary parts
Bearings
Worn Gear Shift Ratchet Shifter Ratchet Refer to chapter 9
Mechanism
Broken or out-of-place Shift Ratchet Spring Refer to chapter 9
spring on shift ratchet
Shift Detent Plunger Stuck Shift Detent Plunger Repair as necessary
Frozen Pivot Point, Bent External Shift Linkage Repair as necessary
External Shift Linkage
Bent or Distorted Shift Fork Shift Fork Rails Replace Shift Fork Rails
Rails
Debris From Broken Parts Transmission Components Repair as necessary
Locking Transmission
Excessive Noise Related to Worn Main Bearings Crankshaft and/or Repair as necessary
Bottom End of Engine Crankshaft Bearings
Worn Connecting Rod Connecting Rod Bearings Repair as necessary
Bearings and/or Connecting Rod and/
or Rod Bearings
Worn Connecting Rod Connecting Rod, Repair as necessary
Small End Bushing Connecting Rod Bushing,
Piston Pin, Piston
Worn, seized, chipped or Transmission Gears Repair as necessary
broken gear teeth
Worn, seized, chipped or Transmission Bearings Repair as necessary
broken Transmission
Bearings
Originates from Primary Clutch, Torque Refer to chapter(s) 9, 16,
Cover Compensator, Flywheel, 17, 18
Starter Drive Assembly,
Starter Clutch, Starter Motor
Oil Pump Oil Pump, Oil Pump Drive Refer to chapter 4
Cam Drive Cam Chain, Cam Sprocket Refer to chapter 7
10.28

Transmission Hard to Shift Improper Clutch Operation Clutch Refer to chapter 9
Incorrect Oil Viscosity Engine oil and filter Refer to chapter 3
Incorrect Clutch Adjustment Clutch Adjustment Refer to chapter 3
Bent, Rubbing, Sticky, Shifter Ratchet Assembly Refer to chapter 9
Broken Shift Shaft
Sticking Pivot Point, Bent External Shift Linkage Repair or replace
External Shift Linkage components as necessary
Bent or Distorted Shift Forks Shift Forks Replace bent shift fork
Damaged Shift Drum Shift Drum Replace damaged shift
Grooves drum
Shift Detent Plunger Stuck Shift Detent Plunger Repair as necessary
Bent or Distorted Shift Fork Shift Fork Rails Replace Shift Fork Rails
Rails
Transmission Jumps Out of Broken Shift Stop Pin Shift Stop Pin Replace stop pin
Gear Worn Shift Drum Pawls or Shift Drum or Shift Linkage Replace damaged shift
Shifter Ratchet drum or shifter ratchet
Broken Shift Ratchet Spring Shift Ratchet Spring Replace spring
Damaged Shift Drum Shift Drum Replace shift drum
Grooves
Bent, Worn, Distorted Shift Shift Forks Replace shift forks 10
Forks
Bent or Distorted Shift Fork Shift Fork Rails Replace shift fork rails
Rails
Worn Engagement Dogs on Transmission Gears Replace necessary parts
Transmission Gears
10.29
NOTES
10.30
DRIVE LINE / REVERSE SYSTEM
CHAPTER 11
DRIVE LINE / REVERSE
SYSTEM
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
DRIVE LINE SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
REAR WHEEL FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
DRIVE SPROCKET FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
BELT GUARD / FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
DRIVE SPROCKET AND SEAL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
DRIVE SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
DRIVE SPROCKET AND SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
REAR SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
REAR SPROCKET REMOVAL: 2008. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
REAR SPROCKET INSPECTION: 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
REAR SPROCKET INSTALLATION: 2008. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
REAR SPROCKET REMOVAL: 2009-2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
REAR SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
REAR SPROCKET INSTALLATION: 2009-2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
REVERSE SYSTEM (2009 - 2010 IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
REVERSE DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
REVERSE GEAR CASE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11 11
REVERSE LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
REVERSE SYSTEM TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
REVERSE COUPLER SHAFT KEY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
11.1
SPECIAL TOOLS
DRIVE LINE SPECIAL TOOLS
Output Shaft Seal Installation Tool: PV-43505A
8mm (5/16) Pin Punch (to hold crankshaft for drive sprocket removal / installation): Commercially available
Torque Wrench with 250 Nm (185 lb-ft.) range: Commercially available
CAUTION
Some drive line repair or maintenance involves supporting the machine with the rear end elevated. Take precautions
so that the motorcycle is securely supported when the tire is off the ground. This reduces the possibility of personal
injury or damage to the motorcycle.
• Replace belt and sprockets as a set if the drive system has been in service for 5000 miles or more (8000 Km).
• Refer to Chapter 2 for MAINTENANCE of drive belt.
• Refer to Chapter 14 for TIRE REMOVAL, REPAIR, & BALANCING.
• Refer to Chapter 15 for BRAKE SYSTEM service and repairs.

REAR WHEEL FASTENER TORQUES
All surfaces and fasteners must be clean, dry, and oil free before assembly.
See Chapter 13 for Rear Wheel Removal / Installation.
M12 (28mm X 28mm) 2008 2009-2010

34 Nm (25 lb-ft) 95 Nm
(70 lb-ft)
Install New
Bolts
Forward
Forward
Flat side in
81 Nm (60 lb-ft)
Sprocket nut
11.2
DRIVE SPROCKET FASTENER TORQUES
Inspect surfaces that contact sprocket and bearing. They must be flat
with no galling or rough finish. Slight chamfer on I.D. faces O-ring.
Lock Plate - hold clockwise against Seal Sleeve

nut when tightening plate screws.
O-ring
9.5 Nm (85 inch lbs.)

Lock Plate
Isolator
Spacer Inspect sprocket teeth and splines

for wear at specified intervals.
48mm / 1-7/8 in. Refer to Chapter 2
244 Nm (180 lb-ft) Primer N + LoctiteTM 262.

Refer to page 11.6 for inspection and installation procedure.
Remove timing cover and CPS timing wheel.
Install 5/16” (8 mm) pin in either of the crankshaft TDC lock
11
holes for removal and installation.
Adhesive bead toward cover
9.5 Nm (85 inch lbs.) Place transmission in 5th gear.
Apply Victory All

Purpose grease 5/16 or 8mm
Pin
11.3
BELT GUARD / FASTENER TORQUE
Drive Belt
(Install so VICTORY can be read from RIGHT side of motorcycle)
V
IC
T
O
R
Screws Y
M6 X 12
Seal
O-ring
Seal Sleeve
Sprocket Nut
244 Nm (180 lb-ft.)
Locking Plate
Screws
11.4
DRIVE BELT BELT INSTALLATION

1. Inspect sprockets and verify sprocket fasteners are
BELT INSPECTION
tight.
1. Refer to Chapter 2 for belt inspection procedures.
2. Place belt onto drive sprocket and rear sprocket.
2. Inspect belt tension and adjust if necessary. Refer to
chapter 2. 3. Install drive sprocket cover. Torque fasteners to
specification (page 11.3).
3. If one or more components are damaged, replace belt
and both sprockets as a set if the drive system has 4. Adjust belt tension and verify proper alignment as
been in service for 5000 miles (8000 Km) or more. required in Chapter 2. Torque rear wheel axle nut to
specification. Refer to Chapter 13.
BELT REMOVAL 5. Install exhaust and right rear tip-over protection. Refer
to Chapter 3.
NOTE: If you plan to remove the front sprocket, refer to
Drive Sprocket Removal located in this chapter. 6. Install right floorboard.
NOTE: If belt is to be reinstalled, always mark the
direction of rotation on the outer surface of belt. Reinstall
DRIVE SPROCKET
belt in same direction as it was removed. DRIVE SPROCKET AND SEAL REMOVAL
1. Refer to the belt removal instructions in this chapter.
WARNING 2. Remove drive sprocket cover and gasket.
A mis-aligned rear axle can cause drive line noise 3. Remove sprocket lock plate screws (A) and lock plate.
and damage the drive belt, which could cause belt
failure and loss of control of the motorcycle.
WARNING A
Care should be taken to be sure the motorcycle will 11

1. Secure motorcycle front wheel in a stand.

2. Place a jack underneath the engine and lift until the
rear tire is not resting on the surface.
3. Remove the right and left mufflers (Chapter 3).
4. Place transmission in 5th gear.
4. Remove the right side floorboard assembly:
5. Remove right side lower timing cover and CPS timing
• Care must been take to prevent damage to brake wheel.
lines.
• Support floor board assembly to allow brake line to
hang freely with out tension.
5. Remove rear exhaust crossover mounting bolt. Bolt is
located at rear of lower right-side engine case.
6. Remove head pipe nuts and flange at cylinder heads.
7. Remove right side rear tip-over protection.
8. Loosen rear wheel axle nut and loosen adjusters an
equal amount of turns.
9. Remove front sprocket cover. Rotate head pipes
outward to gain access to front sprocket cover bolts.
10. Remove drive belt from motorcycle.
11.5
6. Rotate crankshaft (arrow) using Crankshaft Rotation 3. Inspect the back surface of sprocket hub (C) where it
Socket PV-48736 until key way is aligned with one of contacts the seal sleeve. Replace if worn or if surface
the TDC holes in crankcase. is rough.
NOTE: Sprockets and belt normally exhibit a polished
appearance due to normal operation. Belt replacement is
not required unless uncharacteristic damage is noted, or
if the mileage service interval is reached. Belt or sprocket
damage is usually due to debris trapped between belt and
sprocket, or from improper maintenance and adjustment.
4. Inspect outer surface (D), inner surface (E), and
sealing surface (F) of seal sleeve. Surfaces must be
flat without wear or galling. Replace the sleeve if worn,
or if the surface appears rough or chafed. The O-ring
sealing surface of slightly chamfered edge must be
Use Tool
PV - 48736 smooth to seal the shaft.
F
7. Insert an 8mm or 5/16 diameter pin into crankcase
hole and into crankshaft to hold shaft while loosening
sprocket nut.
8. Remove sprocket nut.
D E
9. Loosen rear axle nut.
10. Loosen axle adjuster screw lock nut.
11. Loosen both axle adjuster screws evenly to move
wheel forward until belt is loose.
12. Pull belt off sprocket.
Seal Sleeve
13. Remove front sprocket, spacer, and O-ring from output
shaft.
DRIVE SPROCKET AND SEAL
INSTALLATION
14. If required, remove the shaft seal using a suitable tool.
1. Apply grease to a new O-ring (G) and install on output
DRIVE SPROCKET INSPECTION shaft.
2. Install the shaft seal (if removed) using special tool PV
1. Visually inspect sprocket teeth (A) for excessive wear, - 43505A
foreign material damage.
A Remove drive
sprocket cover
H G
Installation: Tool PV-43505A

B
2. Inspect splines (B) for a tight fit on output shaft splines. 3. Install seal sleeve (H) with the chamfer on inside
diameter of sleeve facing in, toward O-ring.
11.6
4. Clean shaft threads and sprocket nut to remove all 9. Install lock plate.
previous thread locking agent and apply Loctite™
NOTE: The lock plate can be installed in many positions
Primer N.
and either side of the plate can be used. If the plate still
does not align, tighten sprocket nut slightly and try to fit
the lock plate again.
10. Install lock plate screws (A).
11. Rotate the plate CLOCKWISE (B) until it stops and
hold it firmly against the nut.
B
A
5. Apply a light film of anti-seize compound to splines of

shaft. Place belt onto front sprocket, place sprocket B
over splines of output shaft.
6. Apply Loctite™ 262 to threads of shaft and nut.
7. Install drive sprocket nut.
12. Tighten the lock plate screws to 9.5 Nm (85 lb-in).
NOTE: If primary side is disassembled, shift
transmission into 5th gear and install clutch shaft holding 13. After belt installation, adjust belt tension and wheel
tool PV-45028 on the clutch shaft to tighten sprocket nut. alignment as instructed in Chapter 2.
14. Install drive sprocket cover with a new gasket 11
(adhesive side of gasket faces cover). Torque cover
28
50
screws to 9.5 Nm (85 lb-in).

-4
PV
Sprocket Cover Bolt Torque:

9.5 Nm (85 inch lb.)
15. Complete the exhaust installation as outlined in

Chapter 3. Torque all fasteners to specification.
NOTE: If primary side is assembled, follow instructions

to hold shaft as described for Drive Sprocket Removal in
this chapter.
8. Torque nut to specification.
Drive Sprocket Nut Torque:

244 Nm (180 lb-ft.)
LoctiteTM 262
11.7
REAR SPROCKET not required unless uncharacteristic damage is noted, or

if the mileage service interval is reached. Most often, belt
REAR SPROCKET REMOVAL: 2008 or sprocket damage is due to foreign debris getting
1. Remove rear wheel (Chapter 13) and set spacer between belt and sprocket, or from improper
aside. maintenance or adjustment.
2. Loosen all sprocket nuts evenly in a star pattern and 4. Inspect wheel hub and sprocket mating surfaces for
remove nuts and washers. galling, roughness, or cracks. Surface must be flat,
3. Remove sprocket. with no burrs or surface irregularities.
5. Clean threads of wheel studs to remove any residual
CAUTION locking agent, dirt, oil, or grease.
Protect brake disc surface while working.

REAR SPROCKET INSTALLATION: 2008
1. Clean sprocket stud threads to remove all grease or
REAR SPROCKET INSPECTION: 2008 oil residue.
2. Clean mating surfaces of wheel and sprocket.
1. Visually inspect the sprocket teeth (A) for excessive
wear, foreign material damage due to road debris 3. Install sprocket over studs.
between sprocket and belt, bent or cracked flanges, 4. Install washers and nuts. Torque nuts in a star pattern
and cracks of any kind. to specified torque.
2. Visually inspect sprocket hub (B) for cracks or damage.
A Rear Sprocket Nut Torque (2008):

2008 81 Nm (60 lb-ft)
5. Refer to Chapter 13 for rear wheel installation

procedure.
81 Nm (60 lb-ft)
B
3. Visually inspect wheel studs (C) for wear or looseness

in the hub. Mounting flange on wheel and sprocket
must be flat and clean.
2008
2008
Sprocket Nut
Flat side IN (toward washer / wheel)
C
Tapered side OUT
NOTE: Sprockets and belt normally exhibit a polished
appearance due to normal operation. Belt replacement is
11.8
REAR SPROCKET REMOVAL: 2009-2010 3. Inspect sprocket mating surface (D) for galling,
roughness, or cracks. Surface must be flat, with no
1. Remove rear wheel (Chapter 13). burrs or surface irregularities.
2. Loosen all sprocket bolts evenly in a star pattern and
discard.
2009-2010
3. Remove sprocket.
CAUTION D
Protect brake disc surface while working on wheel.
REAR SPROCKET INSPECTION

1. Visually inspect sprocket teeth for excessive wear and
damage from foreign material or road debris. Inspect
hub (B) for cracks or damage.
2009-2010 A
REAR SPROCKET INSTALLATION: 2009-
2010
1. Clean sprocket bolt threads in hub to remove all

grease or oil residue.
2. Clean mating surfaces of wheel and sprocket.

B
3. Install sprocket with new bolts. Do not re-use sprocket
bolts.
11
4. Torque bolts in a star pattern to specified torque.
2. Visually inspect sprocket mounting surface (C) on 5. Install rear wheel (Chapter 13).
wheel for wear.
NOTE: If the drive system has been in service for 5000
miles or more, replace both front and rear sprockets 2009-2010
along with the belt if any one item is damaged or worn
beyond a normal polished appearance. Refer to the
Periodic Maintenance Table in chapter 2 for drive system
replacement interval.
95 Nm
(70 lb-ft)
Install New
Bolts
11.9
REVERSE SYSTEM (2009 - 2010 IF EQUIPPED)

REVERSE DRIVE MECHANISM
NOTE: See page 19.40 for reverse electrical system function, component location, and diagnostics.
Maintenance (reverse idler shaft lubrication) is on page 2.7.
Drive Pinion Gear

Idler Gear
Linkage Rod Reverse Switch

Jam Nut
4.5 Nm (40 lb-in)
26 Nm (19 lb-ft)
U-Joint
Motor
Gear Case
26 Nm
(19 lb-ft)
Reverse Lever
10 Nm (90 lb-in)
3.2 Nm
5.4 Nm (28 lb-in)
(48 lb-in)
Motor cover Shift Lever Shaft
Motor output shaft Hold shaft

here
In Reverse
Reverse actuator lever is lifted up
Arm of switch is up No continuity Spring
M6 washer
Linkage Rod End
Connected to reverse harness

In Forward - continuity through switch 10 Nm (90 lb-in)
grounds Pin C of module
11.10
Press onto shaft until Press onto shaft until
Pinion Gear
seated against shoulder seated against shoulder
9.6 Nm Key
Idler Gear
(85 lb-in)
Lockout Switch
5.6 Nm Press in from outside, 20 Nm Press until

(50 lb-in) flush to surface bottomed 5.6 Nm
(15 lb-ft)
Press into gear hub from (50 lb-in)
fork side, flush to surface
REVERSE GEAR CASE ASSEMBLY VIEW

Cutaway View
Reverse Gear Case
11.11
11
REVERSE LINKAGE ADJUSTMENT 6. Rotate linkage rod to lengthen it until reverse idler gear
lightly bottoms out against gearcase cover. Be sure
Linkage Rod Adjustment lever shaft does not begin to rotate off the fully DOWN
position.
1. Remove reverse lever (A) and motor cover (B).
NOTE: If linkage rod rotated past the point at which
the gear is bottomed in the cover, the reverse lever
A B will begin to rotate upward. If lever move upward,
5.4 Nm 3.2 Nm
shorten linkage rod until reverse lever is down, then
(48 lb-in) (28 lb-in)
repeat adjustment.
7. When adjustment is correct, hold linkage rod and

tighten jam nut firmly against linkage rod. Tighten jam
Align nut.
8. Temporarily install the reverse lever and test the

reverse actuation. Lever should return smoothly to a
horizontal position when disengaged.
2. Be sure the reverse lever is down (rotated fully
counterclockwise). 9. Re-assemble cover and reverse lever. Hold lever by
3. Hold linkage rod (C) and loosen jam nut (D). hand to prevent rotation while tightening screw.
10. Perform Reverse System Test ().
4.5 Nm (40 lb-in)
C
4. Temporarily place reverse lever on lever shaft (E).

5. Verify linkage rod ball joint (F) is tightened securely to
lever shaft (that it did not come loose when jam nut was
loosened in Step 3). If ball joint is loose, hold lever and
tighten ball joint to lever shaft.
F
10 Nm
(90 lb-in)
11.12
REVERSE SYSTEM TEST REVERSE COUPLER SHAFT KEY

REPLACEMENT
1. Seated in a normal riding position on motorcycle,
place transmission in Neutral and move reverse lever The reverse gear drive shaft (coupler) has an inner and an
to the DOWN position (reverse disengaged). outer drive key. If the reverse motor turns but the
motorcycle does not move in reverse gear, inspect both
2. Start engine and let it idle. drive keys on the shaft.
1. Remove reverse lever.
3. Slowly lift reverse lever toward UP (Reverse) position,
while watching the gear position indicator on the 2. Remove reverse motor cover.
instrument panel (“N”). The lever should move at least
3. Hold linkage rod (A) and loosen jam nut (B). Do not
1/4 inch (6mm) and no more than 1/2 inch (12mm)
loosen or remove ball joint at reverse lever shaft (C).
before the gear position indication changes to an “R”
(a slight delay in the display is normal).
Lever travel before “R”

is displayed: C
Minimum: 6mm
Maximum: 12mm B
A
“N” “R”
4. Disconnect reverse motor wire harness and reverse
switch wire connector.
5. Remove motor mount bolts.
6. Rotate linkage rod to unscrew the ball joint while
moving the motor outward until linkage rod is
separated from ball joint. 11
7. Pull motor outward to separate coupler from gear
4. Lift reverse to fully UP (Reverse) position. Press the shaft or motor shaft. Set motor assembly aside.
starter button. The motorcycle should move in
reverse. 8. Pull coupler off motor shaft (or gear shaft).
9. Inspect drive key at each end and replace if damaged.
5. With Reverse engaged (reverse lever UP) pull in the
clutch and place the transmission in any gear. The 10. Lubricate coupler shaft with Moly Assembly Paste
engine should stop immediately. (PN 2871460) and install coupler shaft on gear shaft.
11. Install motor, routing the wire harness smoothly to the
6. Return lever to Forward (down) position. Verify the connector, away from mounting boss or moving parts.
engine will start, and that does not stop when the
transmission is shifted into gear. 12. Screw ball joint into linkage rod and engage motor end
of coupler shaft, aligning key with key way.
7. If reverse system does not operate properly as 13. Start motor mounting bolts and tighten lightly by hand.
described above, see Reverse System Diagnostics Continue to adjust linkage rod until motor mount tabs
beginning on page 19.41. mate squarely with the mounting boss on the frame.
NOTE: Be sure motor is flush with frame before
tightening mount bolts!
14. Assemble remaining parts in reverse order of

disassembly (see page 11.10 for fastener torques).
15. Adjust reverse linkage (page 11.12) and perform a
system test (page 11.13).
11.13
TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED
Belt Shows Excessive Wear On One Out-of-Alignment Align rear wheel
Side
Belt Squeal / Noise Belt too tight Adjust to 32mm Deflection @ 10 lbs.
load (All 2008-2010)
Out-of-Alignment Align rear wheel
Broken Sprocket Teeth Foreign material damage Replace parts or repair as necessary
Loose drive belt or sprocket
Broken or Torn Cogs on Belt Foreign material damage, loose belt or Replace parts as necessary
sprocket
Belt Jumps Sprocket Teeth Worn, damaged or out of adjustment Replace parts as necessary
belt or sprockets
Belt Loose Adjust Belt
Excessive Wear, Binding Suspension Belt Tight Adjust Belt
Broken Belt Belt weakened by foreign
material damage. Replace Belt, Replace Sprockets
Belt run excessively tight or loose for
extended period
Reverse / Starter Motor Inoperative See Chapter 19
Reverse Motor Turns But Vehicle Remove drive motor with shaft and
Reverse drive key(s) sheared.
Does Not Move replace key(s).
11.14
FRONT WHEEL / SUSPENSION
CHAPTER 12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
MAINTENANCE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
MAINTENANCE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
FRONT FORK SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
ASSEMBLY VIEW, FRONT FENDER ATTACHMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
FRONT FORK TYPE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
ASSEMBLY VIEW, TRIPLE CLAMP & FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
ASSEMBLY VIEW, FRONT FORK -TYPE 1 (MARZ / 45MM TUBE DIAMETER) . . . . . 12.7
ASSEMBLY VIEW, FRONT FORK -TYPE 2 (KYB) (46MM TUBE DIAMETER) . . . . . . 12.8
ASSEMBLY VIEW, FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
ASSEMBLY VIEW, FRONT WHEEL / HUB CUT-AWAY . . . . . . . . . . . . . . . . . . . . . . . 12.10
SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
ASSEMBLY VIEW, HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
FRONT WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
FRONT AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
FRONT WHEEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
BRAKE DISC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
FRONT WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
FRONT WHEEL BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16 12
FRONT WHEEL BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
FRONT FORK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
FORK GUARD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30
ASSEMBLY VIEW, STEERING STEM / TRIPLE CLAMPS . . . . . . . . . . . . . . . . . . . . . 12.31
TRIPLE CLAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32
TRIPLE CLAMP INSTALLATION / STEERING HEAD BEARING ADJUSTMENT. . . . 12.33
STEERING STEM BEARING REMOVAL (TYPICAL EXAMPLE) . . . . . . . . . . . . . . . . 12.34
STEERING STEM BEARING INSTALLATION (TYPICAL EXAMPLE) . . . . . . . . . . . . 12.35
LOWER BEARING RACE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.36
LOWER BEARING RACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.36
TROUBLESHOOTING (CONT.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.38
12.1
GENERAL SPECIAL TOOLS

IMPORTANT INFORMATION SPECIAL TOOLS
Fork Seal Driver, 45mm (TYPE 1 Forks) PV-43516-A

WARNING
Fork Seal Driver, 46mm (TYPE 2 Forks) PV-49494
Victory motorcycles are produced using the designated Cartridge Holder PV-49452
tires listed as original equipment. This includes field
Damper Rod Extension Tool PV-49453
testing to ensure stability and superior handling. The
use of tires other than original equipment may cause Fork Spring Compressor PV-49463
instability which could lead to a crash, resulting in seri-
ous injury or death. Use only the recommended tires Oil Level Tool PV-59000-A
inflated to the recommended tire pressures based on Wheel Bearing / Stem Bearing Race
load conditions as listed on the tire inflation decal. PV-43515
Installation Set
Tubeless tires are used on certain Victory models. Stem Bearing Remover PV-43551
Operating the motorcycle with damaged rims creates a
safety hazard including air pressure loss, steering Spanner Socket (Steering Stem) PV-43508
imbalance and/or reduced steering control. Do not Lower Steering Stem Bearing Remover PV-44683
attempt to repair or straighten damaged rims.
Blind Bearing Remover Set
PV-43551
(for wheel bearings)
CAUTION
Work performed to the front end of the motorcycle usually MAINTENANCE PRODUCTS
involves supporting the machine with the front end
elevated. Take precautions so that the motorcycle is MAINTENANCE PRODUCTS
securely supported when the front tire is off the ground.
This reduces the possibility of personal injury or damage
Hand Grip Adhesive - Three Bond 1501 (10
to the motorcycle. 2872575
ml tube)
Leaking front fork seals are a safety hazard and FORK OIL TYPE
should be replaced immediately if a leak is found.
Fork oil may contaminate the front brake components For TYPE 1 Forks
2874828
which could reduce stopping ability of the (All 2008 and some 2009-2010)
motorcycle. Contaminated brake discs or pads For TYPE 2 Forks
greatly reduce the amount of stopping force available 2874568
(Some 2009-2010)
& increase stopping distance. Brake discs can be
cleaned using Victory brake cleaner. NEVER attempt See “FRONT FORK TYPE IDENTIFICATION" page
to clean contaminated brake pads. Replace pads as a 12.5
set.
Refer to page 2.4 for a complete list of maintenance
• Refer to Chapter 2 for MAINTENANCE of front end products and part numbers.
components.
• Refer to Chapter 14 for TIRE REMOVAL, REPAIR, TORQUE SPECIFICATIONS

& BALANCING
• Refer to Chapter 15 for BRAKE SYSTEM service

and repairs. Refer to Assembly Views on page 12.4 through
page 12.11 for fastener torque specifications.
12.2
SPECIFICATIONS
FRONT FORK SERVICE SPECIFICATIONS
2008 - 2010 VICTORY VISION
Axle Runout - .20 mm (.008")
Front Wheel Runout Axial .50 mm (.020") 2.0 mm (.080”)
(Billet and Cast Type)
3.00" x 18" Radial .50 mm (.020") 2.0 mm (.080”)
See “FRONT FORK TYPE IDENTIFICATION" page 12.5

Tube Diameter - TYPE 1 (MARZ) FORKS/TRIPLE CLAMP 45 mm Not Applicable
Tube Diameter - TYPE 2 (KYB) FORKS / TRIPLE CLAMP 46 mm Not Applicable
Fork Tube Runout - .20 mm (.008")
TYPE 1 FORKS Victory Fork Oil PN 2874828
Fork Oil Type
TYPE 2 FORKS Victory Fork Oil PN 2874568
33 mm (1.3”)
TYPE 1 FORKS Not Applicable
(Spacer Length)
Fork Spring Pre-Load
34.5 mm (1.3”)
(Designed)
10.4 - 30 N/mm
(60 - 170 lb/in.)
Rate Transition @ 75 mm
Fork Spring Rate Fork Compression
9.8 - 20.0 N/mm
TYPE 2 FORKS Not Applicable 12
(56 - 114 lb/in.)
TYPE 1 FORKS 422 mm (16.625 in) 416 mm (16.625 in)
Fork Spring Free Length
TYPE 2 FORKS 457.9 mm (18.02 in)
TYPE 1 FORKS: Measured
with spring and pre-load
255 mm (10.04") +1 mm (.039”)
spacer removed, inner tube
Fork Oil Level fully compressed.
(From Top of Tube)
TYPE 2 FORKS: Measured
with spring removed, inner 136 mm (5.35") +1 mm (.039”)
tube fully compressed.
TYPE 1 FORKS: Oil level
Fork Oil Capacity (per leg, dry) must be measured and 330 cc (330 ml)
adjusted to specification. Set Level
See “FRONT FORK
TYPE 2 FORKS: Oil level ASSEMBLY" page 12.25
Fork Oil Capacity (per leg, dry) must be measured and 550 cc (550 ml)
adjusted to specification.
12.3
FRONT FENDER
Disassembly Order: 1 7
3
Assembly Order: 7 1
1 6
2
11 Nm
(96 lb-in)
12.4
FRONT FORK TYPE IDENTIFICATION

Two types of front forks and triple clamps are used on 2009-2010 Victory Vision models. All 2008 models are
TYPE 1. TYPE 1 parts and fork oil are NOT interchangeable with TYPE 2. Identify type before starting service
work and before ordering service parts.
FORK TYPE 1 (MARZ) = 45mm FORK TYPE 1

Fork Slider - Marked “M”
FORK OIL: PN 2874828
Inside Diameter
45mm
(Used on ALL 2008
and some 2009-2010)
PARTS NOT INTERCHANGEABLE! INSIDE SURFACE SHOWN

12
FORK TYPE 2 (KYB) = 46mm
FORK TYPE 2
Fork Slider - Not Marked “M”
FORK OIL: PN 2874568
Inside Diameter
46mm
Used on some
2009-2010
FRONT
12.5
ASSEMBLY VIEW, TRIPLE CLAMP & FRONT AXLE
! IMPORTANT! See Fork Type Identification on page 12.5 to identify fork type before you begin service or repair.
Detailed fork tube installation

procedure is on page 12.30
Detailed front wheel installation

is on page 12.17
12.6
ASSEMBLY VIEW, FRONT FORK -TYPE 1 (MARZ / 45mm Tube Diameter)
ALL 2008 Models

Some 2009-2010
TYPE 1 Tube Diameter is

45mm. Parts are NOT
INTERCHANGEABLE
with TYPE 2 (Tight wound coils DOWN)
Screw cartridge rod

fully into fork cap
12
.5mm (.020 in.)
12.7
ASSEMBLY VIEW, FRONT FORK -TYPE 2 (KYB) (46mm Tube Diameter)
Some 2009 -2010
Fork Cap
15 - 30 Nm
(11 - 22 lb-ft)
O-Ring
Washer
Spring
(Tight wound coils DOWN)
TYPE 2 Tube Diameter is

46mm. Parts are NOT Bushing
INTERCHANGEABLE
with TYPE 1
Screw cartridge rod
fully into fork cap Nut 13.5-16.5 Nm
(10.0-12.0 lb-ft)
Fork Guard Cartridge Assembly
Dust Seal
Retaining Ring
Oil Seal
Backing Washer
Bushing
(Upper Slider)
.5mm (.020 in.)
Slider
(Outer Tube)
Sealing Washer
Screw
20.0-25.0 Nm (14.8-18.5 lb-ft)
12.8
ASSEMBLY VIEW, FRONT WHEEL
O-Ring
5.0 Nm
(45 lb-in)
Slot
See Chapter 14 for installation
5.0 Nm
1.35 Nm
(45 lb-in)
(12 lb-in) 12
Chrome - No Slot Chrome - With Slot
12.9
ASSEMBLY VIEW, FRONT WHEEL / HUB CUT-AWAY
12.10
Apply Thin Layer of Dielectric Grease 2871329 to switch halves Handlebar Switch Wire Note:
Align pin with hole in handlebar All wires from each handlebar cross at the
Tighten driver side screw first front of the handlebars and connect to their
2.8 Nm (25 lb-in) respective mate on the OPPOSITE side
EXCEPT the Audio Control and Cruise
Control (2-Pin) connectors. Mates for these
switches are on the same side as the switch.
Secure all wires with tie straps to allow free
2.8 Nm
movement of handlebars and prevent contact
(25 lb-in)
or interference when bars are turned from full
left to full right.
11 Nm
(96 lb-in)
Tighten driver Heated Grips: Roll back grip
ASSEMBLY VIEW, HANDLEBAR
Contains: side screw first flange to access screws

All switch wires, 1.9 Nm (17 lb-in) Non-Heated Grips:
and both throttle cables. Use adhesive 2872575
Clocking holes
9.5 Nm
(84 lb-in)
Contains: All switch wires,

throttle cables, and front
brake hose.
Contains: All switch wires.
Ness Signature Series
Contains: All switch wires
and hydraulic clutch hose
or clutch cable. Clutch Lever (Cable)
1 each side of cruise

switch on throttle
closing cable on Contain L & R control
RIGHT side of frame. switch wires
Contain both cables.
54.2 Nm (40 lb-ft) Nut
6.0 Nm
Washer .5-1.5mm
(53 lb-in)
(.020-.060 in.)
12.11
12
SERVICE PROCEDURES 9. Remove cruise control switch from mounting plate.

Remove plate from right switch block.
HANDLEBAR REMOVAL
10. Loosen throttle cable adjusters to add maximum cable
freeplay.
CAUTION
11. Remove plate from bottom of right switch cube, then
Left handlebar grip and grip end may be remove switch cube screws and switch cube.
damaged during the removal process. Plan on
replacing the left grip if it must be removed. 12. Remove throttle twist grip assembly from handlebar.
Many items will be hanging loose when removing Carefully remove cables from twist grip (if required).
the handlebars. Cover painted or chrome parts Do not bend or kink cables during removal.
to prevent damage. Keep master cylinder
reservoirs upright to prevent air from entering.
Special care should be taken to protect cosmetic
surfaces from loose parts during the removal
process. Secure or support parts or set them
aside as they are removed. Note wire harness
and cable routing
13. Remove handlebar mounting bolts (16 & 19 mm),
for assembly later. DO NOT bend or kink cables
washers, upper and lower bushings, and sleeves.
during the removal process.
NOTE: Refer to illustration on page 12.11 for torque
values of fasteners. See page 19.20 for Cruise CAUTION
Control cable replacement.
DO NOT pinch harnesses or hoses in the vicinity
IMPORTANT: Keep master cylinder reservoir(s) while removing the fasteners.
upright to prevent air from entering system.
1. Remove seat, instrument bezel, and bridge console 14. Remove handlebars from top triple clamp.
(see Chapter 3).
2. Remove both handlebar ends (4mm Allen). HANDLEBAR INSTALLATION
3. Disconnect heated grip wires (if equipped). NOTE: Refer to illustration on page 12.11.
Non-Heated Grip: Use a screwdriver to lift LEFT grip
and separate the adhesive. Pry off grip. 1. Install new dart straps into handlebars.
Heated Grip: Pull back flange on LEFT grip to expose
(2) fasteners (T20 Torx). Remove fasteners and slide 2. Place upper and lower bushings with sleeve in top
grip off end of bar. triple clamp.
4. Push tab on harness side of left and right handlebar 3. Position handlebars on top of bushings and insert
switch connectors and separate both switch mounting bolts. Torque to 54.2 Nm (40 lb-ft).
connectors.
5. Push lever tab on clutch switch and pull to remove CAUTION

connector. Remove clutch master cylinder or lever
perch on 8-Ball (5mm Allen). Set master cylinder in DO NOT pinch wires or hoses in the vicinity while
console area. installing and tightening fasteners.
6. Remove Audio Control switch from mounting plate 4. Clean inside of throttle grip assembly and throttle grip
and then remove plate from left switch cube. area on handlebar. Apply a small amount of dielectric
grease on clamp area of switch cubes.
7. Carefully cut tie straps and (4) handlebar dart straps.
5. Install throttle grip and bottom half of right switch cube,
8. Disconnect front brake switch wires. Remove front
then position upper half of switch cube, engaging pin
brake master cylinder clamp (5mm Allen). Set master
with clocking hole in handlebar.
cylinder in console area.
12.12
6. Lightly grease throttle cable ends and connect ends FRONT WHEEL REMOVAL
to throttle grip. Do not bend or kink cables.
1. Refer to illustration on page 12.6.
7. Install top of right switch cube over the grip and insert
(2) screws on the bottom. Torque rear (driver’s side) 2. Securely support front end of motorcycle so front
screw first to 2.8 Nm (25 lb-in). wheel is off the ground.
8. Install left switch cube and position via clocking pin
and hole. Torque rear (driver’s side) screw first to 2.8 CAUTION
Nm (25 lb-in).
Take precautions so that the motorcycle is
9. Clean left-hand grip mounting surface on handlebar. securely supported when the tire is off the ground.
10. For non-heated grips, apply a 1/8” bead of grip 3. Remove upper front fender (page 12.4).
adhesive (PN 2872575) to the inner edge of the grip
flange. Install left hand grip and wipe away excess 4. Remove right-hand brake caliper and support so
adhesive. brake line is not stressed.
CAUTION Remove
Bolts
Read and follow all instructions and
pre-cautions on adhesive container.
11. For heated grips, roll back grip portion on end to

reveal holes for (2) screws and install screws. Torque
screws to 1.9 Nm (17 lb-in).
12. Install master cylinders or lever perch (8-Ball) and

torque rear (driver’s side) screws first to 9.9 Nm (88
lb-in) (5mm hex).
13. Route cables and wires along handlebars as indicated 12

on page 12.11, and secure with dart straps and tie
straps as indicated. See Handlebar Switch Wire Note
on page 12.11. CAUTION
14. Install end caps on handlebars and torque screws to Do not twist the brake hose or brake line.
9.5 Nm (84 lb-in). Do not allow caliper to hang from the brake hose.
Secure caliper in such a way to avoid
15. Install bridge console, seat, trim panel and instrument hose damage.
bezel (see Chapter 3).
NOTE: Do not operate the front brake lever with the
16. Adjust throttle cables to freeplay specification of 2 - 4 caliper or wheel removed.
mm (1/8” +/- 1/16”). See page 2.9.
(Cont.)
17. Check operation of throttle assembly.
18. Check operation of switches and controls.
19. Check operation of front brake. Perform lever reserve

test (page 2.11).
12.13
Front Wheel Removal (Cont.) FRONT AXLE INSPECTION

5. Loosen lower pinch bolts (B) on right-hand fork leg. 1. Place axle in V-blocks and inspect runout. Compare
to specifications on page 12.2.
2. Replace axle if it fails inspection. Do not attempt to

straighten a bent axle.
B
FRONT WHEEL INSPECTION
1. Install front wheel in truing stand.
D
NOTE: Bearings must be in good condition to
accurately measure runout.
2. Set up a dial indicator to measure radial runout (up

and down) (A) and compare to specifications
(page 12.3).
3. Position dial indicator to measure axial runout (side to

side) (B) and compare to specifications (page 12.3).
6. Loosen axle (C). Be sure vehicle is stable and
supported.
7. Remove axle. Be prepared to catch spacers (D) and A

remove wheel.
IMPORTANT: Note width and location of spacers.
4. Visually inspect wheel for cracks.
5. Replace wheel if it fails visual or measured inspection.

Do not attempt to straighten cast or billet wheels.
12.14
BRAKE DISC REMOVAL FRONT WHEEL BEARING INSPECTION

NOTE: Disc must be inspected before removing NOTE: Inspect bearings installed in wheel. Do not
from wheel. Refer to Chapter 15 for disc inspection. remove to inspect. Bearings cannot be repacked.
Replace both wheel bearings if either fails
1. Remove front wheel (page 12.13). inspection, or if either bearing was removed. For
inspection with wheel installed, see page 2.31.
2. Remove and discard brake disc screws.
3. Remove brake disc(s) from wheel. 1. Visually inspect bearing seals (A) on each side for
wear or damage.
BRAKE DISC INSTALLATION
1. Clean screw hole threads with Loctite Primer N. A B
2. Clean surface of wheel and brake disc.
3. Install disc on wheel with part number facing OUT.

4. Install with new screws which have a pre-applied
locking agent.
WARNING
Do not re-install brake disc screws. Use only new Billet Wheel
Shown
screws which have a pre-applied locking agent.
2. Check bearings by turning inner race (B) by hand.

All mating surfaces clean, dry, and oil-free
before assembly. • Look for signs of discoloration, scoring, galling, or
contamination from moisture or dirt. Replace
bearings if any of the above are present.
• Turn inner race of bearings. Bearings should turn 12

smoothly and quietly. Inner race should be firm
with minimal side to side movement and no
detectable up and down movement.
3. Discard bearings that fail inspection.
CAUTION
Do not reuse bearings after removing them from the

wheel. Removal damages the bearings internally.
New screws
30 Nm (22 ft. lbs.) 4. Inspect bearing fit in wheel hub. Outer race of bearing
must fit tightly in bore. You should not be able to move
it (or remove it) by hand. Replace wheel if outer race
of a new bearing does not fit tightly in the bore.
Left side ABS
12.15
FRONT WHEEL BEARING REMOVAL FRONT WHEEL BEARING INSTALLATION

NOTE: Replace both wheel bearings as a set. Do not NOTE: Refer to illustration below for Steps 3-9.
replace only one wheel bearing.
1. Clean inside of wheel hub and bearing spacer.
1. Place a shop towel over the edge of seal bore. Replace spacer if any wear is evident on the ends.
2. Place new bearing into left hand side of wheel with
markings facing up (toward outside of hub).
3. Assemble bearing installation tool with flat side of 50-
51 mm collar against bearing. Collar must be slightly
smaller than O.D. of bearing and must be flat to
support inner and outer race equally. DO NOT pull or
press on inner race of ball bearings or bearing will
be permanently damaged! Assemble right side of
tool as shown and pull bearing into hub until fully
seated.
Bearing installation tool set: PV-43515
NOTE: Use of this special tool is shown with rear
wheel bearing installation in Chapter 13.
2. Carefully remove both seals using a pry-bar and 4. Turn wheel over and install bearing spacer.
discard. Be careful not to scratch the seal bore. 5. Place new right wheel bearing onto wheel with
markings facing up.
3. Remove retaining ring from left side.
6. Install another 50-51 mm wheel bearing installation
4. Install bearing remover element into left side bearing tool against bearing.
and remove it.
7. Pull bearing in to right side of wheel until seated
Blind bearing remover PV-43551 against spacer.
5. Remove bearing spacer from wheel hub, measure the 8. Remove tool. Check that spacer is centered with
length and compare to specification. Replace spacer bearings. If not, center it by inserting front axle.
if it is worn beyond the service limit or if the bearing Repeat Step 7 to fully seat bearing on spacer.
contact surface is damaged.
9. Install retaining ring. Be sure it is fully seated in the
Minimum Spacer Length: 121.80 mm (4.795”) groove.
6. Use an appropriate drift, drive out right side bearing.
Step 3 - fully seated LH Bearing Step 4 - Install Spacer Step 7 - seat RH bearing against spacer
Washer
Tool Bearing Washer
Threaded
Rod
Nut
Nut
Flat side of 50-51 mm Flat side of 50-51 mm

Collar Collar
LEFT RIGHT
Step 9 - Install retaining ring
12.16
10. Install new seals using a 52 mm seal driver. 3. Install spacers in wheel hub.
Seal Depth 0.0 - 1 mm (0.00 - .039 in.) NOTE: The left-hand spacer is wider than the right.
Seal 4. Clean brake disc and install wheel noting direction of

rotation, fitting brake disc between brake pads on
caliper.
5. Align and install axle shaft through right-hand side of
the right-hand fork tube.
Surface of
hub bore
11. Rotate inner races of bearings to check for free,

smooth rotation.
12. Install brake discs (see “Brake Disc Installation”).

Clean discs with Victory Disc Brake Cleaner.
CAUTION
Do not allow brake cleaner to

contact painted surfaces.
6. Push axle through the wheel and axle spacers and
into the left fork tube.
WARNING 7. Thread the axle shaft into the left-hand fork tube and
torque to 70.5 Nm (52 lb-ft).
Grease or oil on the brake disc will increase
8. Separate brake pads in brake caliper(s) and install
stopping distance which may lead to loss of
caliper over disc. Torque mounting screws to 42
vehicle control or an accident.
Nm (31 lb-ft). 12
FRONT WHEEL INSTALLATION
42 Nm
NOTE: Also refer to illustration on page 12.6. (31 lb-ft)
1. Clean all wheel components before installation.
2. Lubricate axle and spacers with a light film of grease.
9. Lower front end of machine.

10. Slowly pump front brake lever to regain pressure.
Victory All Purpose Grease: 2872187
12.17
11. Apply and hold front brake. Pump forks to move FRONT FORK REMOVAL
suspension through full range of travel at least 4
times. 1. Securely support front end of motorcycle so front
wheel is off the ground.
NOTE: Fork action should be smooth without
binding. If problems are found, inspect for cause
and correct as necessary.
CAUTION
12. Torque pinch bolts (A) to 23 Nm (17 lb-ft). Take precautions so that the motorcycle is
securely supported when the tire is off the ground.
2. Remove front fender (upper and lower portions).

A 3. ABS models: Remove wheel speed sensor.
4. Remove both front brake calipers.
5. Secure calipers and brake lines out of the way.
Remove
13. Elevate front wheel and spin it to check for drag. Apply
and release front brake. Wheel should spin freely and
quietly without drag when brake lever is released. RH
14. Install the upper front fender (page 12.4).
Remove
15. Lower front end of machine.
16. Inspect operation of front brake lever. Bleed front

brake system if lever is not firm. (Refer to Chapter 15).
LH
CAUTION
Do not twist the brake hose or brake line.

Do not allow caliper to hang from the brake hose.
Secure caliper in such a way to avoid
hose damage.
6. Remove front wheel (page 12.13).
12.18
7. Loosen upper triple clamp pinch bolt for each fork FRONT FORK DISASSEMBLY
tube.
NOTE: See Front Fork Type Identification on
8. If disassembling the fork tube(s), loosen the fork page 12.5. This procedure covers both TYPE 1 and
cap(s) prior to loosening the lower triple clamp bolts. TYPE 2 forks. Differences are noted for each type.
Refer to Front Fork Assembly Views on page 12.7
(for TYPE 1 forks) or page 12.8 (for TYPE 2 forks).
Clean the fork tubes thoroughly before disassembly.
1. Secure Fork Spring Compressor (PV-49463)

vertically in a vise with drive bolt (A) UP.
A PV-49463
Loosen
Fork Cap
9. Loosen lower triple clamp pinch bolts for each fork

tube.
2. Loosen fork cap approximately 1 turn. Do not remove
the cap.
Loosen
12
10. Slide fork legs down and out from the steering stem.
WARNING
Wear eye / face protection. Be sure spring is

engaged properly with pegs of tool as you
compress the spring in the following steps.
12.19
3. Mount special socket PV-49464 in spring 6. Rotate tube until cap is unscrewed completely from
compressor. Center it in holding fixture with all thumb fork tube.
screws (C).
• TYPE 1 forks: 17mm side of socket faces down.
• TYPE 2 forks: 22mm side of socket faces down.
PV-49464
C 7. Back off spring compressor and remove special

socket. Re-adjust length of tool so thumb screws are
aligned with first or second coil at top of spring.
8. Hold fork in center and engage slot of stationary peg

(E) with spring. Turn other screws in and engage
4. Place fork tube in spring compressor tool with hole in spring in notch.
bottom of fork slider over peg on bottom of tool.
E
5. Adjust length of spring compressor by turning drive
bolt (D) as required until fork cap is captive in socket.
12.20
9. Slowly compress spring by turning drive bolt of 12. Remove spring from fork tube.
compressor until cartridge rod nut is accessible. DO
NOT use air or power tools to rotate drive bolt. 13. Pour fork oil out of tube assembly.
14. TYPE 1 FORKS ONLY: Remove spring pre-load

spacer (H).
TYPE 1 ONLY
10. Hold nut and remove fork cap (F) from cartridge shaft.
15. Move cartridge shaft through complete stroke several

F times to drain cartridge (until damping is gone).
IMPORTANT: Fork seal replacement is recommended

at oil change. If you do not intend to replace fork seals
(fork oil change only) STOP HERE and proceed to
Step 14 of Front Fork Assembly. Inner fork tube
removal in the following steps will damage the oil seal
and require seal replacement. For complete fork
disassembly proceed to Cartridge Removal / Step 16. 12
11. TYPE 2 FORKS ONLY: Remove washer (G).
TYPE 2 ONLY
G
12.21
Cartridge Removal 17. TYPE 2 FORKS ONLY: Hold cartridge through top of
fork inner tube with octagonal end (K) of Universal
16. TYPE 1 FORKS ONLY: Remove cartridge screw and
Cartridge Shaft Holder PV-49452. Loosen cartridge
sealing washer using an extended 8 mm internal hex
screw with an extended 8mm internal hex socket as
socket.
with Type 1 fork.
PV-49452
18. Remove cartridge from inner tube.
WARNING
DO NOT disassemble the cartridge. If damaged

or worn, it must be replaced as an assembly.
19. To clean cartridge when removed, submerge oil holes

(L) in clean cartridge fork oil and pump cartridge shaft.
12.22
Fork Seal Removal 24. Remove the lower bushing from the inner tube.
20. Fully compress the fork tube. Carefully lift dust seal out
of outer fork tube with a small flat screwdriver. TYPE TYPE 1
2 forks have access notch to remove dust seal.
25. TYPE 2 FORKS ONLY: Remove oil lock valve (I) and
bushing (J) from bottom of inner tube.
TYPE 2 J
I
21. Remove seal retaining ring. Use care not to scratch the
surface of the inner fork tube.
12
26. Protect top surface of fork slider and pry out oil seal,
using care not to scratch the seal bore.
TYPE 1 and TYPE 2
22. Push inner and outer tube together, then pull apart
quickly to produce a slide hammer motion to remove
the inner tube.
23. Separate the tubes.
12.23
27. Remove oil seal and backing washer. FRONT FORK INSPECTION
1. Inspect inner fork tube for scoring, heavy scratches,
TYPE 1 and TYPE 2 dents due to rocks or other road debris, or excessive
wear. Replace tube if scratched, pitted, or dented.
2. Place fork tube in V-blocks or fixture and measure

runout. Replace tube if runout exceeds service limit.
Upper Bushing Removal

28. To remove upper bushing from fork slider, re-install
fork tube (with lower bushing attached) into fork slider,
working the bushing carefully past the upper (slider)
bushing.
WARNING
29. Use a VERY LIGHT slide hammer motion to tap slider
bushing out of the slider. Do not attempt to straighten bent fork tubes.
Doing so will weaken the structural integrity of
30. Clean tubes and drain completely. Cartridge removal
the forks and make the motorcycle
is not required for seal and bushing replacement.
unsafe to operate.
Cartridge can be cleaned by adding clean fork oil to
slider and pumping the cartridge rod in the clean oil
bath. Discard fork oil used to flush the cartridge. 3. Inspect fork slider (outer tube) for dents, cracks, or
other damage. Assemble inner and outer fork tube
with new bushings and move inner tube through
complete travel range. Check for resistance or
binding. Replace slider if binding or resistance is
evident, or if damaged.
4. Inspect cartridge by moving cartridge shaft through

travel range. If binding is evident, replace the cartridge
assembly.
12.24
FRONT FORK ASSEMBLY 3. Rotate bushing so gap (D) will be opposite the gap of
slider bushing previously installed (arrow).
NOTE: Differences in assembly procedure are noted
for TYPE 1 and TYPE 2 forks as required. Refer to
Front Fork Assembly Views on page 12.7 (for TYPE 1
forks) or page 12.8 (for TYPE 2 forks). Clean all parts
prior to assembly.
1. Lubricate and install new upper bushing into fork

slider. Position gap (A) to left or right side (arrow).
4. Apply a light film of fork oil to outside edge and inside

seal lips of new oil seal.
A
NOTE: Install oil seal with markings facing UP
(toward top of tube and retaining ring).
2. Lubricate and install a new lower bushing (B) on inner

fork tube.
TYPE 2 ONLY: Install oil lock valve (C) in bottom of
fork tube (tapered side to tube as shown).
TYPE 2
B 12
TOP
12.25
5. Lubricate the surface of the inner fork tube and slide 8. Wipe away any excess grease or oil. Install dust seal
backing washer and new oil seal down tube and into (use opposite end of fork seal driver PV-49494) until
outer fork leg. fully seated in outer tube.
PV-49494
Cartridge Installation
6. Use PV-49494 to install oil seal until seated. Be sure 9. Be sure screw threads in bottom of cartridge are clean
top edge of seal is past (below) retaining ring groove. and not damaged.
10. Place cartridge assembly into fork slider, and carefully
PV-49494 PV-47035 align bottom of cartridge with recess in bottom.
11. Install a new cartridge screw and a new seal washer.
12. TYPE 2 ONLY: Hold cartridge with PV-49452.

7. Install a new retaining ring (E) into groove of fork tube.
Be sure it is completely seated around the entire 13. Torque cartridge screw:
circumference of the groove. TYPE 1 - 30.0 Nm (22.0 lb-ft).
TYPE 2 - 20.0-25.0 Nm (14.8-18.5 lb-ft).
12.26
Oil Filling / Cartridge Air Bleeding 21. Slowly compress inner fork tube (F) and cartridge rod
rod (G) until they stop (at bottom of travel) and remove
14. Tip fork leg at an angle to reduce air bubbles. Slowly
damper rod extension tool.
add about 350 cc of Victory fork oil.
TYPE 1: P/N 2874828
TYPE 2: P/N 2874568
NOTE: The oil quantity slightly exceeds the capacity

of the fork. Final fork oil level must be adjusted G
correctly as outlined later in this procedure.
15. Set fork leg upright.
16. Lift outer tube up to top of travel range.
17. Seal top of tube with your hand and push downward
against air pressure. Hold for 10-15 seconds. This will F
help force trapped air from cartridge and tube.
22. Loosen thumb screw on Oil Level Adjustment Tool

PV-59000-A and slide stop plate to adjust tube to
length of specified oil level:
TYPE 1 Fork Oil Level (from top of tube):

255 mm (10.04")
Set level in tube with spring and pre-load spacer
removed, and inner tube and damper rod (cartridge
rod) fully compressed.
TYPE 2 Fork Oil Level (from top of tube):

136 mm (5.35") 12
18. Mount fork assembly upright in a soft jawed vise by
Set level in tube with spring removed, and inner tube
brake caliper mounts on slider.
and damper rod (cartridge rod) fully compressed.
19. Screw Damper Rod Extension Tool PV-49453 onto
cartridge rod.
20. Bleed cartridge by moving shaft up and down to purge
air. Begin with small strokes, increasing stroke length
until all air is removed and damping is smooth and
consistent.
PV-49453
Slide tube to specified oil level
12.27
23. Insert fork oil level tool into fork. Be sure fork leg is
standing upright and fork tube is fully compressed.
24. Draw excess oil out to the specified level. WARNING
Wear eye / face protection. Be sure spring is

engaged properly with pegs of tool as you
compress the spring in the following steps.
28. Attach damper rod extension tool and hold damper

rod up.
29. Carefully compress spring until fork cap threads on

top of damper rod are visible.
25. TYPE 1 ONLY: Install pre-load spacer (H) with spring

seat facing UP. 30. Remove extension tool and hold damper rod up, clear
26. Install spring with tightly wound coils (I) down. of spring.
31. Screw jam nut (J) fully onto damper rod until
bottomed.
I
32. TYPE 2 ONLY: Place backing washer (K) on top of
spring.
H
K
J
27. Mount tube in spring compressor and adjust thumb

screws to catch spring as outlined for disassembly
(page 12.19).
33. Place a new O-ring on fork cap and screw cap FULLY
onto damper rod for maximum thread engagement.
12.28
34. Hold cap and screw jam nut up damper rod until it thread damage.
stops against cap.
35. Hold jam nut and torque fork cap.
27 Nm
(20 lb-ft)
TYPE 1:
27 Nm (20 lb-ft)
TYPE 2:
13.5-16.5 Nm
(10-12 lb-ft)
40. After cap thread is started, continue to turn tube and

adjust spring compressor pressure as required until
cap is fully seated against top of outer tube.
41. Tighten fork cap to outer tube. 68 Nm (50 lb-ft).
36. Slowly release spring pressure and remove fork leg TYPE 1:
from spring compressor. 68 Nm (50 lb-ft)
37. Install special socket in compressor as outlined for TYPE 2:

disassembly. 15-30 Nm
38. Slowly compress fork tube assembly with drive nut (11-22 lb-ft)
until fork cap enters the outer tube, and threads start
to make contact.
12
FORK GUARD REPLACEMENT

1. Protect surface of fork slider.
2. Use a light tapping motion with a soft face hammer to
remove the guard.
39. Rotate outer tube to start cap. Use care to avoid
12.29
FRONT FORK TUBE INSTALLATION

Also refer to illustration on page 12.6.
1. Clean the fork tubes and the clamping surfaces of the
triple clamps to remove any oil or grease.
2. Install one fork tube assembly into lower triple clamp.
3. Continue to slide tube through lower triple clamp and

into upper triple clamp. Stop when the inner fork tube
or bottom of the fork cap is flush with the top of the
upper triple clamp.
NOTE: The bottom of the fork cap should be flush

with the upper triple clamp.
4. Torque upper triple clamp pinch bolt to 23 Nm

(17 lb-ft).
5. Torque lower triple clamp bolts, starting with lower bolt,

then upper bolt to 23 Nm (17 lb-ft).
6. Repeat torque on both lower triple clamp bolts.
7. Repeat steps 1 through 5 for the other fork tube.
8. Install front fender assembly (page 12.4). Torque

mounting screws to 11 Nm (8 lb-ft).
9. Install front wheel (page 12.17).
10. Install brake calipers (page 12.17). Torque mounting

bolts to 42 Nm (31 lb-ft).
11. Inspect all bolts for proper torque.
12. Lower front end of motorcycle to the ground and test

front suspension / fork operation.
12.30
ASSEMBLY VIEW, STEERING STEM / TRIPLE CLAMPS
12
12.31
TRIPLE CLAMP REMOVAL

1. Elevate front of machine so that front wheel can be
removed. Support machine securely in an upright
position.
CAUTION
Take precautions so that the motorcycle is

securely supported when the tire is off the ground.
2. Remove instrument bezel and bridge console (see

Chapter 3).
3. Remove front wheel (page 12.13).
4. Loosen upper triple clamp nut (steering stem nut).
5. Remove fork tubes (page 12.18).
6. Remove handlebars (page 12.12).
7. Remove top nut and slide upper triple clamp off

steering stem.
NOTE: Support lower triple clamp while removing

stem nut.
8. Remove adjustment nut from steering stem with

Victory spanner socket (PV-43508).
9. Remove upper bearing from frame (see assembly

view page 12.31).
10. Remove lower triple clamp with steering stem and

lower bearing.
11. Inspect bearings and bearing races for pitting,

excessive wear or damage.
12.32
TRIPLE CLAMP INSTALLATION / STEERING 8. Place upper triple clamp over steering stem.
HEAD BEARING ADJUSTMENT
9. Install washer and top nut (domed side up) onto stem
Refer to page 12.6 for assembly view and torque and tighten nut hand tight.
specifications.
NOTE: Nut will be torqued after fork tubes are
1. Inspect both upper and lower bearing races for installed.
pitting, dents, or worn surface.
10. Slide fork tube through lower triple clamp and into
upper triple clamp. Align bottom edge of fork cap with
top edge of upper triple clamp and hold in position.
11. Tighten top triple clamp pinch bolt enough to hold

tubes in place. Leave lower triple clamp pinch bolts
loose.
12. Use a 30 mm socket to torque steering stem nut to

97.6 Nm (72 lb-ft).
NOTE: CHECK STEERING BEARINGS at this time.
Pull firmly on fork tubes with a front-to-rear motion.
If movement (play) can be felt in steering bearings,
disassemble and go back to Step 8. Tighten steering
stem adjuster nut an additional 5 degrees, and
reassemble following Steps 8-14. Repeat this
2. Replace bearings and races as a set. procedure until no play can be felt.
3. Apply Victory All Purpose grease to lower bearing and 13. Verify fork tube height in upper triple clamp. Fork cap
install lower triple clamp into frame. seam should be aligned with top edge of fork tube
bore on upper triple clamp.
4. Place upper bearing over steering stem and into
frame. 14. Torque upper triple clamp pinch bolts (left and right
side) to 23 Nm (17 lb-ft).
12
5. Place bearing adjustment nut (shoulder side down) on
steering stem and tighten with a Victory spanner 15. Torque bottom bolts on lower triple clamp to 23 Nm
socket (PV-43508) to 39.3 Nm (29 lb-ft). (17 lb-ft).
16. Torque top bolts on lower triple clamp to 23 Nm (17

Adjustment Nut
lb-ft).
17. Repeat torque on bottom and top bolts of lower triple

clamp.
18. Install handlebars (page 12.12).
19. Install front wheel (page 12.17).
20. Install instrument bezel and bridge console (see

Chapter 3).
21. Verify all fasteners are installed and properly torqued.
6. Turn lower triple clamp from lock to lock five times.
7. Loosen adjuster nut 90 degrees (1/4 turn).
12.33
STEERING STEM BEARING REMOVAL 4. Install two long bolts into bearing collar. The two long
(TYPICAL EXAMPLE) bolts should be threaded into bearing collar
approximately 8 turns each or until flush with the
1. Mask the top cosmetic surface of the triple clamp to bottom of the tapped hole.
protect it from damage.
2. Remove lower bearing cage and rollers. Use a cold CAUTION

chisel to cut through the cage, then use a pliers to
remove the cage. Do not turn the long bolts in too far or the lower
triple clamp finish may be damaged.
5. Install bearing collar onto lower bearing inner race.

The knife edge of bearing collar must catch under top
lip of inner race. Torque bearing collar nuts to 13.6 Nm
(10 lb-ft).
CAUTION
Wear eye protection. Use care not to damage

steering stem bearing surface during
bearing removal process.
3. Drive inner bearing race upward until clear of recess

in lower triple clamp.
12.34
6. Place spacer (A) and puller bracket (B) on top of STEERING STEM BEARING INSTALLATION
steering stem. (TYPICAL EXAMPLE)
1. Thoroughly grease new bearing (grease both upper
B and lower bearings at this time). Ensure that the
grease is packed well into the bearing cage and that
A a thin film of grease completely covers all bearing
elements.
Victory All Purpose Grease: 2872187

2. Clean the stem thoroughly and inspect bearing
support surface for nicks or damage.
3. Install lower bearing over steering stem.
4. Place bearing driver over stem. Place lower triple

clamp, with bearing driver, into hydraulic press.
7. Install puller bolt and turn clockwise to remove bearing
race from stem. Hold puller bracket to prevent it from
turning and bending the long bolts.
12
5. Support the lower triple clamp directly below the
steering stem with a suitable press plate.
6. Press lower bearing down until it is firmly seated.
CAUTION
Make sure bearing driver contacts the inner race

of the bearing only, not the cage or the rollers.
12.35
LOWER BEARING RACE REMOVAL

Center Screw
1. Remove triple clamps (page 12.32). Nut
Washer
2. Drive bearing race evenly out of frame using a long
flat punch through access notch. Tool Bearing
LOWER BEARING RACE INSTALLATION Bearing Plate

1. Clean bearing race bore in frame.
2. Apply a light film of grease to outer surface of new

lower bearing race.
Airbox / Frame
3. Load lower bearing race onto special tool with tapered Assembly
side facing DOWN (Fig. 1).
Steering bearing race installation tool PV-43515

4. Insert tool from bottom of steering neck.
5. Place bearing plate in top bearing cavity (top bearing

removed). Outer Bearing
Race
6. Apply anti-seize compound to the threads of the nuts
and center screw. Apply anti-seize compound to faces Bearing Driver
of each washer, and to the tool bearing.
7. Loosely assemble the tool bearing, washer, and nut Washer

onto center screw.
Fig. 1 Nut
CAUTION
Make sure bearing race starts straight in bearing

bore.
8. Slowly tighten tool to draw lower bearing race into

bearing bore of frame.
9. Continue to tighten nuts on center screw until lower

race is fully seated in bore.
10. Remove tool and clean lower race and upper bearing
bore thoroughly.
11. Assemble triple clamp and adjust bearing lock nut

(page 12.33).
12.36
TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED
Heavy Steering Steering Stem Nut Over Tightened Adjust
Front Tire Damaged or Worn Replace
Low Tire Pressure Inflate to specification
Damaged / Worn Steering Stem
Replace
Bearings or Races
Bent Steering Stem Replace
Pulls to One Side or Wanders Damaged Steering Stem Bearings or
Replace
Races
Steering Stem Nut Over Tightened or
Torque to specification
Under Tightened
Rear Wheel Not Aligned Correctly Align
Bent Front Axle Replace
Damaged or Excessively Worn Front
Replace
Tire / Incorrect Tire
Damaged / Worn Wheel Bearings Replace
Damaged / Worn Swing Arm Bearings Replace
Loose Swing Arm Pivot Nut Torque to specification
Bent Frame or Swingarm Replace
Handlebars Oscillate (Wobble) Incorrect Tire Pressure / Tire Type Correct
Tire Mounted Incorrectly Check Mounting and Balance
Damaged Tire / Worn Tire Replace 12
Loose Steering Stem Nut Torque to specification
Suspension Adjusted Incorrectly Adjust Properly For Load
Bent Front Axle Replace
Front Wheel Oscillates (Wobbles) Bent Front Rim Replace
Damaged Front Wheel Bearings Replace
Damaged or Incorrect Tire Replace
Loose Axle or Axle Pinch Bolts Torque to specification
Fork Tube Height Unequal (L&R) Install Correctly
Fork Oil Level Unequal Set Correctly
Fork Spring Free Length Different Replace
Between Right & Left
Wheel Assembly Out-of-Balance Balance
Noise In Front Suspension Worn Fork Bushings Rebuild Forks
Low Fork Fluid Determine Cause/Replace Fork Oil
Loose Fasteners Torque to specification
Loose Steering Stem Bearings Determine Cause/Correct
Fender, Brake Lines, Brake Caliper Determine Cause/Correct
12.37
TROUBLESHOOTING (cont.)
Front Suspension Too Soft Weak Fork Springs Replace
Low Fork Oil Level Determine Cause/Replace Fork Oil
Wrong Weight Fork Oil Replace
Contaminated and/or Deteriorated Replace
Fork Oil
Low Tire Pressure Set Correctly
Front Suspension Too Hard Tire Pressure Too High Set Correctly
Bent Fork Tubes Replace
Incorrect Fork Oil Replace
Fork Oil Level Too High Set Correctly
Plugged Oil Passages Rebuild Front Forks
Damaged Sliders or Fork Tubes Replace
Forks Binding, Incorrect Assembly Correct
Front Fender and/or Front Wheel
Wheel Turns Hard Damaged Wheel Bearings Replace
Front Axle Bent Replace
Brake Dragging Repair as Necessary
(Hydraulic or Mechanical Problem)
Brake Dragging (Bent Disc) Replace
Improper Assembly After Repairs Correct as Necessary
12.38
REAR WHEEL & SUSPENSION
CHAPTER 13
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
WARNINGS AND PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
TIRE PRESSURE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
SPECIFICATIONS - REAR WHEEL AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 13.3
ASSEMBLY VIEWS & TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
ASSEMBLY VIEW - REAR AXLE & ADJUSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
ASSEMBLY VIEW - SWINGARM & SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
REAR WHEEL - CAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
REAR WHEEL - BILLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
REAR WHEEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
REAR WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
REAR AXLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
REAR WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
WHEEL BEARING REMOVAL (TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
WHEEL BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
BRAKE DISC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
REAR SPROCKET REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
REAR SPROCKET INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
REAR WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
REAR SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
REAR SHOCK SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
REAR SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
REAR SHOCK AND PIVOT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.19
SHOCK ABSORBER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20
SWINGARM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
SWING ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
SWING ARM BUSHINGS / BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 13.22
13
SWING ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23
13.1
GENERAL INFORMATION SPECIAL TOOLS

WARNINGS AND PRECAUTIONS SPECIAL TOOLS
See page 1.21 for tool ordering information.
WARNING
Wheel Bearing / Stem Bearing Race
This motorcycle was produced with the designated PV-43515
Installation Set
tires as original equipment. The testing to ensure Commercially
stability and superior handling was done using the Platform Jack or Hoist
available
OEM tires. Using non-OEM tires could result in poor
motorcycle stability and handling, which can lead to Blind Bearing Remover Set (for wheel
PV-43551
a crash resulting in serious injury or death. bearings)
Use only the recommended tires inflated to the Lower Shock Spherical Bearing and
PV-49060
recommended tire pressures. Lower Pushrod Bushing Tool
Victory Air Pump & Gauge (Rear 2876654 or
Tubeless tires are used on Victory Vision models. Shock Air Pressure) PV-48909
Operating the motorcycle with damaged rims creates a
safety hazard including air pressure loss, steering
imbalance and/or reduced steering control. Do not
attempt to repair or straighten damaged rims.
Always use genuine Victory parts or equivalent so that

quality is not compromised. The use of tire valves and valve
cores other than original equipment replacement Victory
parts could cause tire deflation which may lead to loss of
control, resulting in injury or death. Do not allow any
motorcycle to leave your service area without tire valve
caps securely installed.
CAUTION
Work performed to the rear end of the motorcycle
usually involves supporting the machine with the rear
end elevated. Take precautions so that the motorcycle
is securely supported when the rear tire is off the
ground. This reduces the possibility of personal injury
or damage to the motorcycle.
• The rear shock absorber is a sealed unit and

cannot be re-built.
• Refer to Chapter 2 for maintenance of rear wheel &

suspension components, and suspension ride
height adjustment.
• Refer to Chapter 15 for brake system service.
• Refer to Chapter 14 for tire removal, repair, &

balancing.
13.2
SPECIFICATIONS
SPECIFICATIONS - REAR WHEEL AND SUSPENSION
SPECIFICATIONS
Axle Runout - .20 mm (.008")
Single, Air Adjustable Shock DO NOT EXCEED 72 PSI
Rear Shock Absorber
(Sealed unit not serviceable) operating pressure.
Rear Wheel Runout Axial .80 mm (.030 inch) 2.0 mm (.080”)
(Cast & Billet Type) Radial .80 mm (.030 inch) 2.0 mm (.080”)
Rear Wheel Size / Type 5.0 x 16 --
Rear Wheel Travel 4.7 in. (12 cm) --
Shock Free Length (Eye to eye center) 353 mm (13.9 inch) +/- 3mm (.120 in) --
Perform Air Pressure Adjustment For
DO NOT EXCEED 72 PSI
Suspension Ride Height Measurement Rider Weight and Load with motorcycle
operating pressure.
on side stand. (See Chapter 2)
Swing Arm Pivot Shaft Runout Not Applicable .20 mm (.008")
Swing Arm Pivot Shaft O.D. 16.20 - 16.25 mm (.638 - .640”) 16.08 mm (.633")
Wheel bearing O.D. 52 mm --
Wheel bearing I.D. 20 mm --
Less than 171.3 mm
Wheel bearing spacer length 171.3 - 171.5mm (6.744 - 6.752)
(6.744)
TORQUE SPECIFICATIONS
(Also see Assembly Views page 13.4 and 13.5)
Install NEW screws if
loosened or removed. New
Brake Disc Screws 30.0 Nm (22 lb-ft)
screws have special pre-
applied locking agent.
Clean hub threads, bolt
threads, and mating
Victory Billet Wheels: 75.0 Nm (55 lb-ft) surfaces of hub to remove
13
Hub Bolts (Billet Wheels Only)
Ness Billet Wheels: 88.0 Nm (65 lb-ft) grease, oil, and old locking
agent. Apply Loctite 262
(Red) to bolt threads.
Rear Axle Nut 88.1 Nm (65 lb-ft) --
Rear Axle Adjuster Nut 10.8 Nm (8 lb-ft) --
Rocker Arm Pivot Shaft Retaining Bolts 24.5 Nm (18 lb-ft) --
Sprocket Nuts (2008) 81.0 Nm (60 lb-ft) Torque in star pattern
Sprocket Bolts (2009-2010) 95.0 Nm (70 lb-ft) Torque in star pattern
Sprocket Studs (to wheel hub) (2008) 34.0 Nm (25 lb-ft) --
Swing Arm Nut, Left Side 2.7 Nm (24 lb-in) Apply Loctite 262 (Red)
Swing Arm Nut, Right Side 88.1 Nm (65 lb-ft) --
Shock Mount Bolt (Lower) 81.4 Nm (60 lb-ft) --
Shock Mount Bolt (Upper) 73.2 Nm (54 lb-ft) --
Shock Pushrod Bolt (Lower) 81.4 Nm (60 lb-ft) --
Shock Pushrod Bolt (Upper) 73.2 Nm (54 lb-ft) --
13.3
ASSEMBLY VIEWS & TORQUE

ASSEMBLY VIEW - REAR AXLE & ADJUSTERS
Refer to the illustration below for fastener torque
Apply Victory All

Purpose grease
Retainer
Adjuster 10.8 Nm (8 lb-ft)
88 Nm (65 lb-ft)
Forward
13.4
ASSEMBLY VIEW - SWINGARM & SUSPENSION
Apply Victory All

Purpose grease
24.5 Nm (18 lb-ft)
See page 13.17
Shock Pressure - DO NOT EXCEED

110 PSI when filling
72 PSI (496 kPa) operating pressure
73 Nm
(54 lb-ft) Use PV-49060 or a
Torque the nut slide hammer to remove.
PV-49060 to install.
Pushrod Bushing
81.4 Nm (2008-2009) or
(60 lb-ft) Spherical Bearing
Torque the nut
(2010) 13
Spacer
Swing Arm Nut
Spherical Bearing
88 Nm (65 lb-ft)
Spacer
Forward Swing Arm Nut

2.7 Nm (24 lb-in)
Apply Loctite 262
13.5
REAR WHEEL - CAST
LH (Disc)
FORWARD Apply Victory All Purpose Grease
Metal Stem
5.0 Nm
(45 lb-in)
RH (Sprocket)
O-Ring
Slot
0 - 1mm (0 - .040) 0 - 1mm (0 - .040)
Seal Seal
Disc Side Sprocket Side
Snap Ring
Bearing seated Bearing seated

in hub against spacer
Cutaway View From Rear
13.6
REAR WHEEL - BILLET
LH (Disc)
FORWARD Apply Victory All Purpose Grease
Slotted Metal Stem

5.0 Nm
(45 lb-in)
O-Ring
RH (Sprocket)
No Slot
Metal Stem - No Slot

See Chapter 14 for installation
1.35 Nm
(12 lb-in)
Seal Washer
0 - 1mm (0 - .040) Disc Sprocket
M8 x 1.25 M12 x 1.75 No Slot
Sprocket Side Bearing 13

seated against spacer
Seal Seal
Clean all threads and hub mating

Snap Ring surfaces. Apply Loctite262 (Red).
Torque in pattern below.
Disc Side Bearing Billet: 75 Nm (55 lb-ft)
seated in hub NSS Billet: 88 Nm (65 lb-ft)
4 2
Do not disassemble wheel to No Loctite on hub
replace bearings. See wheel mating surfaces.
bearing replacement procedure.
1 5
3
Hub Torque Pattern
13.7
REAR WHEEL SERVICE

REAR WHEEL REMOVAL
Fig.1
WARNING
Rear wheel removal involves supporting the machine with the rear end elevated. Take precautions so that the
motorcycle is securely supported when the rear tire is off the ground. Severe personal injury or death can occur if the
motorcycle tips or falls.
1. Secure motorcycle in a stand with straps (Fig. 1). 3. Remove the lower shock bolt and lower pushrod bolts
(B) from the swingarm.
2. Place a platform jack (A) under the engine. Elevate the
motorcycle enough to take the weight off the rear
wheel, but still leave the wheel touching the platform.
NOTE: Muffler removal is not required.
4. Raise the motorcycle high enough to gain access to the

axle nut. Loosen axle nut to the end of the shaft.
5. Tap axle to the right until retaining plate is clear of the
A swingarm and remove it.
6. Tap axle from right to left and pull axle out the left side
of the swingarm.
NOTE: Adjuster nut removal or loosening is not required,
however, belt tension and alignment must be inspected
after assembly.
13.8
7. Elevate the motorcycle until the swingarm shock REAR AXLE INSPECTION
mount is raised a minimum of 12 inches (305 mm).
1. Place rear axle in V-blocks and measure runout.
Compare to service limit on page 13.3
2. Axle diameter should be measured on bearing
surfaces at (D).
18 X 1.5 thread 19.97 - 19.99 mm
12” (305mm)
8. Remove the drive belt-side wheel spacer and

disengage drive belt from rear sprocket. D
NOTE: Adjuster nut removal is not required.
9. Remove rear caliper from swing arm.
CAUTION
Do not allow rear brake caliper brake line to hang or
twist. Brake line damage may result.
10. Secure brake caliper to swing arm with tie strap.

11. Remove rear wheel from left side of the motorcycle.
NOTE: Do not apply rear brake pedal once the brake
caliper has been removed.
13
13.9
REAR WHEEL INSPECTION WHEEL BEARING REMOVAL (Typical)

NOTE: Wheel bearings must be in good condition.
CAUTION
1. Set up a dial indicator to measure axial and radial
runout of the wheel. Refer to Chapter 14 for Do not reuse bearings that have been removed.
procedure. Compare measurements to service limits.
NOTE: These instructions depict typical procedures
2. Visually inspect wheel for cracks or other damage. to use the wheel bearing removal and installation
3. Replace wheel if it fails visual or measured inspection. tools. Also refer to instructions included with tool.
1. Remove brake disc (page 13.14).
REAR WHEEL BEARING INSPECTION
NOTE: If possible, also inspect wheel bearings before
removing the wheel from the vehicle (Chapter 2). Do not
remove bearings from wheel to inspect. Bearings cannot
be reinstalled. Replace both bearings if one or both fail
inspection, or if either bearing was removed.
1. Visually inspect integral bearing seal for damage.
2. Inspect bearing fit in wheel hub. Outer race of bearing
must fit tightly in bore.
3. Slide axle into wheel. Check for smooth rotation and
tight fit.
NOTE: Due to extremely close tolerances, the bearings 2. Remove sprocket.
must be inspected visually, and by feel. Look for signs of
discoloration, scoring, galling, or contamination from
moisture or dirt. Replace bearings if any of the above are 2008
present. Turn the inner race of the bearings. The bearings
should turn smoothly and quietly. The inner race should
be firm with minimal side to side movement and no
detectable up and down movement.
2009-2010
13.10
WHEEL BEARING REMOVAL - TYPICAL (Cont.) 7. Remove spacer.

3. Protect hub. Pry seals out of hub on both sides.
4. Remove snap ring from disc side.

8. Extract or drive bearing from the other side.
13
5. Install bearing remover element into bearing. Tighten
bearing remover until firm. Do not over-tighten or tool
may be damaged.
6. Remove bearing by tightening lower nut.
13.11
WHEEL BEARING INSTALLATION (TYPICAL) 5. Install the other 51mm bearing tool (F) in bearing bore
on right side of hub with flat washer and nut. Pull left
1. Clean inside of wheel hub and bearing spacer. bearing into hub by tightening nut on left side of tool
Replace spacer if worn beyond the service limit. until left bearing is fully seated in hub.
Standard: 171.30 - 171.50 mm (6.744 - 6.752)

Service Limit: Less than 171.30mm (6.744)
F
2008 - 2010 Cast and Billet
Wheel Bearing Installation Set PV-43515

NOTE: DO NOT install retaining ring at this time.
2. Slide threaded rod from PV-43515 through wheel hub.
Place new wheel bearing (A) into left (disc) side of 6. Turn wheel over and install bearing spacer (G). Be sure
wheel with markings facing out (toward outside of hub). spacer is centered on bearing.
3. Assemble tool with flat side of 51mm wheel bearing

collar (B) against wheel bearing. This tool must be
slightly smaller than O.D. of bearing and must be flat
to support both inner and outer race equally. DO NOT
pull or press on inner race of ball bearings or bearing G
will be permanently damaged!
4. Install tool bearing (C), washer (D), and nut (E) on

threaded shaft.
E D C B A
13.12
7. Assemble tool through left side with backing disc (or 12. Remove tool and check to be sure that spacer is
bearing tool) flat against left bearing. Be sure the tool centered and trapped firmly between bearing inner
supports both inner and outer race. races. If not centered or not trapped, center it using
the rear wheel axle and repeat Steps 9 - 11 to fully
Left Side seat bearing against spacer.
13. Install snap ring. Be sure it is fully seated in groove.
8. Place new wheel bearing (H) on threaded shaft

(markings out) and start it squarely in the hub.
9. Install 51 mm wheel bearing installation tool with flat
side against bearing, followed by tool bearing, flat
washer, and nut. 14. Rotate inner races of bearings to check for free,
smooth rotation.
H Right Side 15. Install new seals using a 52 mm seal driver.
0.0 - 1 mm (0.00 - .039 in.)

Seal Depth
13
10. Keep the wheel positioned as shown to keep spacer

16. Install brake disc (page 13.14). Clean discs with
centered during installation of right bearing.
Victory Disc Brake Cleaner.
CAUTION
Do not allow brake cleaner to contact painted surfaces.
Typical Wheel Assembly Shown WARNING

Grease or oil on the brake disc or pads will increase
stopping distance which could cause a loss of control
or a crash.
11. Pull bearing in to right side of wheel until seated against 17. Install rear sprocket (page 13.14).
spacer.
13.13
BRAKE DISC REMOVAL REAR SPROCKET INSTALLATION

1. Remove rear wheel (page 13.8). 1. Clean sprocket stud threads (2008) or bolt threads in
2. Position wheel with brake disc facing up. Support hub (2009-2010) to remove all grease or oil residue.
wheel so as not to damage the belt sprocket. 2. Clean mating surfaces of wheel and sprocket.
3. 2008 Models: Be sure studs are tight and properly
torqued to hub. Install sprocket over studs, then install
washers and nuts with tapered side facing OUT.
30 Nm (22 lb-ft)
Replace Screws 4. Tighten nuts in a star pattern to specified torque.
2008
A
Tapered side Flat side IN

OUT (toward washer)
ABS
34 Nm (25 lb-ft)
Pulse Ring
81 Nm
(60 lb-ft)
3. Remove and discard brake disc screws (A).

4. Remove brake disc from wheel.
5. 2009-2010 Models: Install sprocket and new sprocket
BRAKE DISC INSTALLATION bolts.
1. Clean bolt hole threads with Loctite Primer N. 6. Torque bolts in a star pattern to specified torque.
7. Install rear wheel (page 13.15).
2. Clean mating surfaces of disc and hub.
3. Install brake disc on hub with part number to outside. 2009-2010
4. ABS Models: Place pulse ring on disc and align holes Replace Bolts
with disc and hub.
5. Install new brake disc screws and torque to 95 Nm
(71 lb-ft)
specification. Do not re-use brake disc screws. New
screws have a special pre-applied locking agent.
REAR SPROCKET REMOVAL

1. Securely support rear of motorcycle off floor.
TORQUE PATTERN
2. Remove rear wheel (page 13.8). (2008 - 2010)
3. Remove sprocket nuts and washers (2008) or sprocket
bolts (2009-2010).
4. Remove rear sprocket from wheel.
13.14
REAR WHEEL INSTALLATION 5. Using the platform jack, lower the swingarm over the
wheel assembly while guiding the brake caliper, belt
1. Place rear wheel into position underneath the wheel adjusters into alignment.
well.
2. Install the rear wheel spacers in their correct locations.

Long spacer on sprocket side and short spacer on disc
side of wheel.
3. Verify that the rear sprocket is aligned into the belt

guard and install the drive belt. Verify the teeth are
engaged completely on both the front and rear
sprockets.
4. Prepare the caliper for installation by slightly spreading

the brake pads. Place the caliper into position on the
brake disc. Verify caliper bracket tab (A) inserts into the
slot on the left inside of swingarm once you start to
lower it into position.
Apply Victory All
Purpose grease 6. Apply a thin film of grease to axle surface.
7. Insert axle through left side swingarm and axle

adjuster, through caliper bracket, left spacer, and into
wheel. Push axle in through entire wheel assembly,
right wheel spacer and right axle adjuster and right side
of swingarm until retaining plate can be installed in slot
of axle (wheel alignment marks on plate facing OUT).
8. Tap or pull axle back toward left side until plate is

engaged in swingarm. Install washer and axle nut on
left side of axle (if removed).
13
A
88 Nm (65 lb-ft)
9. Verify the tab of caliper bracket is still engaged in slot

on left side of swingarm.
13.15
10. Tighten axle nut until seated and back off one full turn. 15. Adjust belt tension and wheel alignment (Chapter 2).
Tap axle forward on each side to be sure adjuster nuts
are seated against swingarm. 16. Apply rear brake pedal 2-3 times to re-set brake pads.
firmly against the disc. You should feel firm resistance
11. Torque rear axle nut to 88 Nm (65 lb-ft). when applying pressure to the brake pedal. If pedal
feels spongy, verify proper assembly of rear wheel and
12. Inspect lower shock mount spherical bearing and caliper bracket. I correctly assembled, bleed brake
spacers. Inspect lower pushrod bushing. Replace system as described in Chapter 15.
worn parts using bushing / bearing tool PV-49060.
17. Rotate the rear wheel and check for smooth rotation
13. Lower the motorcycle with the platform jack until the without brake drag. If drag is evident, verify brake pedal
shock eyelet (arrow) is aligned with the spherical clearance is within specified 1-2mm range. (Ch. 15)
bearing in the swingarm. Install spacers on each side
of spherical bearing. Align parts and install bolt with nut 18. Lower the motorcycle and test drive to ensure proper
on the inside. Torque nut to 81.4 Nm (60 lb-ft). operation.
14. Continue to lower the motorcycle with the platform jack

until the lower shock pushrod eyelet is aligned with the
swingarm. Install bolt with nut on the inside. Torque the
nut to 81.4 Nm (60 lb-ft).
13.16
REAR SHOCK
REAR SHOCK SERVICE DATA
The rear shock is not serviceable. Use dry compressed air or Victory Air Pump and Gauge (2876654 or PV-48909)
to pressurize the shock. Set ride height by performing air pressure adjustment (see Chapter 2).
Do not store the shock horizontally. If left horizontal for a period of time, cycle shock at least 10 times in upright
position before installation
DO NOT EXCEED 72 PSI operating pressure. Shock Air
DO NOT EXCEED 110 PSI when filling. Line Routing
2010 Vision 8-Ball and

2010 Ness Signature
Series Model
73.0 Nm
(54 lb-ft)
13
81.4 Nm
(60 lb-ft)
Suspension Rocker: 2008-2010 Vision Suspension Rocker: 2010 Vision 8-Ball / Ness
(except 2010 8-Ball & Ness)
60.0 mm 46.5 mm
13.17
REAR SHOCK REMOVAL 7. Remove rear wheel (page 13.8).

8. Remove both pivot pin retaining fasteners.
WARNING
Shock absorber removal involves supporting the
machine with the rear end elevated. Take precautions so
that the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death can
occur if the motorcycle tips or falls.
1. Remove seat (Chapter 3).

2. Open left saddlebag and remove air pressure fitting (A)
from inner bag compartment.
9. Drive pivot pin (C) from the backside forward, until

clear of the suspension rocker arm. Leave driver in
place.
3. Remove side covers (Chapter 3).

4. Place a wide-based platform jack under rear of engine.
5. Elevate the jack slightly until weight is removed from
shock and pushrod mounting bolts. 10. Remove driver while guiding bottom shock mount into
opening in swingarm with pushrod along side.
6. Loosen lower shock mounting bolt and pushrod bolt,
and remove the fasteners (B).
11. Remove shock, rocker arm, and pushrod as an

assembly when clear of the frame.
13.18
REAR SHOCK AND PIVOT INSPECTION 8. Inspect the pivot mechanism and pivot pin. Bearing
needles should turn freely and be free of corrosion or
WARNING contamination. Thrust bearings should be free of
cracks or wear. Inspect surface of pivot pin for
The rear shock absorber is air pressurized and is not roughness, galling or uneven surface. Replace rocker
rebuildable. DO NOT attempt to disassemble or service arm and pin as an assembly if either is worn or rough.
the shock.
Needle Bearings
1. Inspect shock for signs of oil seepage around the
shock body. If leakage is suspected replace the shock
absorber assembly.
2. Inspect eyelets (A) for cracks or damage. Replace
shock if either eyelet is cracked.
Seals
A
Thrust
Bearings
9. Assemble shock, rocker arm, and pushrod assembly.

Torque upper fasteners to 73 Nm (54 lb-ft). Torque
lower fasteners to 81.4 Nm (60 lb-ft). See page 13.5.
=T
Shock & Pushrod To Rocker Arm:
73 Nm (54 lb-ft)
A
10. Inspect lower pushrod bushing (B) (this is a spherical
bearing with spacers on 2010 models).
3. Clean shock thoroughly.
11. Inspect lower shock mount spherical bearing (C) and
4. Inspect for corrosion, pitting, or damage. Replace spacers (D) for wear. Replace any worn parts before
shock if any of the above is evident. installing the shock and pushrod. Use special tool PV-
5. Depressurize the shock. 49060 to remove and install bushings or bearing. 13
Follow instructions provided with tool. Replacement
6. With shock upright, cycle through entire travel range. can be performed with swingarm installed.
Shock should move smoothly with consistent damping
NOTE: A slide hammer puller can be used to remove
through the entire travel range, and return to the fully
spherical bearings. Installation requires PV-49060.
extended position when released. Replace shock
assembly if damping is inconsistent, oil leakage has
occurred, or if the damper rod does not fully extend B
when released.
Use PV-49060
7. Inspect shock spring for cracks or coil distortion.
Measure free length and compare to specification.
D
C
13.19
SHOCK ABSORBER INSTALLATION 6. Raise or lower swingarm as needed to align shock and
1. Grease all pivot points before assembly. pushrod lower mounts on swingarm.
2. Lubricate and install pivot pin through front side of 7. Install lower shock bolt from left to right. Install nut.
frame.
8. Install lower pushrod bolt from right to left. Install nut.
9. Torque (A) (nut side) to specification.
Apply Victory All

Purpose grease A
3. Drop the shock assembly down through opening in
Apply Victory All
swingarm with pressure hose routed between pushrod Purpose grease
and vent hose. Raise shock into position.
=T
Shock Eyelet Fastener Torque:
81.4 Nm (60 lb-ft)
10. Install air line (C) securing it to channel in debris flap.

11. Route air line fitting through channel in debris flap to
opening in left inner saddlebag. Tighten nut securely.
Apply Victory All

Purpose grease
C
4. Align the rocker arm bore with frame hole, and tap pivot
pin through rocker and into rear portion of frame.
5. Install pin retaining bolts. Torque to 24.5 Nm (18 lb-ft).
24.5 Nm (18 lb-ft)

13. Install side covers (Chapter 3).
14. Install seat (Chapter 3).
13.20
SWINGARM SERVICE 3. Remove brake line guide from left-hand side of

swingarm (A).
SWING ARM REMOVAL 4. Remove swingarm pivot nut (C) and shaft (D). Collect
1. Remove rear wheel assembly (page 13.8). the washer (E).
2. Remove the lower shock mounts. 5. Remove swingarm.
88 Nm (65 lb-ft).
C
E 13
Loctite 262 (Red)

2.7 Nm (24 lb-in).
B
D
13.21
SWING ARM BUSHINGS / BEARING 5. Support the inside left edge of the swingarm pivot on
REPLACEMENT a pressing surface.
1. Remove sleeve (A) from right side of swingarm.

Apply Victory All
Purpose grease
2. Remove seals (B) and bearing (C) from right side of
swingarm.
A
C
F
E
D
B 6. Grease outside surface of new bearings (F) and press

into bore until seated, using a 41.5mm drive adaptor
or a suitable arbor. Press on the OUTER RACE only.
7. Install snap ring (E) and be sure it is seated properly

3. Remove bushing (D) from left side of swingarm. in groove.
CAUTION 8. Install bushing (D) into left side of swingarm. Left side
bearings are pre-lubricated. Do not apply grease to this
Do not reuse bearings that have been removed. bushing.
4. Remove snap ring (E) and drive bearings (F) out from 9. Support inside right edge of swingarm.
inside to outside.
10. Grease surface of a new bearing (C) and press into
bore until centered. Use a 31.5mm drive adaptor or a
suitable arbor.
11. Apply grease to inner lip of seals (B) and install seals
flush with outside of swingarm.
A
E C
D
F
12. Grease right side bearing sleeve (A) and install with a
twisting motion until centered in the seals and bearing.
13.22
SWING ARM INSTALLATION 10. Move swingarm through travel range to be sure it
pivots smoothly and freely.
1. Clean inside of pivot shaft bore in frame (A).
11. Replace rear brake line clamp to left side of swingarm
and torque screw to 8 ft. lbs. (10.8 Nm).
12. Install shock and pushrod to swingarm. Install bolts

from outside to inside and install nuts. Torque nut side
of fastener to 73 Nm (54 lb-ft).).
13. Install rear wheel assembly (page 13.15).

A
14. Raise rear of motorcycle again and check to make sure
that the following applies:
• The rear wheel turns freely, without any
interference between the belt guard, the tire, and
2. Grease swingarm pivot shaft (B). the swingarm.
3. Apply Loctite 262 (Red) to threads on left end of shaft • Brake line is properly routed and secured.
and install left side nut (C) until outer surface is even
• The left and right axle adjusters are aligned
with end of shaft.
properly (wheel is in alignment).
4. Install washer (D) onto shaft. • The rear brake functions properly. It is critical that
the peg on the caliper mount rides inside the
5. Place swingarm assembly with bearings, seals, and channel in the swingarm. If brake pedal does not
bushings installed into position on frame. feel firm refer to Chapter 15 for brake inspection
and bleeding procedure.
6. Install pivot shaft from left to right. Be sure right-hand
sleeve (E) is in place and does not get pushed out of • All fasteners have been tightened correctly.
swingarm when shaft is installed.
• There is adequate clearance between swingarm
7. Install right side washer (F) and nut (G) hand tight. and exhaust mufflers and mounting.
• The swingarm is not loose, it doesn’t wobble from
8. Torque LEFT side nut to 2.7 Nm (24 lb-in). side to side, and it doesn’t move up and down when
pushed and pulled firmly.
9. Tighten RIGHT side nut to 88 Nm (65 lb-ft). 13
15. Test ride motorcycle to be sure rear suspension
Apply Victory All operates smoothly without binding or abnormal noises.
Purpose grease
B 16. Adjust air pressure for rider weight and load (see
E Chapter 2). DO NOT EXCEED 72 PSI operating
F pressure.
G
887 Nm (65 lb-ft).
D
2.7 Nm
(24 lb-in). C
13.23
TROUBLESHOOTING
TROUBLESHOOTING
Rear Wheel Feels “Loose” or Wobbles Low tire pressure Inflate to specification
Worn or damaged wheel bearings Replace wheel bearings
Worn or damaged swing arm, rocker, Replace bushings or bearings
pushrod, or shock bushings/bearings.
Damaged or incorrect rear tire Replace rear tire
Unbalanced rear wheel assembly Balance tire/wheel
Distorted (bent) rear wheel Replace wheel
Loose swing arm, axle or suspension Torque to specifications
fasteners.
Rear Suspension Bent / corroded shock damper rod Replace shock
Too Hard Dry, seized, damaged, corroded Correct as necessary
suspension bushing(s) / bearing(s)
Incorrect preload adjustment Adjust to rider & load
Damaged, dry, or corroded swingarm, Lubricate or Replace
rocker, pushrod, or shock bushings,
bearings, or shaft
High tire pressure Deflate to specification
Drive belt adjustment too tight Adjust drive belt tension
Rear Suspension Shock leaking air / oil Replace shock / repair line leak
Too Soft Weak shock spring Replace shock spring
Incorrect air pressure adjustment Adjust to rider & load
Excessive load placed on motorcycle Educate rider / operator
Low tire pressure Inflate to specification
Rear Suspension Loose fasteners Torque to specifications
Noisy Worn wheel bearings Replace
Worn swing arm, rocker arm, pushrod, Replace
or strut bushing / bearings
Damaged shock absorber Replace as necessary
Check all swingarm, wheel, and
brake system components for contact
Contact between moving and
with frame, exhaust, body, etc. Check
stationary parts
routing and the all fasteners are in
place and tight
Rear Wheel Drag (Turns Hard) Incorrect drive belt adjustment Adjust drive belt tension
Tire contact with object or chassis Determine point of contact and correct
Bent rear axle Replace
Damaged wheel bearings Replace
Brake problem Refer to chapter 15
13.24
TIRES / WHEELS
CHAPTER 14
TIRES / WHEELS
GENERAL / SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
WARNINGS / PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
TIRE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
TIRE PRESSURE / LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
WHEEL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
WHEEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
TIRE WEAR PATTERNS & GENERAL CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
OZONE CRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
FRONT TIRE CUPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
TIRE CHANGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
TIRE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
TIRE REMOVAL (TYPICAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
VISUAL INSPECTION & RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
TIRE REPAIR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
VALVE STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
TIRE VALVE AND STEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
VALVE STEM INSTALLATION - RUBBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
VALVE STEM INSTALLATION - METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
TIRE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
TIRE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
TIRE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
14
14.1
TIRES / WHEELS
GENERAL / SAFETY
WARNINGS / PRECAUTIONS
WARNING
If a consumer wishes to replace the Original Equipment Manufacturer (OEM) tires with another brand of tire, Victory
recommends contacting the tech-line department of the tire manufacturer being considered to ensure compatibility.
Victory makes no other recommendation other than the OEM tires. Tires other than OEM may or may not adversely
affect the handling characteristics of the motorcycle or may not have adequate clearance between tire and various
parts of the motorcycle.
WARNING
Victory motorcycles are produced using the designated tires listed as original equipment. This includes field testing
to ensure stability and superior handling. The use of tires other than original equipment may cause instability which
can lead to a crash resulting in serious injury or death. Use only the recommended tires inflated to the recom-
mended tire pressures.
Operating the motorcycle with damaged rims creates a safety hazard including air pressure loss, steering imbal-
ance and/or reduced steering control. Do not attempt to repair or straighten damaged rims.
The use of tire valves and valve cores other than original equipment replacement Victory parts could cause tire
deflation during driving. Always use genuine Victory parts or their equivalent. Be certain to install the valve stem
caps securely. Do not allow the motorcycle to be ridden without properly installed valve stem caps.
WARNING
Do not attempt to repair tires that have:
- Punctures with a diameter of greater than 6mm (0.240").
- Cuts with a length of greater than 6mm (0.240").
- Any punctures or cuts on the sidewall of the tire.
- Tread depth of less than 1.6mm (.063") for the front tire.
- Tread depth of less than 1.6mm (.063") for the rear tire.
- Ply separation
- Tread separation
- Severe tread cupping.
- Cuts, gouges or scratches on the sealing surface of the bead.
- Flat spots on the tread.
- Bubbles, separation or any unusual damage to the inner liner of the tire.
- Chemical sealants or balance additives added to the tire.
WARNING
All repairs must be made from inside the tire. Victory recommends the use of “head-type” plugs such as: Tech Tire
RepairTM Uni-Seals. Complete Tech Tire RepairTM kits are commonly available at most automotive parts outlets.
WARNING
No form of temporary repair should ever be attempted. Secondary damage caused by a penetrating object may not
be detected and tire or tube deflation may occur at a later date.
14.2
TIRES / WHEELS
WARNING
It is dangerous to ride with a worn tire. When a tire reaches the minimum tread depth listed below, replace
the tire immediately.
FRONT TIRE MINIMUM TREAD DEPTH REAR TIRE MINIMUM TREAD DEPTH
1.6 mm (.063") (1/16 inch) 1.6 mm (.063") (1/16 inch)
CAUTION
Two of the biggest factors contributing to premature tire wear are overloading and under-inflation. Do not deviate
from the specifications for loading or inflation.
TIRE DATA
TIRE PRESSURE / LOADING
Refer to Chapter 2 or to the decal on the motorcycle for tire pressure and loading information.
WHEEL DATA
WHEEL SPECIFICATIONS
Front Wheel
Front Wheel Size 3.00 x 18 -
Front Wheel Runout Axial .75 mm (.030 inch) 2.0 mm (.080”)
(Billet and Cast Type) Radial  .75 mm (.030 inch) 2.0 mm (.080”)
Rear Wheel
Rear Wheel Size 8.50 x 18 -
Rear Wheel Runout Axial .75 mm (.030 inch) 2.0 mm (.080”)
(Billet & Cast Type) Radial .75 mm (.030 inch) 2.0 mm (.080”)
14
SPECIAL TOOLS
SPECIAL TOOLS
Rim Protectors: PV-43536
Tire Irons (for manual tire changing): Commercially available
14.3
TIRES / WHEELS
TIRE INSPECTION
TIRE WEAR PATTERNS & GENERAL CAUSES
WEAR PATTERNS AND GENERAL CAUSES
SYMPTOM CAUSE
Wear on Left Side Riding on Crowned Roads
Edges Worn Underinflation or Excessive Loads
Excess Wear in the Middle of Tire Over-inflation or Tire Abuse
Cracks in Tread Grooves Underinflation, Excessive Loads, Suspension Bottoming
Tread Block Cupping (Usually Front Tire -See Below) Normal Braking Wear
OZONE CRACKING
Ozone cracking usually shows up on the sidewalls of tires and is caused by sunlight, electric motor emissions, smog,
or other environmental factors. Ozone cracking does not pose a problem unless the cracks reach the cords. If this occurs,
moisture may penetrate the carcass of the tire causing cord separation. Tires showing signs of severe ozone cracking
(cords visible at the bottom of the cracks) must be replaced.
FRONT TIRE CUPPING

Front of tread block worn more than rear of tread block:
• The cupping of front tires is somewhat normal.
• Rear tires are subjected to forces in both directions. The forces of braking and acceleration result in even tire
wear.
• Front tires are subjected only to the forces of braking. When the brakes are applied, tire deflection is increased
and wear occurs in only one direction.
• Incorrect tire pressure is the number one cause of excessive tire cupping. Too little tire pressure causes the tire
to over-deflect which increases the amount of scrubbing and causes more tire cupping.
• Binding or improperly assembled front forks can also contribute to excessive tire cupping. If the front forks do
not react as they should the tire acts as the sole suspension component and tread deflection increases.
14.4
TIRES / WHEELS
TIRE CHANGING
GENERAL
There are three generally acceptable methods to dismount and mount a tubeless motorcycle tire from its rim.
Furthermore, there are countless variations for each of the three methods.
The three general methods are:

• Pneumatic or electrically operated tire machine.
• Manually operated tire machine.
• Manual manipulation of tire irons.
The seal between the tire and its rim is one of the most critical factors contributing to the safe operation of the wheel/
tire assembly. Each of the three generally acceptable methods to dismount and mount tires is permissible and recom-
mended by Victory. However, careless or improper work habits can damage both the tire and rim regardless of which
method is used.
The pneumatic or electrically operated tire machine is preferred as it is the most efficient method to dismount and mount
tires. It is also the most expensive way to change tires.
The manually operated tire machine is the next preferred method to dismount and mount tires. It can be just as efficient
as a power assisted tire machine. With some types of manually operated tire machines, it will be necessary to remove
the belt driven sprocket to gain sufficient clearance for tire removal.
Manual manipulation of tire irons is the least preferred method of tire dismounting and mounting. It will not generally
deliver the same efficiency as the other two methods and greater care needs to be taken when performing the operation.
Use care not to damage or stress the tire bead when using tire irons. Be sure opposite bead is in drop center of wheel
when mounting and dismounting the tire.
Be very careful not to damage the rim, tire, inner tube, brake disk or sprocket regardless of which method is used.
The following method describes the procedure using manually manipulated tire irons. Other than the actual operation
of various tools, the general concept is the same regardless of which method is used.
The following procedure shows the front tire being removed from its rim. Other than the possibility of interference of the
sprocket, the procedure is the same for the rear tire.
NOTE: Rear sprocket bolts and brake rotor bolts have a pre-applied locking agent and bolts should either be replaced
or a locking agent applied upon assembly. Refer to Chapter 11 for rear sprocket removal and installation. Refer to
Chapter 13 for rear brake rotor removal and installation. Brake rotor bolts should not be re-used. 14
14.5
TIRES / WHEELS
TIRE REMOVAL NOTE: This procedure can be performed on an empty

drum or similar fixture. The top lip of the drum should be
TIRE REMOVAL (TYPICAL) covered with protective material or split hose to protect
the rim. (Fig. 3)
1. Remove wheel / tire assembly from motorcycle (front
refer to Chapter 12, rear refer to Chapter 13).
Fig. 3
Fig. 1 5. Position wheel assembly so brake disc will not be

damaged and rim will not be scratched.
2. Remove valve core from valve stem and let all air
escape. (Fig. 1) 6. Push tire down and lubricate tire bead with tire lubricant
on both sides of tire. (Fig. 4)
CAUTION
If the tires have a directional arrow it must be observed
and the tire installed correctly.
3. Mount the wheel assembly into a tire bead breaker and

break the bead. (Fig. 2)
Fig. 4
7. Install rim protectors at 12:00 and 2:00 positions.

(Fig. 5)
PV-43536
Fig. 2
4. Flip the wheel assembly over and break the bead on

the other side.
CAUTION
IMPORTANT: Take great care not to bend or otherwise
damage the brake disc and/or belt driven sprocket. If the
bead breaker being used interferes with either the brake
disk and/or belt driven sprocket, remove the disc or
Fig. 5
sprocket as required.
Rim protectors PV-43536
14.6
TIRES / WHEELS
8. Stand opposite of rim protectors. Use your knee to WHEEL INSPECTION

push tire bead down into the rim’s drop center at
location (Fig. 6, A) while pulling bottom bead up into VISUAL INSPECTION & RUNOUT
drop center. Beads must be kept in drop center during
following steps. 1. Refer to chapter 12 for complete front wheel
inspection procedures.
9. With both beads in the drop center, slide a tire iron
2. Refer to chapter 13 for complete rear wheel inspection
between tire bead and 12 o’clock rim protector (Fig. 6,
procedures.
B), lift the bead up with the tire iron, and hold.
3. Clean the rim of all rubber particles and corrosion.
B WARNING
A
If any of the following problems are discovered, replace
the wheel.
4. Inspect wheel for cracks and/or distortion.

5. Inspect bead seating area of scratches, gouges,
distortion or any damage that could create a sealing
problem.
Fig. 6
6. Inspect wheel for axial runout, measured on a smooth
10. Using another tire iron to lift the bead at the 2 o’clock outer edge surface of wheel as shown in Fig. 7 (A).
position.
7. Measure wheel for radial runout (Fig. 7, B)
11. Remove the 2 o’clock tire iron and slide rim protector
to the 4 o’clock position, and lever the bead up.
IMPORTANT: The top and bottom tire beads that are
opposite the area being worked with the tire irons must
continually be pushed into the drop center of the wheel, or
bead removal will be difficult and tire could be damaged.
12. Continue going around the tire in small steps, until one A
side of the tire is off the rim.
13. Turn the tire and wheel assembly over on the drum, so B
the removed bead is on the bottom side. Fig. 7
TUBE TYPE TIRES: NOTE: Measure radial runout on tire bead sealing 14
surface of wheel. Be sure surface is clean before
Remove valve stem nut, push stem through rim. measuring
Remove tube and inspect tube carefully for signs
of abrasion or other damage. 8. Compare measurements of axial and radial runout to
specifications listed on page 14.3. Replace wheel if
Replace tube and rim band whenever a tire is
any measurement exceeds Service Limit. Cast or Billet
removed.
wheels cannot be straightened.
14. Push the tire away from you so the remaining bead is 9. Clean the sealing surfaces of the rim thoroughly. Use
in the drop center of the rim. a soft brush (nylon) soap and water if necessary.
15. Lubricate the bead and start it over the rim with a tire
iron. WARNING
16. In most cases the tire can be forced off of the rim by
hand. Continue to work around the tire until the tire is Do not scratch or damage sealing surfaces of rim. Loss
completely dismounted. of air pressure can cause a loss of control and an
accident, resulting in serious injury or death.
14.7
TIRES / WHEELS
TIRE REPAIR PRECAUTIONS VALVE STEM INSTALLATION - METAL

1. Remove tire from wheel and remove old stem.
WARNING 2. Clean gasket or O-ring seal surface of wheel.
3. Place tire valve (with seal washer or O-ring installed)
Only permanent plug-patch repairs of small tread area through hole in rim and secure it hand tight with nut.
punctures from inside the unmounted tire are
recommended. Never perform an exterior repair and 4. Refer to Fig. 10. On Type 2 valve stems (with no
never use an inner tube as a substitute for a proper holding slot) tighten upper nut (A) to stem cap (B).
repair. Speed should not exceed 50 MPH for the first 24 5. Hold nut (A) to prevent valve stem rotation, and torque
hours after repair and the repaired tire should never be lower stem nut (C) to 1.35 Nm (12 lb-in) using an open
used over 80 MPH. Inspect inflation pressure after the end torque wrench.
tire cools for at least three hours following initial
6. Release upper nut from cap and screw it down against
operation.
stem nut.
VALVE STEM 7. Hold stem nut and tighten lock nut to 12 lb-in).
TIRE VALVE AND STEM INSPECTION

1. Remove and inspect valve core (Fig. 8). Replace if
seal is worn, deformed or otherwise damaged. Inspect
tire valve for cracks or visible damage and replace if
necessary.
NOTE: Valve stem replacement is recommended when
tire is being replaced.
TYPE 1 TYPE 2
VALVE STEM INSTALLATION - RUBBER
1. Remove tire from wheel and cut valve stem with a
diagonal cutter to remove. TYPE 1 (HOLDING SLOT)
2. Clean tire valve hole and sealing area thoroughly.
3. Lubricate tire valve and hole with P-80 rubber lubricant
or equivalent. 45 lb-in
4. Place tire valve into hole and screw a tire valve (5.0 Nm)
installation tool (commercially available) onto valve.
5. Place a small wood block against the rim to improve
leverage point and keep the pulling angle as straight
as possible. (Fig. 9)
6. Pull the valve until fully seated and remove tool.
Fig. 8 TYPE 2 (NO HOLDING SLOT)

A B
C
12 lb-in
B (1.35 Nm)
A
Fig. 9 Fig. 10
14.8
TIRES / WHEELS
TIRE INSTALLATION The wheel assemblies must be free of foreign debris that
would affect balancing.
TIRE MOUNTING Carefully inspect the wheel bearings, seals and axle for
1. Lubricate both tire beads with rubber lubricant. damage or corrosion.
(Fig. 11). Ensure that bead is correctly seated.
TUBE TYPE TIRES:
Install new rim band (rim flap) on rim with hole
oriented over valve stem hole in rim.
1. Place tire on drum.
CAUTION
Support tire assembly in such a way that brake disk or
belt drive sprocket will not be damaged.
Fig. 11 2. Lubricate the bead.
WARNING 3. Orient tire correctly as to the balance dot and

directional arrow.
Never apply grease, oil, gasoline, spray type lubricants
or anything other than rubber lubricant or a neutral soap 4. Push tire on to rim until one bead is installed. It
and water solution to the tire bead. Doing so can shouldn’t be necessary to use tire irons to put one side
damage the tire. of the tire onto the rim. Remember to keep bead(s) in
the drop center of the wheel whenever possible.
Balance Dots
5. Turn the tire / wheel over on the drum so the un-
Dunlop tires have a yellow dot on the sidewall which installed portion of tire is facing up.
corresponds to the lightest part of the tire. This dot is meant
to line-up with the tire valve which often is the heaviest part NOTE: Confirm tire is positioned correctly by observing
of the rim (although this is not always the case). directional arrows. (Fig. 12)
WARNING
Victory does not recommend the use of liquid balancer/

sealers. These are a form of temporary repair which
14
may adversely affect ply material and mask secondary Valve Stem
damage caused by the penetrating object. Reliance
upon sealants can result in sudden tire failure and
accident.
Directional Arrows Directional Arrow: Balance Dot: Align

Corresponds to tire with valve stem
If tires have directional arrows, they must be observed and rotation direction.
tires installed correctly. When tires are manufactured, tread
rubber is laid down as a strip and its ends connect as Fig. 12
overlapping joints. When the tire is mounted correctly the
scrubbing forces of acceleration (rear) or braking (front)
press the lap joints together rather than try to separate the
joint.
14.9
TIRES / WHEELS
6. For tube type tires, also observe the following: will make tire inflation easier. (Fig. 13)
TUBE TYPE TIRES:
Apply baby powder to new tube and install by
inserting valve stem through rim band and rim.
Tube must be completely deflated at this time.
Install the valve stem lock nut a few threads. Do
not tighten the lock nut at this time.
Install tube in tire starting at valve stem and

working your way around until entire tube is
laying inside the tire in a natural position.
Arrange the tube if necessary to eliminate kinks

or bends, and be sure the valve stem projects Fig. 13
straight out. The stem should form a 90 degree
angle with the rim. 16. Inflate tire observing the precautions listed below and
on page 14.10.
Finger tighten lock nut to hold stem in position.
TIRE INFLATION & PRECAUTIONS
CAUTION • Wear approved eye protection
Make sure your tire irons are smooth and free of
scratches or any sharp edges. Polish them if necessary. • Lubricate the tire beads with a tire mounting
Do not slide the tire iron in any more than is necessary. lubricant before inflation.
When installing tube type tires, avoid lifting the tire iron
• Before inflating a tube type tire, check to be sure
past vertical to minimize the chance of pinching the
valve stem is still straight. If not, rotate tire slightly
tube.
on rim (in the direction the stem is pointing) to align
7. Lubricate the tire bead. (Fig. 14).
8. With your hands, push as much of the remaining tire
bead as possible into the rim, pinching both upper and
lower beads into the drop center.
9. When no more of tire can be installed by hand, press
down on portion of tire in front of you with your knee to
keep the top bead in the drop center.
10. Carefully slide a tire iron between the rim and tire at the
other side of the un-installed portion of the tire.
NOTE: Be sure both beads are forced as far as Valve Stem Alignment (Tube Tires)
possible into the drop center of the rim. Fig. 14
11. Lever the tire iron over and install that portion of tire. • Lock assembly on mounting machine or place in
Continue to move tire iron in small increments until tire safety cage before inflating to seat beads
is completely installed.
• Use extension gauge and hose with slip-on air
12. Install valve core if it was removed. chuck.
13. Line up balance dot. • Stand back with no part of your body within the
perimeter of the assembled tire and rim.
14. Confirm that the directional arrows are pointing in the
correct direction. • Inflate with core in valve stem
• Never inflate above 42 psi to seat beads
15. Bounce tire on the floor several times while rotating
tire. This will expand tire bead outward slightly which • If beads do not seat by 42 psi. Deflate and repeat
procedures. Never use a volatile substance or
rubber “donut” to aid bead seating.
14.10
TIRES / WHEELS
1. Inspect the line molded onto the tire side walls. It must TIRE BALANCING
be the same distance from the rim all the way around
the tire. If the distance varies it indicates that tire is not TIRE BALANCING
seated properly. (Fig. 15)
WARNING
Tire Molding Line It is essential that the wheel assembly be balanced

before use and rebalanced each time the tire is
removed.
Wheel balance affects stability, handling and overall

safety of the motorcycle.
Edge of Run
All Dunlop street tires should be installed with the yellow
Fig. 15
balance dot at the tire valve.
2. If tire is not seated correctly, deflate and unseat the tire,
relubricate the tire beads and repeat inflation The use of liquid balancer/sealer is not recommended.
procedure. This procedure will outline balancing wheel assembly in a
3. Install wheel assembly onto balance stand and spin. gravity balance stand. If a pendulum or spin type balancer
Observe the wheel assembly while it is spinning to is being used, reference the manufacturer’s instructions
make sure the tire is seated properly. that came with the equipment.
4. Adjust tire pressures to specifications. 1. Mount wheel assembly in a balance stand.
5. Balance tire / wheel assembly. Refer to page 14.11. Typical Balance Stand (Commercially available)
(Fig. 16)
WARNING
FOR REPAIRED TIRES: Speed should not exceed 50

MPH for the first 24 hours after repair and repaired tire
should never be used over 80 MPH. Inspect inflation
pressure after tire cools for at least three hours follow-
ing run-in.
FOR NEW TIRES: Replacement of OEM tires or

replacement with differently constructed tires will not 14
immediately produce improved reactions the same as
Fig. 16
the original tires when new. When new tires are
installed, they should not be subjected to maximum 2. Remove all balance weights. Clean tire and rim
power or hard cornering until a reasonable “scrub” thoroughly.
period of approximately 100 miles has been covered. NOTE: While it is possible to balance a wheel assembly
This will permit the rider to become accustomed to with axle and grease-free wheel bearings as the pivot
“feel” of new tires or tire combination, and achieve point, it is not recommended. Use an inspection stand
optimum road grip. that has knife edge bearings and its own axle.
3. Spin the wheel assembly. Allow it to stop on its own and
Inspect and adjust tire inflation pressure after tire cools mark the highest (lightest) part of the wheel.
down for at least three hours following “run-in”.
14.11
TIRES / WHEELS
4. Repeat the spinning process to verify the heaviest part If more than the recommended weight is necessary to
of the wheel. (Fig. 17) balance the wheel, dismount the tire and rotate it 90o
without regard to the yellow balance dot, and re-balance
the wheel / tire.
Mark lightest
part of tire
Adhesive Weight P/N 1520253
1. Spin tire.
2. Allow tire to stop
on its own.
3. Mark lightest
part of tire
Fig. 17
NOTE: If the bearings are totally free to rotate and the

wheel does not stop in the same place each time, the
wheel is in balance.
5. Place balance weights at the lightest portion of wheel
in small increments. (Fig. 18)
Add small amounts

of weight to the
lightest part of the
rim.
Fig. 18
6. After each addition of weight, spin the wheel assembly

and allow it to stop by itself.
7. When correct amount of weight has been added to
wheel, it will no longer stop in the same location and
the wheel assembly is balanced.
8. Install wheel / tire assembly tire on motorcycle.
Front wheel installation: Chapter 12

Rear wheel installation: Chapter 13
CAUTION
Do not add more than 85 grams (3.0 oz.) of weight to the rear
wheel.
Do not add more than 85 grams (3.0 oz.) of weight to the front
wheel
14.12
TIRES / WHEELS
TROUBLESHOOTING
TROUBLESHOOTING
Rear Wheel (Wobbles) Bent rim Replace
Worn or damaged wheel bearings Replace as a set
Worn or damaged swing arm Replace as a set
bushings.
Damaged or incorrect tire Replace rear tire
Wheel assembly out-of-balance Balance wheel
Low tire pressure Inflate to specification
Loose swing arm, axle or suspension Torque to specification
fasteners.
Handlebars Oscillate (Wobble) Bent front axle Replace
Tire mounted incorrectly Inspect and re-mount tire
Damaged tire Replace
Loose steering stem nut Adjust to specification
Incorrect tire Replace
Incorrect tire pressure Inflate to specification
Front Wheel Oscillates (Wobbles) Bent rim Replace
Damaged or incorrect tire Replace
Loose axle or axle pinch bolts Torque to specification
Right and left fork not installed at Repair
same height
Fork oil level incorrect Fill to specification
Fork spring free length different Replace spring that does not meet
between right & left specification
14
Wheel assembly out-of-balance Balance wheel
14.13
TIRES / WHEELS
NOTES
14.14
BRAKES
CHAPTER 15
BRAKES
BRAKE SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
ASSEMBLY VIEWS & ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
FRONT BRAKE SYSTEM ASSEMBLY AND DETAIL VIEWS . . . . . . . . . . . . . . . . 15.4-15.5
REAR BRAKE SYSTEM, ASSEMBLY AND DETAIL VIEWS. . . . . . . . . . . . . . . . . 15.6-15.7
MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8
FRONT BRAKE / CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9
CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
MASTER CYLINDERS / BRAKE CALIPERS / DELAY VALVE / PROPORTION VALVE15.12
BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
BRAKE FLUID REPLACEMENT & BLEEDING PRECAUTIONS. . . . . . . . . . . . . . . . . 15.13
BRAKE BLEEDING / FLUID CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
FRONT BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
REAR BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
FRONT BRAKE MASTER CYLINDER / CLUTCH MASTER CYLINDER SERVICE . . 15.20
FRONT MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
FRONT CALIPER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
FRONT CALIPER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
REAR MASTER CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
REAR MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
REAR CALIPER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29
REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.31
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
ABS SYSTEM SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
ABS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
ABS SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
ABS OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
ABS SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.34
ABS SYSTEM CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.35
ABS SYSTEM WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.35 15
ABS SYSTEM - FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.36
ABS SYSTEM - REAR BRAKE (LINKED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.37
ABS SYSTEM - WIRING HARNESS / TIE STRAP LOCATION . . . . . . . . . . . . . . . . . . 15.38
ABS SYSTEM - MODULE CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.39
ABS BRAKE VACUUM BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.40
ABS FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.40
ABS REAR (LINKED) BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.40
ABS FRONT BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.42
ABS FRONT BRAKE SUPPLEMENTARY BLEEDING PROCEDURE . . . . . . . . . . . . 15.43
FRONT BRAKE LEVER RESERVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.44
ABS TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.45
TROUBLESHOOTING - BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.46
TROUBLESHOOTING - ABS BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.48
15.1
BRAKES
BRAKE SYSTEM SAFETY

GENERAL
Use only genuine VICTORY replacement parts when servicing the brake system. Clean all system components prior
to disassembly, including the fluid reservoir cover(s) to reduce the chance of debris entering the system during repair
or maintenance work. Start with a clean work area away from dust, water or other contamination. Cleanliness is very
important for proper brake system maintenance and repair. Follow procedure outlined in this manual carefully,
including fastener torques and the application of special lubricant in required areas. Special lubricants are included
with service kits.
The following warnings apply to Anti-Lock Brake Systems (ABS) as well as non-ABS. ABS specific information begins
on page 15.32.
WARNING
Contaminated brake discs or pads greatly reduce the amount of stopping force available & increase stopping distance.
Brake discs can be cleaned using a commercially available brake disc cleaner. Follow the manufacturer instructions
printed on the container. NEVER attempt to clean contaminated brake pads. Always replace pads as a set.
WARNING
The brake system uses ethylene-glycol based fluid (DOT 4). Do not use or mix with different types of fluid such as
silicone-based (DOT 5) or any petroleum-based fluid.
Do not let water or moisture enter the master cylinder when refilling. Water significantly lowers the boiling point of the
fluid and can result in poor braking.
Do not use brake fluid taken from old, used or unsealed containers. Never reuse brake fluid.
Keep brake fluid containers completely sealed and out of reach of children.
Brake fluid should be completely replaced every 24 months or 12,500 miles.
Brake hoses should be replaced whenever the exterior shows signs of deterioration or damage. Brake hoses should
be replaced every four (4) years regardless of their exterior condition.
Bleed the brake system any time it is disassembled or when the brake action is spongy.
Always inspect the operation of the brakes before riding the motorcycle.
Replace sealing washers whenever brake lines are removed.
Always remove the master cylinder fluid reservoir cover and inspect the fluid level when brake pads are replaced.
NOTICE: Brake fluid and some types of brake cleaners will damage paint, plastics and some rubber compounds.
Cover or remove plastic and painted parts before working on the brake system. If brake fluid is spilled on cosmetic
surfaces, immediately rinse the area with a mild solution of soap and water until all traces of brake fluid are removed.
Make sure the master cylinder reservoir being worked on is level and clean before removing the cap.
15.2
BRAKES
SPECIAL TOOLS
BRAKE SERVICE SPECIAL TOOLS
Caliper Piston Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially Available
Front Brake Lever Reserve Inspection Adapter, . . . . . . . . . . . . . . . . . . . . . . PV-50104
Front Master Cylinder Snap Ring Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially Available
Tension Scale (to measure Front Brake Lever Reserve pull force) . . . . . . . . Commercially Available
Vacuum Brake Bleeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially Available
Pressure / Vacuum Pump (alternative to Vacuum Brake Bleeder above) . . . PV-43545
SPECIFICATIONS
GENERAL SPECIFICATIONS
BRAKE SYSTEM
Replace every 24 months, 12,500 miles, or
Brake Fluid DOT 4 (PN 2872189)
if contaminated
Less than specified pull to bar contact. See
Non-ABS Models: 45 lbs. (Minimum)
Brake Lever Reserve, Front Front Brake Lever Reserve Inspection
ABS Models: 34 lbs. (Minimum)
page 15.44.
Brake Disc Runout - .30 mm (.012") (Max)
Brake Disc Thickness, Front 5mm 4.5 mm (.177")
Brake Disc Thickness, Front / Rear 7mm 6.5 mm (.256")
Brake Lever Freeplay (Front) No Adjustment -
Brake Pad Friction Material
- 1.0mm (.039 inch)
Thickness (Front and Rear)
Brake Pedal Free Play
1 - 2 mm (.040 - .080") -
(Pedal Clearance)
Master Cylinder Diameter, Front
0.551 in. (14.00 mm)
(All models)
Master Cylinder Diameter, Rear Replace master cylinder if bore taper or
5/8 in. (15.875 mm)
(2008-2009) out-of-round exceeds .0015 in. (.04mm)
Master Cylinder Diameter, Rear 11/16 in. (17.460 mm)
15
(2010)
BRAKE SYSTEM TORQUE SPECIFICATIONS
Refer to the exploded views in this chapter for components and fastener torque. ABS information begins on page 15.32.
15.3
BRAKES
ASSEMBLY VIEWS & ROUTING

FRONT BRAKE SYSTEM ASSEMBLY VIEW
ABS INFORMATION BEGINS ON PAGE 15.32

Disconnect negative (-) battery cable from
battery before servicing ABS brake lines.
15.4
BRAKES
FRONT BRAKE SYSTEM DETAIL VIEWS

15
15.5
15.6
BRAKES
REAR BRAKE SYSTEM, ASSEMBLY VIEW

BRAKES
REAR BRAKE SYSTEM DETAIL VIEW
-ASTER#YLINDER
.M
LB FT .M
LB FT
3EALING 0USH2OD
7ASHERS !DJUSTMENT.UT
3EALING
7ASHERS
.M
.M LB FT $%4!),#
LB FT $%4!),"
.M ABS INFORMATION BEGINS ON PAGE 15.32

LB FT
battery before servicing ABS brake parts.
.M
LB FT .M
3EALING LB FT
7ASHERS 15
$ELAY6ALVE
.M
LB FT
.M .M
LB FT LB FT
0ROPORTIONING6ALVE
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15.7
BRAKES
MASTER CYLINDERS
FRONT BRAKE / CLUTCH MASTER CYLINDER
This symbol indicates special lubricant from

Brake service kit must be applied to this part.
Brake
Brake CCI OIL (009-Z00-313) SPECIAL GREASE (009-Z00-115)

Application: Internal: Master cylinder bore, Application: External: Lever pivot screw
piston, and piston seal cups. and contact surface of lever to master
cylinder piston.
Refer to assembly views and rebuild procedure for detailed application of special lubricants.
Follow Front Master Cylinder service procedure

for clutch master cylinder rebuild.
FRONT BRAKE
CLUTCH
1.5 Nm (13 lb-in)
1.0 Nm (9 lb-in)
(Lever Screw)
Replace Washers
Switch Screw
1.2 Nm (11 lb-in)
9 Nm (80 lb-in)
6.0 Nm (52 lb-in)
(Lever Nut) 24.4 Nm (18 lb-ft.)
15.8
BRAKES
REAR BRAKE MASTER CYLINDER
Supply Hose
Reservoir
Supply Fitting
2008-2009 Diameter: 5/8 in. (15.875 mm)

2010 Diameter: 11/16 in. (17.460 mm)
Supply Fitting
Stop Washer
Lock Nut
17.2 Nm (12.5 lb-ft)
15
Snap Ring
Pushrod
Snap Ring Clevis
Boot
15.9
BRAKES
CALIPERS
FRONT BRAKE CALIPER
KS62F
Brake
SILICONE GREASE (009-Z00-111) KS62F

Application: Internal: Caliper piston seals,
CCI OIL (009-Z00-313) Brake
piston dust seals. External: O-ring at the tip of the
brake pad retaining pin.
Application: Internal: Caliper pistons.
LH CALIPER SHOWN
Brake
Bleeder Screw SPECIAL GREASE (009-Z00-115)

Application: External: Rear caliper guide pins / boots.
5.4 Nm (48 lb-in) Boot & Guide Pin
Refer to assembly views and rebuild procedure
Brake
O-Ring for special oil and grease application
Brake
(009-Z00-115)
(009-Z00-111) Brake
(009-Z00-111)
Dust Seal
Clean
Grooves
Outer Pad
Pad Guide Plate

Pad Retaining Pin
13.5 Nm (120 lb-in) Inner Pad
Boot & Guide Pin
Brake
(009-Z00-115)
Piston Seal
Brake
(009-Z00-111)
Pad Spring
Brake
Piston
Apply special assembly OIL
Pad Backing Plate
(009-Z00-313) Must not protrude past
(included with parts kit) edge of pad
Caliper Body Bolt
27 Nm (20 lb-ft)
Loctite 242 (Blue)
15.10
BRAKES
REAR BRAKE CALIPER

KS62F
Brake
SILICONE GREASE (009-Z00-111) KS62F

Application: Internal: Caliper piston seals,
piston dust seals. External: O-ring at the tip of the
brake pad retaining pin.
Brake CCI OIL (009-Z00-313)
Application: Internal: Caliper pistons.
Pad Retaining Pin Brake
13.5 Nm (120 lb-in)

Bleeder Screw SPECIAL GREASE (009-Z00-115)
O-Ring 5.4 Nm (48 lb-in) Application: External: Rear caliper guide pins / boots.
Brake
(009-Z00-111) Boot Guide Pin Refer to assembly views and rebuild procedure
for special oil and grease application.
Brake Brake
(009-Z00-115) (009-Z00-115)
Piston Seal
Brake
Dust Seal
(009-Z00-111)
Brake
(009-Z00-111)
Pad Spring
Clean all grooves
Piston
15
Brake
Pads
Apply special assembly OIL

(009-Z00-313)
(included with parts kit)
Pad Backing Plate

Must not protrude past
edge of pad
Boot and Pin
Brake Pad Guide Plate
Pad Insulator
(009-Z00-115)
15.11
BRAKES
BRAKE SYSTEM OPERATION

MASTER CYLINDERS / BRAKE CALIPERS / DELAY VALVE / PROPORTION VALVE

battery before servicing ABS brake parts.
Conventional (Non-ABS) Linked Brake Configuration Shown
Front Master Cylinder
Rear Master Cylinder
Under moderate to heavy braking, pressure

will build and then be diverted to the front
caliper through the delay valve.
The delay valve is normally

Delay Valve gated to the rear caliper.
Proportion Valve
The proportioning valve regulates pressure to reduce the chance of
rear wheel lock-up during heavy rear brake application.
15.12
BRAKES
BRAKE SYSTEM SERVICE

BRAKE FLUID REPLACEMENT & BLEEDING PRECAUTIONS
WARNING
Contaminated brake discs or brake pads greatly reduce braking performance and increase stopping distance. Do not
attempt to clean contaminated pads. Replace them. Clean the brake disc with brake cleaner.
WARNING
This brake system requires ethylene-glycol based fluid (DOT 4). Do not use or mix different types of fluid such as
silicone-based or petroleum-based.
WARNING
Do not use brake fluid taken from old, used or unsealed containers. Never reuse brake fluid. Brake fluid can
accumulate moisture, reducing it’s performance.
WARNING
Brake fluid is poisonous. Keep brake fluid tightly sealed and out of reach of children.
WARNING
A soft, spongy feeling in the brake lever and/or brake pedal could indicate a hazardous condition in the brake system.
Do not operate the motorcycle until the failure in the brake system is corrected.
WARNING
An unsafe condition exists when air is trapped in the hydraulic brake system. Air in the brake hydraulic system acts
like a soft spring and absorbs a large percentage of the pressure developed by the master cylinder. Without this
pressure, the braking system cannot develop full braking force to allow for safe, controlled stops. It is extremely
important to bleed the brakes properly after any brake system work has been performed or when inspection reveals
spongy brakes.
Keep these points in mind when bleeding hydraulic brakes:

• The master cylinder reservoirs have limited capacities. It is easy to empty them during the bleeding procedure.
This introduces air into the system which you are trying to purge. Watch the reservoir closely and add fluid when
necessary to keep the level above the LOW mark and prevent air from re-entering the system.
• Do not pump the lever or pedal aggressively when bleeding the brake system. Rapid movement could cause air
15
bubbles to form in the fluid. (See ABS Brake Bleeding Procedure for ABS equipped vehicles).
• Small amounts of air can become trapped in the banjo bolt fittings at the master cylinder(s), brake lines, and
junction points of brake lines. On non-ABS vehicles, these fittings can be purged of air by following a standard
bleeding procedure at these fittings (instead of the bleed screw on caliper) if necessary to speed the bleeding
process. This is usually only needed if system was completely drained of fluid. Bleed each line connection,
starting with the fitting closest to the master cylinder, working toward the caliper, and ending with the bleed
screw. (See ABS Brake Bleeding Procedure for ABS equipped vehicles).
• Always torque banjo bolts and other brake system fasteners and components to specified torque.
• Always install NEW genuine Victory parts. Apply special lubricant included in service kits where specified.
• .Always perform a Brake Lever Reserve inspection after brake system bleeding or service.
15.13
BRAKES
BRAKE BLEEDING / FLUID CHANGE FRONT BRAKE SYSTEM BLEEDING

NOTE: Refer to page page 15.40 for ABS system
NOTE: Bleed the right front lines and caliper first
bleeding procedure.
(closest to master cylinder) and then bleed the left
front lines and caliper (farthest from master cylinder).
NOTE: Throughout the following procedure, monitor
fluid level in master cylinder reservoir constantly. Do
NOTE: Repeat the bleeding procedure at least once.
not allow fluid level to fall below minimum level
(Fig. 1 and 2). ABS NOTE: Refer to page 15.40 for ABS system bleeding
procedure.
Remove cover and fill reservoir with DOT 4 brake fluid from
a sealed container. 1. Remove the rubber cap from the top of the front left-
Fill and maintain above the LOW
hand caliper and install an 8mm box end wrench over
mark. the bleeder screw and attach a tight-fitting clear hose
to the nipple on the screw (as shown for right side
caliper below A).
Minimum level
2. Place a small quantity of fresh brake fluid into a small,
clear container (B).
3. Place the other end of bleeder hose into container (B).
Fig. 1
A
Use Only Victory DOT 4 Brake Fluid 2872189.
Between fills, set reservoir cover on reservoir to prevent

entry of contaminants. B
MAX
4. Slowly pump the brake lever until pressure builds and

MIN
then hold light pressure on the lever.
Fig. 2 5. Open bleed screw until lever pressure is gone then
close the bleed screw before you release the lever.
NOTE: If system is dry or very low on fluid due to 6. Release brake lever.
parts replacement or disassembly, pump the lever or
pedal slowly until air bubbles no longer rise through 7. Check level of fluid in reservoir and add if necessary
the fluid in the reservoir. For normal bleeding or (see Fig.1).
system flush, continue on with procedure.
8. Repeat Steps 4, 5, 6, and 7 until brake lever is firm and
NOTE: Brake systems should be flushed every 2 no air can be seen moving through the clear hose.
years or more often if the fluid is discolored. To flush
the system, follow normal brake bleeding process, 9. Torque bleed screw to 5.4 Nm (48 lb-in).
and continue bleeding and filling the reservoir until
the fluid moving through the bleeder hose is clear.
15.14
BRAKES
10. Repeat this process for the front right caliper. REAR (LINKED) BRAKE SYSTEM BLEEDING
NOTE: Bleed the right front lines and caliper first

(closest to master cylinder), then bleed the left front
lines and caliper (farthest from master cylinder), and
bleed the rear lines and caliper last.
NOTE: Repeat the bleed procedure at least once.
ABS NOTE: Refer to page 15.42 for ABS system bleeding

procedure.
1. Remove the rubber cap from the side of the front right
caliper and install an 8mm box end wrench over the
bleeder screw (C). Connect a tight-fitting clear hose to
the caliper bleed screw (C).
11. Once you have bled both front calipers, repeat this 2. Place a small quantity of fresh brake fluid into a small,
bleeding procedure again to ensure all air has been clear container.
bled from the system.
3. Place the other end of bleeder hose into the container.
12. Inspect brake fluid level. Clean the reservoir cover,
diaphragm, diaphragm form plate, and reservoir C
sealing surface. If diaphragm is extended, return it to
normal (flat) position. Install diaphragm, form plate,
and cover.
4. Slowly pump brake pedal until pressure begins to build.
5. Apply firm pedal pressure and then hold.
6. Quickly open and close the bleed screw while holding 15

firm pressure on the brake pedal.
13. Perform Front Brake Lever Reserve Inspection on
page 15.44 to verify system is completely purged of air. IMPORTANT: Firm brake pedal pressure is required
during this procedure to ensure the delay valve opens
14. Once front brake system is properly bled and passes allowing fluid to reach the front calipers.
the lever reserve inspection, proceed to “Rear (Linked)
7. Release brake pedal pressure.
Brake System Bleeding”.
8. Check level of fluid in reservoir and add if necessary
(see Fig. 2 on page 15.14).
9. Repeat Steps 4, 5, 6, and 7 until brake pedal is firm and

no air can be seen moving through the clear hose.
15.15
BRAKES
10. Torque bleed screw to 5.4 Nm (48 lb-in). 20. After completing the bleeding procedure, inspect brake
fluid level. Clean the reservoir cover, diaphragm, and
11. Repeat this process for the front left caliper. reservoir sealing surface. If diaphragm is extended,
return it to normal (flat) position. Install diaphragm and
cover.
12. Remove the rubber cap from the rear caliper and install
an 8mm box end wrench over the bleeder screw (D).
Connect a tight-fitting clear hose to the caliper bleed
21. Inspect the feel when pressure is applied to the brake
screw (D).
pedal. The pedal should feel firm, not spongy.
13. Place a small quantity of fresh brake fluid into a small,
NOTE: A properly bled rear brake system should not
clear container (E).
allow the brake pedal to travel more than 20 mm
14. Place the other end of bleeder hose into container (E). (.79”) with 20 lbs. (9.07 kg) of force applied.
15. Slowly pump brake pedal until pressure builds and

then hold.
16. Quickly open and close the bleed screw while holding
pressure on the brake pedal.
17. Release brake pedal pressure. 22. If pedal is not firm, repeat bleeding procedure and
insect brake system. See Troubleshooting at the end
18. Check level of fluid in reservoir and add if necessary of this chapter.
(see Fig. 2 on page 15.14).
19. Repeat the bleeding procedure to ensure all air has

been bled from the system.
15.16
BRAKES
FRONT BRAKE PAD REPLACEMENT 5. Wipe brake disc clean with a shop towel sprayed with
Victory Brake Cleaner.
NOTE: Always replace brake pads as a set. Refer to
page 2.15 for front pad inspection. 6. Inspect piston dust seals (C) for signs of fluid leakage.
1. Loosen the brake pad retaining pin (A) and remove

the brake caliper mounting bolts (B) and caliper. C
A 7. Clean caliper body with Victory Brake Cleaner.

8. Install isolator on new inner brake pad. Be sure isolator
2. Using the existing brake pads, apply inward pressure
plate does not protrude from the pad backing plate.
on the caliper pistons to gain enough clearance to
install new brake pads into caliper and onto the disc.
Tabs should face
NOTE: Brake fluid will be forced back into the toward pistons Pad
Retainer
reservoir when pads are pushed back. Remove
reservoir cover and monitor fluid level, or attach a
hose to the brake bleeder screw (as described in Inner
Brake Bleeding on page 15.13) and open the bleed Pad
screw while pushing the pads and pistons back.
3. Remove each brake pad from the caliper and discard.
Spring Plate Isolator
9. Install the spring plate and pad retainer into the caliper.
10. Install caliper. Torque mounting bolts: 42 Nm (31 lb-ft). 15
42 Nm
(31 lb-ft)
4. Remove the spring plate and pad retainer from the

caliper; note direction of plate and retainer for
assembly.
15.17
BRAKES
11. Install new brake pads with friction material toward REAR BRAKE PAD REPLACEMENT
disc. Be sure pads are fully seated in pad retainer.
NOTE: Always replace brake pads as a set. The rear
12. Apply Silicone Grease (009-Z00-111) to O-ring on brake pads can be changed with the caliper installed
brake pad retaining pin. on the motorcycle. Refer to page 2.15 for rear pad
inspection.
13. Insert pin through caliper and slide pin through the
outer pad followed by the inner pad. Torque retaining IMPORTANT: Do not attempt to remove the caliper
pin to 13.5 Nm (120 lb-in). from the bracket with bracket installed.
1. Push caliper toward wheel to push pad and pistons

back and provide clearance for new pad installation.
NOTE: Brake fluid will be forced back into the

reservoir when pads are pushed back. Remove
reservoir cover and monitor fluid level, or attach a
hose to the brake bleeder screw (as described in
Brake Bleeding on page 15.14) and open the bleed
screw while pushing the pads and pistons back.
A Push In
13.5 Nm
(120 lb-in)
14. Inspect brake fluid in reservoir and set to proper level

(page 15.14).
15. Slowly pump lever to set brake pads against disc.

Lever should be firm, not spongy. If lever is spongy,
inspect pad installation, bleed brake lines (page 15.14)
and inspect brake disc (see page 15.20).
16. Install reservoir cover. Torque screws to 1.6 Nm NOTE: The caliper should move freely on guide pins.
(14 lb-in).
2. Loosen the retaining pin (A).
17. Operate brake lever several times until lever is firm and
pressure can be felt. 3. Slide the retaining pin out to allow the brake pads to
be removed.
WARNING
After pad installation or any brake system repair,
safely elevate wheel, apply and release brake
pedal or lever 2-3 times and release.
Verify wheel turns freely without drag.
If brake drag is evident, do not operate the
motorcycle. Inspect vehicle to determine cause
and then repair as necessary.
15.18
BRAKES
4. Note orientation of spring plate and pad retainer. 9. Apply Silicone Grease (009-Z00-111) to O-ring on pad
Replace both parts with new. retaining pin. Install the pin and torque to 13.5 Nm
(120 lb-in).
5. Wipe brake disc clean with a shop towel sprayed with
Victory Brake Cleaner. 13.5 Nm
(120 lb-in)
6. Thoroughly clean the brake caliper body with Victory
Brake Cleaner.
7. Install new inner brake pad. Be sure backing plate (C)

(with insulation pad) is properly installed on new pad.
Slide pad into place and engage tab (E) in the pad
retainer in the back of the caliper.
No protrusion of isolator plate

from pad backing plate.
10. Inspect fluid level in the reservoir and adjust as

necessary (page 15.13).
C 11. Pump brake pedal slowly several times to set new pads
against disc, until lever is firm and pressure can be felt.
12. Bleed brake system if necessary (page 15.14).
WARNING
After pad installation or any brake system repair,
safely elevate wheel, apply and release brake
pedal or lever 2-3 times and release. Verify
wheel turns freely without drag. If rear brake
drag is evident, inspect pedal clearance as
outlined on page 15.28. Do not operate the
motorcycle if drag is still evident after clearance
adjustment. Inspect vehicle to determine cause
and repair as necessary.
15
Metal plate against floating side

of caliper (not against pistons).
8. Install new outer brake pad. Be sure tab is engaged

with caliper as for inner pad (see Step 7).
15.19
BRAKES
BRAKE DISC INSPECTION FRONT BRAKE MASTER CYLINDER /

1. Visually inspect disc for cracks or damage. CLUTCH MASTER CYLINDER SERVICE
2. Measure brake disc thickness in several locations
around disc with a micrometer, and along wear surface NOTICE: Brake fluid and brake cleaners could
and compare to specifications found on page 15.3. damage paint, plastics and some rubber compounds.
Cover or remove plastic and painted parts before
working on the brake system. If brake fluid is spilled
2 mm on cosmetic surfaces, immediately rinse the area
with a mild solution of soap and water until all traces
of brake fluid are removed. Make sure the master
cylinder reservoir being worked on is level before
removing the cap.
Measure runout here IMPORTANT: Replace all rubber parts upon assembly.
NOTE: Procedure is the same for the clutch master
cylinder. Refer to Chapter 9 for specifications.
1. On ABS models, disconnect the negative (-) battery

cable from battery. Clean the master cylinder. Drain
brake fluid from the top bleed screw on both front
calipers by attaching a drain hose to each caliper
bleed screw and place the end in a suitable container.
Drain brake fluid from the front brake system by slowly
pumping the brake lever.
Measure thickness at 4 points around
NOTE: DO NOT drain brake fluid from the side bleed
disc and 2 spots at each point.
screws on the front caliper. Fluid in that portion of
the caliper is controlled by the foot pedal brake, and
does not need to be removed when servicing the
front master cylinder.
2. Disconnect front brake light switch wires at switch (B).

3. Remove switch (C) and brake lever nut (D), brake lever
pivot screw, lever and bushing.
4. Remove brake line from master cylinder (E).
5. Remove screws (F), clamp, and master cylinder.
B
NOTE: Replace the brake disc if any measurement is
worn beyond the service limit.
3. With disc mounted to wheel, inspect for brake disc
runout / warpage with and compare to specifications
found on page 15.3. Runout should be measured 2 -
4 mm in from outside edge of disc.
4. If runout is excessive, refer to Troubleshooting at the
end of this Chapter. Replace brake disc if dial indicator
reading displays excessive brake disc runout and other E C D
F
possible causes have been eliminated.
5. Refer to Chapter 12 for front brake disc removal and
installation. Refer to Chapter 13 for rear brake disc 6. Remove reservoir cover and diaphragm.
removal & installation.
15.20
BRAKES
7. Pull dust boot off piston and out of cylinder bore. 12. Measure the diameter of the bore. Replace master
cylinder if worn beyond the service limit.
8. Remove snap ring.
Brake Master Cylinder - Bore Diameter
9. Slide piston out with spring. Note spring orientation for Service Limit: 14.043 mm (.553”)
assembly of new spring (new parts).
Clutch Master Cylinder - Bore Diameter
Service Limit: 12.743 mm (.502”)
13. Measure the diameter of the master cylinder piston in

two places as shown below. Replace piston if worn
beyond the Service Limit.
10. Clean master cylinder with isopropyl alcohol and dry

with compressed air. DO NOT soak in alcohol for more
than 30 seconds. DO NOT aim pressurized air directly
at the level sight glass.
11. Inspect bore (G) and chamfer of bore (H) for corrosion, 15
scratches, scoring, or pitting. Replace master cylinder
if any of these conditions are evident.
Brake Master Cylinder - Piston Diameter

H
Clutch Master Cylinder - Piston Diameter
G Service Limit: 12.55 mm (.494”)
15.21
BRAKES
14. Remove deflector (A) from reservoir. 18. Carefully install spring / piston assembly into master
cylinder bore. Work the front piston seal carefully past
the chamfer and into bore. Use care not to damage or
fold the seal when working it past the chamfer.
19. Continue to install the piston until the rear seal is past
the chamfer. Push and hold the piston in far enough to
allow the retaining ring to be installed.
15. Clean the compensating port (B) and supply port (C)
with compressed air to be sure they are clean and
unobstructed. Re-install the deflector.
B C
009-Z00-115
Brake
16. Apply a light film of special lubricant from piston kit to

each piston seal cup.
20. Be sure retaining ring is fully seated in the groove.
17. Assemble spring to new piston assembly as shown
21. Clean the bore from the retaining ring outward, so the
with small end to piston. Large diameter of beveled
outer edge of the new dust boot adheres properly and
edge on piston seals (D) face toward spring. Install a
will not dislodge from the bore.
new retaining ring on end of piston with machined edge
(sharpest of the two edges) facing out (E). 22. Install new boot, seating the outer edge fully in the bore
and engage outer lip of boot in piston groove.
D
23. Apply special grease (009-Z00-115) from kit to brake
lever contact surface.
24. Install master cylinder on handlebar. See page 15.23.
Brake E
Apply special assembly oil (009-Z00-013)
to cups (included with parts kit)
15.22
BRAKES
FRONT MASTER CYLINDER INSTALLATION 8. Re-connect negative battery cable on ABS models.
1. Clean the mounting surface on the handlebar.

WARNING
2. Loosely install master cylinder, clamp, and screws.
After pad installation or any brake system repair, safely
Rotate clamp on handlebar until parting line (A) of
elevate the wheel, apply and release the brake pedal
clamp is aligned with parting line (B) of handlebar
or lever 2-3 times and release. Verify the wheel turns
control block.
freely without drag. If brake drag is evident, do not
operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.
FRONT CALIPER REMOVAL

NOTICE: Brake fluid and brake cleaners will damage
paint, plastics and some rubber compounds. Cover
or remove plastic and painted parts before working
A on the brake system. If brake fluid is spilled on
cosmetic surfaces, immediately rinse the area with a
C B mild solution of soap and water until all traces of
brake fluid are removed. Make sure the master
cylinder reservoir is level before removing the cap.
3. Torque rear clamp screw (C) first then torque front
IMPORTANT: Replace all rubber parts upon assembly.
screw to 11 Nm (96 lb-in).
4. Connect brake hose to master cylinder with banjo bolt cable from battery.
(D) and new sealing washers. Torque banjo bolt (D)
to 24.4 Nm (18 lb-ft). 2. Remove banjo bolts (A), sealing washers, and brake
lines from caliper body and allow it to drain into a
5. Install brake light switch (E). Torque screws to 1.2 Nm suitable container.
(11 lb-in). Connect switch wires (F).
3. Loosen the pad retaining pin (B) prior to removing the
6. Lubricate brake lever bushing with special lubricant caliper to allow brake pad removal.
from kit and install lever. Torque pivot screw to 1.0
Nm (9 lb-in). Hold screw and torque nut (G) to 6 C
Nm (52 lb-in).
F A
15
A
D E G
4. Remove front caliper mounting bolts (C) and remove
the caliper.
7. Turn handlebars until top of reservoir is level. Fill 5. Cover brake line ends to prevent debris from entering.
reservoir with Victory DOT 4 Brake Fluid and bleed the 6. If servicing both front calipers, repeat this procedure to
front hydraulic brake system (see page 15.14). remove the other front caliper.
15.23
BRAKES
FRONT CALIPER SERVICE 5. Remove each piston with a caliper piston pliers. If a
caliper piston pliers is not available, wrap the caliper
1. Cover the brake hose connection on the caliper and in a shop towel and apply short bursts of compressed
clean the outer surfaces of caliper assembly with air through the brake line hole and through the transfer
Victory brake cleaner or isopropyl alcohol. Dry with passage to force the pistons out of the bore.
compressed air.
2. Remove brake pads. Pads contaminated with oil or
grease must be replaced as a set.
6. Remove dust seals and piston seals. Use care not to

damage the seal bores.
3. Remove the (3) caliper body bolts (A) and remove the
caliper guide pin bracket (B).
B 7. Clean all parts thoroughly with isopropyl alcohol. Be

sure the seal bores are clean, removing all traces of dirt
or dried brake fluid.
4. Keep parts in order for assembly in the same bore.
15.24
BRAKES
8. Clean piston seal and dust seal bores (C) to remove 11. Measure the outside diameter of each caliper piston in
residue that could cause the pistons to stick, resulting two spots 90 degrees apart, 5mm from outer edge.
in brake drag. Repeat the measurements 5mm from the inner edge.
Replace piston if worn beyond the service limit at any
measuring point.
22.614 mm
9. Inspect each piston bore for corrosion, scratches,

scoring, or pitting. Replace caliper if any of these
conditions are evident.
Front Brake Caliper - Piston Diameter
10. Measure the diameter of each piston bore. Replace
caliper if any is worn beyond the service limit.
Outer Pistons
Service Limit: 26.935 mm (1.060”)
Middle Piston
22.671 mm
IMPORTANT: Install all new rubber parts during
assembly. Do not reuse old seals or boots.
12. Apply Silicone Grease (009-Z00-111) from service kit

to new piston seals and dust seals (see page 15.10).
13. Apply CCI Oil (009-Z00-313) from service kit to outer
surface of all pistons (see page 15.10).
Front Brake Caliper - Bore Diameter 14. Install piston seals and dust seals in caliper body.
15
Outer Piston Bores
Middle Piston Bore

15.25
BRAKES
15. Install pistons in their respective bores. 18. Evenly tighten the bolts by hand until halves are
secured together.
19. Torque bolts to 27 Nm (20 lb-ft).
20. Install the brake pad retainer onto the caliper guide pin
bracket as shown.
16. Install the spring plate to the outer portion of the caliper
body as shown.
Pad Retainer
21. Apply Special Grease (009-Z00-115) to the boots and

guide pins, then install the caliper guide pin bracket.
(009-Z00-115)
Spring Plate
17. Clean the threads of each caliper body bolt. Be sure

threads are free from any oil, grease, or brake fluid.
Apply a few drops of Loctite 242 (Blue) non permanent
locking agent to the threads of each bolt. (009-Z00-115)
22. Install brake pads.
23. Apply Silicone Grease (009-Z00-111) to O-ring on

brake pad retaining pin and install the pin.
Apply Loctite
242 (Blue)
15.26
BRAKES
FRONT CALIPER INSTALLATION 7. Torque brake line banjo bolts to 24.4 Nm (18 lb-ft).
1. Connect brake lines to caliper with banjo bolts and

new sealing washers.
8. Fill and bleed the front brake hydraulic system

2. Clean mounting surfaces of caliper and fork leg. (page 15.14).
3. Apply Victory brake cleaner or isopropyl alcohol to a
clean shop towel and wipe brake disc(s) clean.
WARNING
4. Separate brake pads and install caliper assembly over
brake disc. After pad installation or any brake system repair, safely
elevate the wheel, apply and release the brake pedal or
5. Install caliper mounting bolts. Torque to 42 Nm
lever 2-3 times and release. Verify the wheel turns freely
(31 lb-ft).
without drag. If brake drag is evident, do not operate the
motorcycle. Inspect the vehicle to determine the cause
and then repair as necessary
42 Nm
(31 lb-ft)
15
13.5 Nm
(120 lb-in)
6. Torque brake pad retaining pin to 13.5 Nm (120 lb-in).
15.27
BRAKES
REAR MASTER CYLINDER REMOVAL 5. Install the brake line with new sealing washers and
torque banjo bolt to 24.4 Nm (18 lb-ft).
NOTICE: Brake fluid and brake cleaners will damage
paint, plastics and some rubber compounds. Cover
or remove plastic and painted parts before working
on the brake system. If brake fluid is spilled on
cosmetic surfaces, immediately rinse the area with a
mild solution of soap and water until all traces of
brake fluid are removed. Make sure the master
cylinder reservoir being worked on is level before
removing the cap.
1. Remove clamp for reservoir hose at master cylinder
(A) and disconnect fluid supply hose. Allow fluid to
drain into a container.
2. Remove brake line banjo bolt (B), sealing washers and
brake line.
3. Remove retaining clip (C) from pushrod pin (D) and
remove pin from clevis.
6. Verify the pushrod length adjustment. There must be

1 - 2 mm (.04 - .08) clearance between the brake
pedal casting and the pedal stop when the pedal is in
the fully released position and master cylinder piston
is against its internal stop.
4. Remove master cylinder from floorboard support by

removing the two mounting screws (E).
REAR MASTER CYLINDER INSTALLATION

1. Install master cylinder on floorboard support,
engaging clevis with brake pedal.
2. Apply a light film of grease to clevis pin and install from

outside to inside. Install a new retaining ring on pin.
3. Attach fluid supply hose to master cylinder supply

fitting using a new clamp.
4. Install the master cylinder mounting screws and torque

to 24.4 Nm (18 lb-ft).
15.28
BRAKES
7. Re-adjust pushrod length to provide specified 5. Remove pin (A) and brake pads. Note orientation of
clearance if necessary. spring plate (B) for assembly.
A
B
Adjustment Nuts
8. Fill the reservoir with Victory DOT 4 brake fluid and 6. Slide caliper bracket off pins and remove spring plate.
bleed the system as outlined on page 15.13.
WARNING
elevate the wheel, apply and release the brake pedal
or lever 2-3 times and release. Verify the wheel turns
freely without drag. If brake drag is evident, do not
operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.
REAR CALIPER SERVICE

cable from battery.
2. Remove banjo bolt and sealing washers from rear 7. Remove caliper pistons. Keep pistons in order for
caliper and allow fluid to drain into a container. installation in their respective bores.
3. Loosen the brake pad retaining pin (A).
A
15
Remove
8. Remove dust seals and piston seals. Use care not to

4. Remove rear wheel (Chapter 13). Caliper and bracket damage the seal bores.
must be removed as an assembly.
15.29
BRAKES
9. Clean caliper thoroughly with isopropyl alcohol. Dry 13. Apply special assembly oil to outer surface of all
with compressed air. Clean seal grooves thoroughly. pistons.
Any residue left behind in the grooves could cause
caliper pistons to stick and result in brake drag. Pistons:
Apply special
10. Inspect each bore and surface of each piston for OIL included
corrosion, scratches, scoring, or pitting. Replace with parts kit.
caliper assembly if any of these conditions are evident.
Seals:
Brake Apply silicone
grease included
with parts kit.
14. Install piston seals and dust seals in caliper body.
15. Install pistons in their respective bore.
16. Replace caliper pin boot (C) on bracket and (D) on

caliper. Apply special grease (009-Z00-115) from
service kit to boots and both pins. Clean excess
grease from outside of boots.
11. Measure diameter of each bore and piston. Replace Brake
caliper assembly or parts if worn beyond service limit. D
17. Be sure brake pad guide plate is in place on bracket

with arrow (E) pointed up.
Rear Brake Caliper - Bore Diameter E
Rear Brake Caliper - Piston Diameter
12. Install all new rubber parts during assembly. Do not

reuse old seals or boots. Apply special lubricant from
18. Assemble bracket to caliper. Remove excess lubricant.
service kit to new piston seals and dust seals.
19. Install spring plate and outer brake pad. Start pad pin
through outer pad.
15.30
BRAKES
20. Install inner pad with backing plate. REAR CALIPER INSTALLATION
1. Install caliper and bracket (see “REAR WHEEL
INSTALLATION” on page 13.15).
2. Install brake hose, and banjo bolt with new sealing

washers.
3. Torque banjo bolt to 24.4 Nm (18 lb-ft.)
21. Torque brake pad pin to 17 Nm (12.5 lb-ft).
22. Be sure end tabs of pads are both fully engaged in the
heel plate (F) on bracket.
F
4. Fill and bleed rear hydraulic brake system. Refer to
page 15.13.
5. Re-connect negative (-) battery cable on ABS models.
WARNING
elevate the wheel, apply and release the brake pedal or lever
2-3 times and release. Verify the wheel turns freely without
drag. If brake drag is evident, do not operate the motorcycle.
Inspect the vehicle to determine the cause and then repair as
necessary.
15
15.31
BRAKES
ANTI-LOCK BRAKE SYSTEM (ABS) ABS GENERAL INFORMATION

The Anti-Lock Brake System is a safety feature designed
to prevent wheel lock-up and improve control of the
motorcycle during extreme braking events, including:
ABS SYSTEM SAFETY PRECAUTIONS
• Panic braking
Before working on a Victory motorcycle equipped with anti-
lock brakes, review and understand all general brake • Slick surface braking (such as wet road surfaces)
system and brake fluid precautions on page 15.2, and the • Surface transitions (from asphalt to oily asphalt or
following ABS specific precautions and system cobblestone, etc.)
information. Do not attempt maintenance or repair of the
Here are a few general points to note about ABS:
anti-lock brake system without the proper tools. Refer to
non-ABS component information in this chapter for master • The anti-lock brake system cannot be turned OFF.
cylinder and caliper removal, disassembly, and assembly. • The ABS indicator lamp (located on the Instrument
Cluster) always illuminates when the key is in the
Troubleshooting specific to ABS is on page 15.48. ON position and remains on until the anti-lock
system activates, which occurs when vehicle speed
exceeds 6 mph (10 kph).
WARNING
• If the lamp is not illuminated when the key is ON,
Proper brake system bleeding is extremely important to connect Digital Wrench and perform an ABS
ensure adequate lever reserve in the system. Always System inspection to determine the cause.
perform the Brake Lever Reserve test described in this
• When the ABS lamp is illuminated, the anti-lock
manual after bleeding the anti-lock brake system.
brakes will not activate, but the conventional brake
• Operating with non-recommended tires or improper system will continue to operate normally.
tire pressure may reduce the effectiveness of the • If the lamp continues to illuminate after the vehicle
anti-lock brake system. speed exceeds 6 mph (10 kph), the system is not
functioning. Connect Digital Wrench and perform
• Always install the recommended size and type of
an ABS System inspection to determine the cause.
tires specified for the vehicle.
• When the anti-lock brakes engage during a braking
• Always maintain the recommended tire pressure. event, the rider will feel pulsing at the brake lever or
pedal. Continue to apply steady pressure to the
• Victory DOT 4 Brake Fluid is recommended.
brakes for the best stopping performance.
Change every 2 years or more often if
contaminated. • The ABS system is not adjustable. The wheel
speed sensor-to-pulse ring air gap is fixed. Air gap
• The anti-lock brake system will not prevent wheel will not change unless a sensor or pulse ring is
lock-up, loss of traction, or loss of control under all loose, damaged, worn, or has debris attached.
conditions. Always adhere to all safe motorcycle-
riding practices as recommended. • The ABS system is not re-programmable.
• The ABS light is controlled by the ECM via CAN BUS.
• It is not unusual to leave tire marks on the road
surface during a hard braking event. • Diagnostic codes are unique to ABS and can only
be viewed with Digital Wrench. ABS Trouble Codes
• The anti-lock braking system does not compensate will not appear on the Instrument Cluster display as
for or reduce the risk associated with: an SPN / FMI code.
• excessive speed • Wheel speed sensors are used only for ABS. The
Vehicle Speed Sensor is used for vehicle speed.
• reduced traction on rough, uneven or loose
surfaces • If fuse is open or removed, ABS light will remain
ON after 6 mph (10 kph). ABS will not be active.
• poor judgement Normal (conventional) braking will be available
provided the system components (master cylinder,
• improper operation lines, calipers, etc.) are in working order.
15.32
BRAKES
ABS SYSTEM COMPONENTS ABS OVERVIEW OF OPERATION

The following parts function in the same manner as the The ABS system is active and available when vehicle
same component in a non-ABS system, although parts are speed exceeds 6 mph (10 kph).
not necessarily interchangeable. Always refer to the
appropriate ABS parts information when replacing a The system uses two independent Hall-Effect Wheel
component or component parts. Refer to the non-ABS Speed Sensors. One sensor is mounted to the front left fork
portion of this chapter for removal, installation, operational leg and one is mounted to the rear brake caliper bracket.
overview, and repair of these components. Refer to Two Pulse Rings are also used, one mounted to the left
page 15.34 for ABS System Component Diagram. front brake disc hub and one to the rear brake disc hub,
which rotate with the wheels. When the vehicle is in motion,
• Front Brake Caliper the multiple reluctor segments on each pulse ring pass by
the center pole of the respective wheel speed sensor,
• Rear Brake Caliper
generating an electrical pulse signal in the sensor which is
• Front Master Cylinder sent to the ECM (mounted under the seat).
• Rear / Linked Master Cylinder The ECM interprets wheel speed signal pulses to
• Delay Valve determine speed, rate-of-change, and front / rear wheel
speed differential to “decide” if wheel lock-up is about to
• Proportion Valve occur. When wheel lock-up is imminent during a braking
• Brake Light Switch event, the ECM controls the operation of solenoids and a
pressure pump (located inside the ABS Module) to regulate
• Brake Lines the amount of line pressure and cycles (length of time)
In addition to the brake system components listed above, applied to the caliper pistons and brake pads. This
the following are used on ABS equipped vehicles: pressure / time modulation can often be felt at the brake
lever or the brake pedal during an ABS braking event and
• Wheel Speed Sensors (Front located on front left is a normal condition. Note that the brake fluid is not
fork leg; Rear mounted on rear caliper bracket) diverted inside the module and does not “flow” in the
system any more than occurs in a conventional (non-ABS)
• Wheel Speed Sensor Pulse Rings (Front and Rear brake system.
mounted to wheel with 3 disc bolts)
If the surface coefficient changes (such as moving from wet
• ABS Module Assembly pavement to dry pavement) the ABS system will
recalculate (in a matter of milliseconds) and adjust
• ABS Related Wiring
pressure output to caliper(s) as required.
In the event of a system fault, the ECM turns on the ABS

indicator lamp (via the CAN BUS) and leaves it on even
after vehicle speed exceeds 6 mph (10 kph) activation
speed.
If a system fault occurs, the light will remain on (and ABS 15

will not be active) until the ignition key is turned to OFF
position and back to ON.
The ABS Module Assembly is serviceable only as an

assembly. The module itself is not rebuildable.
Disconnect negative (-) battery cable from battery before

servicing ABS brake lines or system components.
15.33
BRAKES
ABS SYSTEM COMPONENTS
A
J
B
E F
C D
A Master Cylinder (Front) F Master Cylinder (Rear / Linked)
B Calipers G Wheel Speed Sensor (Rear)
C Pulse Ring (Front) H Pulse Ring (Rear)
D Wheel Speed Sensor (Front) I Proportion Valve
E Delay Valve J ABS Module (Rear)
15.34
BRAKES
ABS SYSTEM CIRCUIT DIAGRAMS
FRONT
REAR / LINKED
ABS WIRE HARNESS
15
15.35
1.6 Nm
(14 lb-in)
FRONT 6.8 Nm
(60 lb-in)

10.8 Nm
(96 lb-in) 24.5 Nm
(18 lb-ft)
42.0 Nm
(31 lb-ft)
10.8 Nm
(96 lb-in)
24.5 Nm
(18 lb-ft)
Bleed Screws (All) 24.5 Nm
(18 lb-ft)
5.4 Nm
10.8 Nm (48 lb-in)
(96 lb-in) Banjo Bolts (All)
ABS SYSTEM - FRONT BRAKE
24.5 Nm
(18 lb-ft) 10.8 Nm
(96 lb-in)
All Flare
All M6 Line Fasteners 18.0 Nm
10.8 Nm (13.5 lb-ft)
(96 lb-in)
24.5 Nm
(18 lb-ft)
24.5 Nm
BRAKES
(18 lb-ft)
6.8 Nm
(60 lb-in)
15.36
10.8 Nm
(96 lb-in)
FRONT
ABS SYSTEM - REAR BRAKE (LINKED)

See previous page (ABS System Front Brake) for notes and fastener torque values.
15.37
BRAKES
15
Route ABS harness along top of
tank and through side opening
in front cockpit subframe

Strap ABS harness to
one hard brake line only
Strap ABS harness
to engine mount bracket
ABS SYSTEM - WIRING HARNESS / TIE STRAP LOCATION
FRONT
Strap ABS harness
to brake lines
Strap ABS harness
to main chassis
harness
Strap speed sensor
wire to brake lines
Strap ABS harness
to brake lines
BRAKES
15.38
15
15.39
BRAKES
Hand Master Cylinder

Foot Master
Brake Line
Cylinder Brake
Line
All Hard Line Flare Fittings:
18.0 Nm (13.5 lb-ft)
FRONT

Electrical Connector
No Dielectric Grease ABS MODULE SIDE VIEW
Front Caliper
Brake Line
Proportion Valve
ABS SYSTEM - MODULE CONNECTIONS
Brake Line
Delay Valve
Brake Line
ABS MODULE TOP VIEW
Do not disassemble the module.
Module is serviceable only as a
sealed assembly (pre-bled).
Attach brake lines as shown.
BRAKES
ABS BRAKE VACUUM BLEEDER ABS REAR (LINKED) BRAKE BLEEDING

A vacuum bleeder is recommended for ABS system NOTE: Bleed calipers of the linked brake in this
bleeding and can also be used to bleed conventional (non- order: Rear, Front Left, Front Right. The use of a
ABS) brake systems. One style of bleeder is shown below. vacuum bleeder is recommended. DO NOT allow fluid
level in reservoir to drop below the LOW mark at any
Pressure / Vacuum Pump PV-43545 can also be used as time during the bleeding procedure.
a vacuum source.
NOTE: Repeat entire bleed procedure at least once.
1. Remove rubber cap from rear caliper bleed screw (A)

and place an 8mm box end wrench (B) on the screw.
2. Attach a tight-fitting clear hose (C) from the vacuum
bleeder to the bleed screw and apply vacuum.
B
A
Commercially Available C
ABS FLUID CHANGE

Review Brake Fluid Replacement and Bleeding
Precautions on page 15.13 before working with brake fluid.
Refer to page 15.14 for reservoir fluid level information.

Approximately 3 pints of brake fluid are required for a 3. Fill rear brake fluid reservoir and leave cover off so fluid
complete system fill. can be added as it is drawn through the system.
NOTE: When bleeding or flushing the system,
monitor fluid level in master cylinder reservoir 4. Open bleed screw about 1/4 turn.
constantly. DO NOT allow fluid level to fall below the
LOW level. 5. Pump brake pedal repeatedly with smooth full strokes
while adding brake fluid to the reservoir as required.
Use only DOT 4 brake fluid from a sealed container. For best results pump the pedal at a fairly rapid rate
but avoid pumping too fast or fluid may become
NOTE: EMPTY LINES - If system is dry or very low on aerated. After about 2 cups of fluid have been run
fluid due to parts replacement or disassembly, fill through the system, the bleeder hose should have
reservoir and pump lever or pedal slowly through clear, bubble-free fluid running through it.
stroke range until air bubbles no longer rise through
the fluid into the reservoir. 6. Close bleeder screw and fill the brake fluid reservoir.
NOTE: FLUSHING THE SYSTEM - Brake systems 7. Proceed to Step 8 to bleed the linked center piston of
should be flushed every 2 years or more often if the the left front brake caliper.
fluid is discolored. To flush the system, follow normal
brake bleeding process, and pump fluid through the
system until fluid moving through the bleeder hose is
clear. Do not allow reservoir level to fall below the
LOW level or complete system bleeding will be
required.
15.40
BRAKES
8. Remove rubber cap from the lower bleed screw (D) of 15. Pump brake pedal repeatedly with smooth full strokes
front left caliper and install an 8mm box end wrench. while adding brake fluid to the reservoir as required.
For best results pump the pedal at a fairly rapid rate
9. Connect bleeder hose to the bleed screw and start but avoid pumping too fast or fluid may become
vacuum. aerated. After about 2 cups of fluid have been run
through the system, the bleeder hose should have
D clear, bubble-free fluid running through it.
16. Close bleeder screw and fill the brake fluid reservoir.
17. Repeat the entire bleeding process on the rear, left

front, and right front calipers to be sure all air is purged
from the system.
NOTE: A properly bled rear brake system should not
allow the brake pedal to travel more than 20 mm
(.79”) with 20 lbs. (9.07 kg) of force applied.
IMPORTANT: Firm brake pedal pressure is required

during this procedure to ensure the delay valve opens
enough to purge the front calipers.
10. Pump brake pedal repeatedly with smooth full strokes

For best results pump the pedal at a fairly rapid rate
but avoid pumping too fast or fluid may become
aerated. After about 2 cups of fluid have been run
through the system, the bleeder hose should have
clear, bubble-free fluid running through it.
11. Close bleeder screw and fill the brake fluid reservoir.
12. Proceed to Step 13 to bleed the linked center piston of

the right front brake caliper.
13. Remove rubber cap from the lower bleed screw (E) of 18. Torque all bleed screws to 5.4 Nm (48 lb-in) and install
front right caliper and install an 8mm box end wrench. the rubber caps.
14. Connect bleeder hose to the bleed screw and start 19. After completing the bleeding procedure a second
vacuum. time, inspect brake fluid level and add if necessary.
15
E 20. Clean the reservoir cover, diaphragm, and reservoir
sealing surface. If diaphragm is extended, return it to
normal (flat) position. Install diaphragm and cover.
21. If pedal is not firm, repeat bleeding procedure and
insect brake system. See Troubleshooting at the end
of this chapter.
15.41
BRAKES
ABS FRONT BRAKE SYSTEM BLEEDING 6. Pump brake lever repeatedly with smooth full strokes
NOTE: Bleed left front caliper first (upper bleed For best results pump the lever at a fairly rapid rate but
screw) then right caliper (upper bleed screw). avoid pumping too fast or fluid may become aerated.
After about 2 cups of fluid have been run through the
NOTE: Repeat the bleeding procedure at least once.
system, the bleeder hose should have clear, bubble-
free fluid running through it.
1. Pull brake lever forward and rotate reach adjustment
dial to the “1” position (longest reach) to maximize 7. Close bleeder screw and fill the brake fluid reservoir.
lever stroke for bleeding.
8. Proceed to Step 9 to bleed the right front brake caliper.
9. Remove rubber cap from top bleeder screw on front

right caliper and install an 8mm box end wrench (C).
10. Connect vacuum bleeder hose to the bleed screw and

1 start vacuum.
2. Remove front brake fluid reservoir cover and leave it

off so fluid can be added as it is drawn through the
system.
3. Remove rubber cap from top bleeder screw on front left
caliper and install an 8mm box end wrench (A).
11. Hold lever to handlebar or hold firm pressure on lever,
4. Attach tight fitting clear hose from vacuum bleeder (B) then open bleed screw about 1/4 turn.
to bleed screw and apply vacuum.
12. Pump brake lever repeatedly with smooth full strokes
B For best results pump the lever at a fairly rapid rate but
avoid pumping too fast or fluid may become aerated.
A After about 2 cups of fluid have been run through the
system, the bleeder hose should have clear, bubble-
free fluid running through it.
13. Close bleed screw.
14. Once both front calipers have been bled, repeat
procedure again on left caliper, then right to ensure all
air has been purged.
15. Fill fluid reservoir and install diaphragm and cover.
Torque screws to 1.5 Nm (13 lb-in).
16. Perform Brake Lever Reserve Inspection on
page 15.44. If lever reserve is not sufficient (lever
5. Hold lever to handlebar or hold firm pressure on lever,
contacts hand grip at less than specified pull force)
then open bleed screw about 1/4 turn.
perform the Supplementary Bleeding Procedure on
page 15.43. If lever reserve is sufficient, reset lever
reach to original position.
15.42
BRAKES
ABS FRONT BRAKE SUPPLEMENTARY

BLEEDING PROCEDURE
If air is still trapped after performing the bleeding
procedure on ABS Front Brakes:
This additional bleeding procedure will help purge trapped

air from the front ABS brake system lines and must be
performed if the front brake lever does not pass the Lever
Reserve Inspection.
17. Move the motorcycle to an area with a flat, hard-

surfaced floor or concrete.
18. Place protective mats along right side of motorcycle

and position them to protect the contact surface of the
front and rear tipover boards in the next step.
19. With the aid of an assistant, set the motorcycle on the

right side tipover boards with mats placed underneath.
20. Pump the front brake lever 10-15 times and tap lightly
on brake lines to release air bubbles.
21. Allow 15 minutes for air to move up through the lines

and into the reservoir.
22. With the aid of an assistant, set the motorcycle upright

and onto the side stand.
IMPORTANT: The passenger hand rails are not
intended for use as a lift point. DO NOT lift the
motorcycle with the hand rails. Have an assistant help
you and use the handlebars to stand the motorcycle
back to the upright position.
23. Perform the Brake Lever Reserve Inspection to verify

the system is sufficiently purged of air.
24. Reset lever reach to original position.

15
15.43
BRAKES
BRAKE LEVER RESERVE INSPECTION 5. Keep tool centered so it does not touch hand grip.
Pull on scale to specified force.
1. Turn handlebars fully LEFT.
2. On levers with adjustable reach, set lever reach to

position 5 (closest to handlebar).
Hold handlebar forward
Tool not touching grip
Front Brake Lever Reserve Pull Force

MODEL PULL FORCE (MINIMUM)
Vision (Non-ABS) 20.4 kg (45 lbs).
Vision ABS 15.5 kg (34 lbs).

3. Place grommet of Brake Lever Reserve Inspection
Tool PV-50104 on ball end of front brake lever.
6. Have an assistant verify brake lever does not contact
hand grip. Clearance must exist at specified pull force
as shown.
Grommet
Scale end
Specified pull force
PV-50104
Clearance
4. Connect a scale (commercially available) with a

minimum of 25 kg / 50 lb capacity to end of tool.
7. If lever makes contact with hand grip or bar end, bleed

the front brake system (page 15.42). If system has
already been bled, perform the Supplementary
bleeding procedure (page 15.43) to purge remaining
trapped air and then repeat the lever reserve test to
ensure reserve (clearance) exists.
8. See troubleshooting if bleeding problems persist.
15.44
BRAKES
ABS TROUBLE CODES Connect Digital Wrench to view codes.

ABS CODE
DESCRIPTION
NUMBER
C0020 ABS Motor Lock
C1020 ABS Motor Stuck OFF
C1021 ABS Motor Stuck ON
C1022 ABS Pulsar Front

C1023 ABS Pulsar Rear
C1024 ABS Solenoid (RRI) Open or Shorted
C1025 ABS Solenoid (RRO) Open or Shorted
C1026 ABS Solenoid (FFI) Open or Shorted

C1027 ABS Solenoid (FFO) Open or Shorted
C1028 ABS Solenoid (RFI) Open or Shorted
C1029 ABS Solenoid (RFO) Open or Shorted
C1030 ABS Front Wheel Speed Sensor Open or Shorted to

Ground
C1031 ABS Front Wheel Speed Signal Failure
C1032 ABS Actuator (Front) Wheel Lock or VSS Failure
C1033 ABS Actuator (Rear) Wheel Lock or VSS Failure
C1034 ABS Failsafe Relay Fault

C1036 ABS Rear Wheel Speed Sensor Open or Shorted to 15
Ground
C1037 ABS Rear Wheel Speed Sensor Signal Failure
C1038 ABS Source Voltage Low
C1039 ABS Source Voltage High

C1040 ABS Tire Size Mismatch
C1041 ABS Module Fault
C1042 ABS Incomplete Evacuation and Fill
C1045 Trip Sudden Deceleration - Open / Short
15.45
BRAKES
TROUBLESHOOTING
TROUBLESHOOTING - BRAKE SYSTEM
ABS system troubleshooting chart is on page 15.48.
Problem Symptom and/or Possible Cause Possible Repair

Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component
Erratic Braking Fluid Leakage (Internal of Master Cylinder) Replace Master Cylinder
Action Worn Pads Replace Brake Pads
Oil Contamination of Brake Pads and/or Brake Disc Pads Must Be Replaced. Disc May Be Cleaned.
Air In System Bleed Air From System
Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid Level.
Excessive Brake Disc Runout Replace Brake Disc.
Worn or Damaged Wheel Bearings. Replace Wheel Bearings.
Loose Front Axle Nut or Clamps or Loose Rear Axle Torque Correctly, See Chapter 12 & 13
Caliper Mount Surface Uneven Or Misaligned; Missing Inspect / Repair

or Damaged Fasteners
Clogged or Restricted Hydraulic Line Replace Line(s)

Caliper Bracket Misaligned, Bent or Distorted Replace Bracket
Loose Brake Disc Install New Screws. Torque to Specification
Brake Pads Glazed Replace Pads. Avoid Needless Heavy Braking for
100-200 miles (Burnish New Brake Pads).
Poor Brakes or No Air In System Bleed Air From System
Brakes When First Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid Level.
Applied. Brake Lever Brake Disc is Bent or Warped Replace Brake Disc
Pressure Present If Caliper Misalignment Determine Cause and Correct
Lever Is “Pumped”. External Leak Repair or Replace Damaged Component
Internal Leak (master cylinder) Repair or Replace Master Cylinder
Faulty Brake Hose / Pinched Supply Inspect for Bulges/ Kinks / Replace
Burr on Disc Inspect Disc
Brake Pedal or Brake Disc Bent or Warped Replace Brake Disc
Brake Lever Mounting Surface of Brake Disc Uneven / Disc Loose Repair or Replace as Necessary
Pulsates
Caliper Mount Surface Uneven Or Misaligned; Missing Repair or Replace as Necessary
or Damaged Fasteners
Excessive Lever or Air in System Bleed Air From System
Pedal Travel / Loose Mounting Hardware Repair as Necessary
Spongy Brake Feel. Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid Level.
Incorrect Brake Fluid Used Flush System and Replace With Correct Fluid
See “Weak / Erratic Brakes” and Poor Brakes” possible

causes above.
Fluid Leakage Loose Banjo Fittings Tighten to Specified Torque
Damaged Banjo Fitting Sealing Washers Replace
Cracked / Damaged Hose Replace
Worn Master Cylinder Piston, Caliper Piston(s) or Seals Repair / Replace Master Cylinder or Wheel
Caliper.
Diaphragm (master Cylinder reservoir) Leaking
Inspect / Replace Cover, Cap, Diaphragm or
Reservoir as Required
Fluid level too high (new brake pads installed without
removing added fluid) Correct fluid level
15.46
BRAKES
Brakes Drag Excessively or Reservoir Over-filled Adjust Level As Necessary

Self-Apply
(Brakes Overheat) Brake Pedal Or Lever Not Returning Completely Inspect Linkage, Pivots and Mechanism For
To Rest Position Cause Of Binding Or Restricted Movement;
Inadequate Freeplay Measure Pedal Clearance / Adjust
Compensating Port Plugged Repair or Replace Master Cylinder
Internal Corrosion of Components (Master Replace Damaged Component

Cylinder / Caliper)
Rear Caliper: Corrosion of Sliding Parts, Bent or Repair or Replace As Necessary

Damaged Parts
Contaminated Brake Fluid Flush System, Install Correct Fluid
Caliper Pistons Sticking Repair / Replace Caliper (Corrosion / Buildup of

Residue In Caliper Piston Seal Grooves)
Educate Operator
Rider Error (Operator Riding Brakes)
Brake Squeal/Squeak If noise is minor and inconsistent, some brake Apply non oil-based solvent (such as Victory
squeak / squeal is characteristic of disc brakes Brake Cleaner or isopropyl alcohol) to a clean
and usually caused by dust / dirt on pads and / or shop towel and wipe dust / dirt from brake disc.
brake disc.
Pad Not Secure in Caliper Repair as Necessary. Inspect Pad Installation
Aftermarket (not genuine Victory) Parts Install Genuine Victory Parts
Worn or Damaged Wheel Bearing(s) Replace
Worn Pads / Disc Replace
15
15.47
BRAKES
ABS SYSTEM TROUBLESHOOTING
ABS SYSTEM TROUBLESHOOTING

ABS light on at all Blown Fuse (ABS Fuse Open) Replace Fuse; Inspect wiring for cause
times
System Fault (Fault Code Active) Connect Digital Wrench - View Code(s)
Sensor Fault; Loose sensor; Damaged sensor Inspect wheel speed sensor / pulse ring for
or pulse ring. Improperly assembled fork, debris or damage. Inspect sensor mounting.
brake, wheel, or axle. Inspect front fork, both brake calipers, wheels
and axles for proper assembly, and wheel
bearings. Inspect all ABS wiring connections.
ABS light on Wire Connection Fault Inspect connector at ABS module for loose,
intermittently broken, or corroded wiring or connector pins.
Check power supply (fuses) and ground.
Sensor Fault; Loose sensor; Damaged sensor Inspect wheel speed sensor / pulse ring for debris
or pulse ring. or damage. Inspect sensor mount, ABS wiring
connections, and wheel bearings.
ABS Noise When Transmission or Drive Line Noise Some drive line noise may be evident and is
Active normal depending on conditions / road surfaces.
Inspect brake pads, brake discs, caliper mounts,
tire pressure, tread wear, and tire type. Pulsation
at lever or pedal normal when ABS active.
ABS Pulsation at Normal System Operation Pulsation at lever or pedal is normal when ABS is
Lever or Pedal active due to feedback in the brake lines from
pressure modulation at the ABS module. If
pulsation can be felt during normal system
braking (non-ABS active braking) inspect the
brake system as you would for a non-ABS
equipped vehicle (brake pads, brake discs,
caliper mounts, tire pressure, tread wear, and tire
type, etc.)
ABS Poor System not properly bled (air in system). Bleed system properly as described on
Performance page 15.40 and perform Front Brake Lever
Reserve test on page 15.44 to verify all air is
purged from the system. Inspect brake system
components (discs, pads, etc.)
ABS Light On After Rear wheel loss of traction was initiated below Careless or reckless driving not recommended.
Rear Wheel Spin 6 mph (10 kph) and exceeded maximum time Bring motorcycle to a safe stop. Cycle ignition key
allowance parameter of system. OFF / ON to reset system. Light should go off
when vehicle speed exceeds 6 mph / 10 kph.
Careless or reckless driving not recommended.

Rear wheel loss of traction initiated above 6 System Fault Code logged immediately due to
mph (10 kph). wheel speed differential when ABS is active
(above 6 mph / 10 kph). Bring motorcycle to a safe
stop. Cycle ignition key OFF / ON to reset system.
Light should go off when vehicle speed exceeds
6 mph / 10 kph.
15.48
BATTERY CHARGING SYSTEM
CHAPTER 16
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
BATTERY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
CHARGING SYSTEM & ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
BATTERY CHARGING - NEW BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
BATTERY CHARGING - GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
CURRENT DRAW INSPECTION (KEY OFF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
REGULATED VOLTAGE / AMPERAGE OUTPUT INSPECTION . . . . . . . . . . . . . . . . . 16.8
STATOR NO-LOAD AC VOLTAGE OUTPUT INSPECTION . . . . . . . . . . . . . . . . . . . . . 16.9
STATOR RESISTANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
STATOR WINDINGS TO GROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
VOLTAGE DROP: RECTIFIER / REGULATOR TO BATTERY(+) . . . . . . . . . . . . . . . . 16.11
RECTIFIER / REGULATOR CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 16.11
DIODE LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
REGULATOR / RECTIFIER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
RECTIFIER / REGULATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
STATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15
STATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15
16
16.1
IMPORTANT INFORMATION
GENERAL
WARNING
All electrical system and component service can be
performed with the engine in the frame. Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
CAUTIONS TO OBSERVE
DURING ELECTRICAL SYSTEM SERVICE:
External: Flush with water.
CONNECTORS Internal: Drink large quantities of water or milk. Follow

with milk of magnesia, beaten egg, or vegetable oil.
Always turn off ignition switch before disconnecting any Call physician immediately.
electrical component.
Eyes: Flush with water for 15 minutes. Call physician
Always verify that bullet-type connectors are free of
immediately.
corrosion, contamination or breaks when troubleshooting
electrical problems.
Batteries produce explosive gases. Keep sparks,
Verify that bullet-type connectors are firmly seated. Listen flame, cigarettes, etc. away. Ventilate when charging
and/or feel for a click when connecting them. or using in an enclosed space. Always shield eyes
when working near batteries.
Ensure to release the lock on lock-type couplers before
disconnecting them to avoid damaging the connector. KEEP BATTERIES AND BATTERY ACID
OUT OF REACH OF CHILDREN.
Pulling on the wires when disconnecting couplers can
introduce problems. Hold the connectors themselves when
disconnecting them, not their associated wires. NOTICE
Inspect each male and female terminal of multi-pin The charging system used on the motorcycle is
connectors for corrosion, contamination, loose or bent calibrated for the maintenance free battery that is
pins. installed as original equipment. Do not replace with
a conventional lead-acid battery.
BATTERY SAFETY
Before troubleshooting the charging system,
inspect the battery thoroughly. A discharged, poorly
BATTERY LABEL charged or faulty battery will make the readings
obtained during charging system troubleshooting
erroneous or difficult to interpret.
NOTICE
Even with a good battery, battery voltage can

recover after charging, but under excessive load the
battery voltage will drop quickly. Often the charging
system is suspect when it is not the cause of the
problem. Always inspect for excessive loads or
current draw with the key OFF. Items such as
incorrect wattage bulbs or a sticking brake or trunk
light light switch can drain a battery even if the
charging system is operating correctly.
16.2
A battery will self-discharge when the motorcycle is not in

use. Make sure to properly store the battery as outlined CAUTION
later in this section.
ELECTRONIC COMPONENTS
Maximum voltage and service life is only achieved when Semiconductor parts used in electronic components
the battery is properly serviced initially. Make sure to follow will not withstand careless handling.
instructions outlined later in this section.
Do not drop or strike parts that contain
Overcharging can be caused by a faulty battery (shorted semiconductors such as the ECM or rectifier/
cell). Test system with a known good battery when regulator. Dropping electronic components can
diagnosing an overcharge condition. cause damage to the component.
New batteries must be properly maintained as outlined in Follow instructions supplied in this chapter, including
this section to ensure proper service life. chapter 5 (Fuel Injection) and chapter 17 (Ignition
System), very carefully when working on electronic
components. Failure to follow instructions may
CAUTION cause irreparable damage to the part being
CONNECTING AND DISCONNECTING THE inspected.
BATTERY
Always disconnect the negative battery cable first SPECIAL TOOLS
when removing the battery.
The following tools are available for purchase from our tool
supplier, SPX:
Always connect the positive battery cable first when
connecting the battery. Engine Stop Tool: PV-43502
If corrosion is found on terminals, remove battery Flywheel Puller: PV-43533

and clean terminals with a solution of baking soda
and water. Finish the process by cleaning terminals Digital Multi-Meter: PV-43546
(both battery and battery cables) with a wire brush.
Connector Test Kit: PV-43526
Once connections are secured, apply a thin film of
Nyogel™ grease to the terminals.
Verify the positive terminal has it’s protective boot in

place.
CAUTION
WIRE ROUTING
Make sure that all wires are routed correctly.
CAUTION 16
FUSES
Fuses are in place to protect circuit wiring and
components. Always determine the cause of an
open fuse before installing a new fuse.
Do not increase the value of the fuse to correct the

problem.
Do not use wire, tin foil or other substitutes for fuses.
16.3
SPECIFICATIONS
GENERAL
Item Specifications
Starting System Electric
Electrical Charging System Permanent Magnet / 3 Phase / Full Wave Rectification
(General) Regulator/Rectifier Solid State Three Phase Voltage Regulator/Rectifier
Lighting System 12 V DC
CHARGING SYSTEM & ALTERNATOR

Item Specifications
Alternator No Load AC Output (Minimum) 17.5 V AC @ Idle
Alternator No Load AC Output @ 2000 RPM (Minimum) 38.5 V AC @ 2000 RPM
Stator Coil Resistance (@ 21oC / 70oF) (stator Black wire to other Black wire) Less than 1 ohm
Stator Coil Resistance To Ground (each stator Black wire to ground) Infinite (no continuity)
Regulator/Rectifier Regulated Voltage 14-14.8 V DC
Alternator Output (Amps / Watts) 50 A
Type Yuasa: YTX20HL-BS
Voltage 12 Volts DC
Nominal Capacity @ 10 Hr Rate 18 AH
Battery (P/N 4011374)
Recommended Battery
STD: 1.85 A for 5 to 10 hrs
Charging Current
Cold Cranking Amp Rating 310
FASTENER TORQUE
Charging System
Description Torque Nm Torque lb-ft (in-lb)
Battery Holder Screw 10 Nm (85 in-lbs)
Battery Terminal Screws 4.5 Nm (40 in-lb)
Belly Pan Screws 10 Nm (85 in-lbs)
Center Grill Screw 4.0 Nm (36 in-lb)
Circuit Breaker Terminal Nuts 2.8 Nm (25 in-lb)
Flywheel (Rotor) Bolt 102 Nm 75 lb-ft
Primary Cover Screws 13 Nm (115 in-lbs)
Regulator/Rectifier to Bracket 10 Nm (85 in-lb)
Regulator/Rectifier Bracket to
10 Nm (85 in-lb)
Crankcase
Stator Mounting Screws 11 Nm (100 in-lbs) Loctite™ 242
16.4
BATTERY BATTERY CHARGING - GENERAL
BATTERY REMOVAL
1. See page 2.20.
BATTERY CHARGING - NEW BATTERY

1. Charge the battery at 1.8 amps for 5 to 10 hours. use
a straight rate charger (not load sensing or battery
tender type) for the initial charge of a new battery.
CAUTION
Do not attempt to quick charge the battery at any
time.
1. Measure battery voltage with a digital multimeter. The
reading should be above 12.5 Vdc. If battery voltage
is lower than 12.5 Vdc, battery must be charged
+ 12.5 Vdc according to the instructions given below.
CAUTION
Do not remove caps on battery while recharging. Do
not attempt to inspect or add fluid to a maintenance
free battery.
2. Charge battery at 1.8 amps for 5 to 10 hours.
Battery Charging Specification:

2. Remove battery from charger and let it sit for 30
minutes or longer. 1.8 A for 5-10 hours
3. Measure voltage with a digital multimeter. If lower than
12.5 Vdc, battery must be recharged again in 3. Remove battery from charger and let it sit for 30
accordance with step 1 and 2 above. minutes or longer.
4. After charging battery and letting it sit for 30 minutes 4. Measure battery voltage with a digital multimeter. If
or more, check battery voltage again. If battery voltage battery voltage is lower than 12.5 Vdc, battery must be
is still below 12.5 Vdc, replace the battery. recharged again in accordance with step 1 and 2
above.
5. After charging battery and letting it sit for 30 minutes
or more, check the battery voltage again. If battery
voltage is still below 12.5 Vdc, replace battery.
NOTE: When motorcycle is not used for one (1) month or 16
more, remove battery and store it in a cool, dry area.
Inspect voltage monthly and charge according to above
instructions if necessary.
16.5
DIAGNOSTICS
TROUBLESHOOTING
NOTICE: The battery must be fully charged and in good condition to obtain accurate readings. Battery charging
current is automatically reduced by the regulator / rectifier if the regulator / rectifier unit reaches a critical temperature
(overheated). The system should be cool when testing DC charging output or when testing the regulator / rectifier to
ensure accurate readings. Refer to test procedure for individual charging system components for more information.
START Battery Load Test

Measure Current Draw
(Page 16.8) Incorrect Test Regulator/Rectifier Unit
Correct
Good
Faulty Excessive Loads or
Above Shorted Wiring
Inspect Regulated Voltage &
14.8 V DC Shorted Components**
Amperage Output (Page 16.9)
Replace Regulator / Rectifier

Less Than 13.8 V DC 13.8 - 14.8 V DC
Battery or Battery Connections
or
Inspect Voltage Reg / Rect 3-Pin Charging System O.K., check
connector. Inspect Black wire Operator Driving Habits
(ground) path and BK/R wire
(current path back to battery +
Incorrect Correct Wiring Problem
Correct
Inspect No-Load AC Voltage

Output from Stator (Page 16.10) Correct Test Regulator / Rectifier (page 16.12)
Incorrect
Inspect Stator Resistance ** Disconnect any accessory items

(Page 16.11) Correct to see if load disappears
Incorrect
Faulty Stator or Open / Short Faulty Wiring or Connectors;

Circuit In Wiring. Damaged Flywheel Magnet
Repair or Replace As Necessary
16.6
BATTERY LOAD TEST CURRENT DRAW INSPECTION (KEY OFF)

1. Perform a battery load test using a battery load tester. Current draw is suspect if battery discharges when
Follow the load tester manufacturer’s instructions motorcycle is not in operation (short periods of storage).
carefully.
NOTE: If the vehicle is equipped with an accessory
Headlight Load Test CD player, current draw will be considerably higher.
Headlight On For The higher draw remains for 36 hours after the key is
One Minute
shut off, at which time the CD player is automatically
disconnected from the system. Current draw
specifications listed below are for vehicles not
equipped with a CD player.
1. Turn key OFF and wait at least 30 seconds for all

powered circuits to disconnect before performing the
Voltmeter Should Read key-off current draw test.
+ 10.5 V DC After One
Minute
Current Draw Inspection
(Key Off)
NOTE: Although not as conclusive, the following test can

be used to direct troubleshooting efforts if a battery load
tester is not available.
2. Charge battery as outlined in this section.
3. Install fully charged battery.

Less than 5 mA
4. Connect a digital multimeter to battery and keep it
connected for duration of test.
2. Disconnect ground cable (-) from battery.
5. Turn ignition key on.
3. Connect digital multi-meter red (+) probe to ground
6. Switch head light to high beam position and leave it on cable and connect black DMM (-) probe to battery
for 1 minute (without the engine running). negative (-) terminal.
7. At end of one minute, the digital multimeter should Fluke™ 73 Multimeter PV-43546
show a reading of above 10.5 V DC.
4. Read current draw (be sure 30 seconds has passed
8. If battery voltage drops below 10.5 V DC, battery since key was turned OFF).
should be charged again and the test repeated.
5. If current draw exceeds specifications, inspect wiring
and components for short to ground.
Specification: Less than 5 mA 16

6. Locate the faulty component or wiring by disconnecting
wiring connections one-at-a-time while observing
current draw. Use the wiring diagram to locate possible
current draws from battery. When current draw falls
within specifications, the last connection disconnected
shows which circuit or component is affected.
16.7
REGULATED VOLTAGE / AMPERAGE 6. Increase engine RPM to 2500. The ammeter should
OUTPUT INSPECTION rise a slight amount, then stabilize. Volt meter should
read above 14 V DC.
1. Remove negative battery leads and connect a 12V
shunt as outlined in the instructions provided with 7. Use results obtained from preceding tests and the
shunt or use an inductive amperage clamp. following descriptions to determine if charging system
is functioning properly.
NOTICE: Current can easily exceed the measuring
limits of your ammeter or its internal fuse. CHARGING SYSTEM OPERATING CORRECTLY:
An inductive ammeter clamp or a suitable shunt Ammeter goes up a small amount, then stabilizes slightly
must be used to avoid meter or fuse damage. above +0 amps. Volt meter rises toward 14.8 ± V DC,
drops off a little and starts to stabilize.
LOW BATTERY: Amperage continues to rise, voltage

levels off as battery is absorbing voltage. Charging
system may be O.K. Need to charge battery fully or use a
good battery and repeat test. Meters will indicate similar
reading to the overcharging chart.
CHARGING SYSTEM UNDERCHARGING: Ammeter

drops to 0 or remains below 0 (negative reading) at all
rpm, volt meter remains the same or goes down. Go to
voltage drop inspection.
CHARGING SYSTEM OVERCHARGING: Ammeter rises

well above 0 and remains there or continues to rise. Volt
meter goes well above 14.8 V DC and may continue to
rise. Go to voltage regulator/rectifier inspection.
EXCESSIVE LOAD: Amperage levels off or starts to drop,

voltage continues to rise. Load may be excessive
Voltage (accessories or shorted components). Determine if
excessive loads are present. Disconnect accessories and
re-test).
8. Turn ignition key off.

2. Set digital multimeter (DMM) to V DC scale.
9. Remove ammeter shunt or inductive clamp.
3. Connect DMM red (+) lead to battery red (+) lead and
DMM black (-) lead to battery black (-) lead. 10. Re-connect negative battery cables to battery.
4. Start engine and warm to operating temperature. 11. Install seat and right and left side covers.
5. At 1000 RPM or slightly above; the ammeter should

reach the “break-even” point (no amperage leaving the
battery) and the voltmeter should be rising toward 14
VDC.
Specification: “Break-even” point for charging

Idle RPM (Approx.)
16.8
STATOR NO-LOAD AC VOLTAGE OUTPUT 3. Set Digital Multimeter (DMM) to AC Volts scale.
INSPECTION 4. Connect one lead of DMM to Pin A on wire connector
NOTE: DMM set to VAC (if meter has Vrms selection that comes from stator.
use Vrms). Engine cool - not to operating ~
temperature. Regulator Rectifier disconnected (3-pin Meter Set To AC volts: V
connector). Engine must be running. Be sure to heed
the following Warnings and Cautions. Retainer Clip
WARNING
HOT COMPONENTS
The engine and exhaust system become very hot A B C
during operation and remain hot for a period of time Front View
after the engine is shut off. Wear insulated
protection for hands and arms or wait until the Male Connector
From Stator
engine and exhaust system have cooled sufficiently (Female Pins)
before working on the machine.
5. Connect other lead to pin B.

WARNING
6. Start engine and let it idle. Observe DMM reading.
CARBON MONOXIDE
Never run an engine in an enclosed area. Exhaust 7. The DMM should indicate a minimum reading of 21 V
contains poisonous carbon monoxide gas that can AC at idle.
cause loss of consciousness and may lead to
death. If you must run the engine to do some 8. If using a meter other than the Fluke 73, be sure your
repairs, do so in an open area or with an exhaust meter reads rms volts.
evacuation system operating.
9. Repeat test for pins A & C.
CAUTION 10. Repeat test for pins B & C.
VOLTAGE / ARCING Specification:

Use caution not to touch any of the connections or No load AC Volts @ 900 RPM:
allow the exposed terminals to come close to any 50A Alternator - Approx ~ 17.5 VAC +/- 1 @ 900 RPM
other part of the vehicle or other objects, as an arc
may occur.
NOTE: The test results in steps 7, 8 and 9 can read
1. Locate three wires coming from stator and follow the more than specified VAC, but it is important that the
wires to the 3-pin connector. reading for each pair of wires is approximately equal.
2. Disconnect 3-pin connector (A).
11. Increase RPM to 2000. Repeat Steps 4-10.
Specification: 16
No load AC Volts @ 2000 RPM:
50A Alternator - Approx ~ 38.5 VAC +/- 1 @ 2000 RPM
NOTE: The test results obtained in step 11 can read

A more than specified VAC, but it is important that they
are all approximately equal.
16.9
STATOR RESISTANCE INSPECTION EXAMPLE: Connect meter leads together, meter reads
0.3 ohms. Measure stator resistance, meter reads .7
ohms. Subtract 0.3 ohms (meter/lead resistance) from .7
NOTICE ohms.
True reading is:
Do not run the engine during this test. .7 ohms (observed reading when checking stator)
- 0.3 ohms (meter/lead resistance)
= 0.4 ohms (true stator winding resistance)
NOTE: Meter set to measure resistance. Engine OFF 5. Remove one of the DMM leads and connect it to the
and cool. other pin in the multi-connector. The reading should be
the same as the first test reading.
Meter Set To Ohms: 6. Remove the lead that was connected to the same
Retainer Clip multi-connector pin for the first two tests and connect
it to the other multi-connector pin. This reading should
 also be the same as the first two readings.
A B C STATOR WINDINGS TO GROUND

Front View INSPECTION
Male Connector NOTE: DMM set to resistance. Engine OFF and
From Stator cooled. Disconnect the stator (3-pin connector).
(Female Pins)
1. Disconnect the 3 pin connector from stator.

1. Connect one DMM lead to one of the multi-connector
2. Set DMM to OHMs scale. pins and place the other lead of the DMM in contact
NOTE: Make sure DMM leads are plugged into with a good engine ground, observe resistance to
correct jacks. ground reading.
3. Connect one lead of DMM to any one of pins in multi-
connector leading from stator.
Meter Set To Ohms:
4. Connect other lead of DMM to any one of the other two
Retainer Clip
pins in the multi-connector and observe circuit
resistance reading.
Specification:
Stator Resistance: A B C
0.1-0.5  (plus meter resistance, see below) Front View
Male Connector
NOTICE From Stator
(Female Pins)
Do not touch meter leads or reading obtained will be

inaccurate. Specification: Stator Windings to Ground:
Open Circuit (OL)
NOTE: 0.3 to 0.5 ohms may be less than the
internal resistance of your meter leads or meter. 2. Repeat test for other two stator leads to ground.
Before measuring stator resistance, connect the
meter leads together and read the display and record 3. There should be no connection from stator windings to
this measurement. Subtract this reading from stator ground.
resistance readings.
16.10
VOLTAGE DROP: RECTIFIER / REGULATOR RECTIFIER / REGULATOR CONNECTOR

TO BATTERY(+) INSPECTION
NOTE: Leave regulator / rectifier connected for this test. 1. Disconnect 3 pin connector.
From stator (connected)

Red lead to ring Black (BK) RED (to circuit breaker)
terminal at circuit
breaker
BK (Ground to
engine case)
A B C
BK BK BK
3-Pin Stator Leads
2. Inspect male and female pins in the 3-pin connector

and the ring terminals of the positive (red) and negative
1. Remove the electrical cover (below the oil cooler). (black) regulator / rectifier leads. Check for corrosion,
2. Set Digital Multi-Meter (DMM) to DC Volts scale (or 300 loose pins, poor connections, or evidence of
mV scale). overheating or other damage.
3. Connect red lead (+) of DMM to the ring terminal of the 3. If the wiring and connectors are undamaged and
Red regulator / rectifier lead at the circuit breaker. appear to be clean and tight, inspect the battery, stator,
and related wiring. Test the regulator / rectifier as
4. Connect black lead (-) of DMM to positive (+) battery described in the following tests.
cable at battery.
NOTE: Do not touch the meter leads when testing the
5. DMM must read below 0.1 volts DC (100 mV). If it does regulator rectifier. Readings in the following chart are
read 0.1 V DC or less the circuit is O.K. correct for a Fluke™ 73 multimeter. Use of other 16
meters may affect test results.
Specification: 0.1 V DC
6. If DMM reads above 0.1 volts DC there is excessive
resistance in the circuit that must be corrected.
7. Possible problem areas could be the battery cable,
cable end connections, cable to battery terminal
connection, the ring terminal connection to the
regulator rectifier red wire. Visual inspections or
continued voltage drop inspections are necessary to
determine the cause.
16.11
DIODE LEAKAGE TEST

NOTE: Engine must be OFF. Perform this test at the
40A circuit breaker (under the electrical cover below
the oil cooler).
NOTE: Do not touch the meter leads when testing the
regulator rectifier. Readings in the following chart are
correct for a Fluke™ 73 multimeter. Use of other
meters may invalidate the test.
Diode Leakage Test
DC Amps, 300 mA scale
Leave 3-Pin
Connected
Red Red
Blk
Circuit Breaker
Terminal
Blk
Reg/Rect
Leave ground connected to engine
1. Disconnect the voltage regulator / rectifier red wire

from the circuit breaker terminal, reinstall the nut on
the circuit breaker.
2. Install a jumper wire as shown to provide a complete

ground path.
3. Connect meter as shown, with red (+) meter lead to the

red wire on harness side, and the black meter lead to
the red wire on the regulator / rectifier side.
4. Compare leakage to specification below.
Specification:
Leakage: Less than 1.0 mA
16.12
REGULATOR / RECTIFIER TEST • Use DIODE CHECK function on the Fluke 73 DMM
• Remove regulator / rectifier or completely • Perform all tests described in test table below. Test
disconnect all wires (3-Pin stator connector, ground results describe a properly functioning part.
(black) from engine case, and BK/R wire from
circuit breaker (inside) terminal). Unit must be cool
for accurate testing.
Case 3-Pin
Stator AC Phase Leads

RED
Black
A B C
BK BK BK
Regulator / Rectifier Test Table - Set DMM to DIODE CHECK Function
DMM RED LEAD DMM BLACK LEAD RESULT
AC Phase 1 (Pin A of 3-pin) AC Phase 2 (Pin B of 3-pin) Open Circuit
AC Phase 2 (Pin B of 3-pin) AC Phase 3 (Pin C of 3-pin) Open Circuit
AC Phase 1 (Pin A of 3-pin) AC Phase 3 (Pin C of 3-pin) Open Circuit
AC Phase 2 (Pin B of 3-pin) AC Phase 1 (Pin A of 3-pin) Open Circuit
AC Phase 3 (Pin C of 3-pin) AC Phase 1 (Pin A of 3-pin) Open Circuit
AC Phase 3 (Pin C of 3-pin) AC Phase 2 (Pin B of 3-pin) Open Circuit
Battery + Lead (Ring terminal of Red wire) Ground Lead (Ring terminal of Black wire) Open Circuit
Ground Lead (Ring terminal of Black wire) Battery + Lead (Ring terminal of Red wire) Open Circuit
Ground Lead (Ring terminal of Black wire) Case Closed Circuit (continuity) 16
Ground Lead (Ring terminal of Black wire) Any Phase Open Circuit
Any Phase Ground Lead (Ring terminal of Black wire) Open Circuit
Battery + Lead (Ring terminal of Red wire) Any Phase Open Circuit
AC Phase 1 (Pin A of 3-pin) Battery + Lead (Ring terminal of Red wire) 400mV to 650mV
AC Phase 2 (Pin B of 3-pin) Battery + Lead (Ring terminal of Red wire) 400mV to 650mV
AC Phase 3 (Pin C of 3-pin) Battery + Lead (Ring terminal of Red wire) 400mV to 650mV
16.13
RECTIFIER / REGULATOR REPLACEMENT

1. Remove electrical cover (page 16.5).
2. Lift cover off circuit breaker (A) and remove engine
ground screw.
7 Nm (60 lb-in.)
3. Remove regulator / rectifier ground wire (black) (B).

4. Remove nut securing regulator rectifier black/red (+)
wire to the inner circuit breaker terminal.
INSTALLATION NOTE: This wire is installed first on
the breaker terminal, followed by the battery positive
(+) red wire (D),
9.6 Nm (85 lb-in.)
C
D
Circuit Breaker Nuts

2.8 Nm (25 lb-in.)
5. Remove mounting screws.

6. Lift tab and separate the 3-pin connector.
7. Reverse order of removal to install. Be sure mounting
bracket is clean and all connections are clean and tight.
Secure wires and connectors, and torque all screws.
8. Torque circuit breaker nuts to 2.8 Nm (25 lb-in).
Route wires between starter motor
and regulator
16.14
STATOR REMOVAL STATOR INSTALLATION

1. Remove primary cover (page 9.11). 1. Clean stator mounting surface and screw holes in
primary cover.
2. Place primary cover on bench with padded material
between primary cover and bench top. 2. Place stator in primary cover taking care to route wires
correctly in the channel.
3. Remove wiring retainer plate (A).
3. Install screws and torque 12 Nm (100 lb-in).
4. Remove three (3) socket head screws (B).
4. Install grommet (C) into groove in cover and then install
5. Remove stator from primary cover. retainer plate. Torque screws to 5.7 Nm (50 lb-in).
5. Pull wires to remove any slack or loop at point (D).

Wires must not protrude into flywheel rotor area.
B A
C
PULL
D
FLYWHEEL REMOVAL
Refer to page 9.26.
16
16.15
NOTES
16.16
IGNITION
CHAPTER 17
IGNITION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2
IGNITION SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
BASICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
IGNITION CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
TEST LEAD ADAPTER KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
IGNITION SYSTEM TEST FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
BATTERY VOLTAGE INSPECTION - TEST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
SPARK INSPECTION - TEST 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
COIL HIGH TENSION LEADS - TEST 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
IGNITION COIL SIGNAL - TEST 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
IGNITION COIL RESISTANCE - TEST 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION - TEST 6 . 17.10
CRANK POSITION SENSOR CIRCUIT AND SIGNAL TEST 6A . . . . . . . . . . . . . . . . . 17.11
CRANK POSITION SENSOR CIRCUIT CONTINUITY TEST 6B. . . . . . . . . . . . . . . . . 17.11
GROUND CIRCUIT INSPECTION - TEST 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.11
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
IGNITION COIL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
IGNITION COIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
IGNITION SWITCH REMOVAL / CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . 17.13
17
17.1
IGNITION
GENERAL INFORMATION
SAFETY INFORMATION
There are many hazards present when working on or around the ignition system. Read and pay close attention to the
following warnings and cautions when working on any component in this section.
Never run an engine in an enclosed area. Exhaust The engine and exhaust system become very hot
contains poisonous carbon monoxide gas that can during operation and remain hot for a period of
cause loss of consciousness and may lead to death. time after the engine is shut off. Wear insulated
If you must run the engine to do some repairs, do protection for hands and arms or wait until the
so in an open area or with an exhaust evacuation engine and exhaust system have cooled before
system operating. working on the machine.
Some procedures call for the engine to be run in Parts containing semi-conductors can be
order to warm the engine to operating temperature. easily damaged if handled carelessly. Do not
If this is done the exhaust pipes can “blue" if a drop or subject the electronic components
cooling air stream is not provided by means of a to shock loads.
shop fan directed at the exhaust system
(particularly the head pipes).
Follow the instructions closely when troubleshooting Using incorrect heat range spark plugs can
items in this section. Some electrical components damage the engine. Always follow the
can be damaged if they are connected or discon- manufacturer's recommendations for spark
-nected while the ignition switch is ON and plug heat range.
current is present.
GENERAL CAUTIONS TO OBSERVE WHEN WORKING ON IGNITION SYSTEM
• This ignition system is controlled electronically and no provisions are available to inspect or change ignition
timing. A timing light is still valuable as a diagnostic tool.
• Poor connections are the most common cause of ignition problems. Inspect all connections and replace the
spark plugs before doing extensive ignition system troubleshooting.
• Make sure the battery is fully charged and that the charging system is operating correctly.
• A signal from the Crankshaft Position Sensor must be present for spark to occur.
IGNITION SYSTEM SPECIFICATIONS

Ignition Specifications
Item Specifications
Spark Plug NGK DCPR6E
Spark Plug Gap 0.8 mm (.032 in.)
Primary 0.3 - 0.6 Ohms ± 20%
Secondary See coil test page 17.9
Ignition Coil Resistance
2009: Front: 1500 - 2000 Ohms** / Rear 400 - 600 Ohms**
Plug Wire (with cap*)
2010: Front: 4360 - 5780 Ohms** / Rear 4080 - 5050 Ohms**
Crank Position Sensor Resistance 280 Ohms ± 10% (No short to ground)
* Spark plug end caps are not removable ** See page 17.8 for test procedure
17.2
IGNITION
Fastener Torque Specifications - Ignition System
Description Torque Nm Torque lb-ft (in-lb) Notes
CPS Screws (to cover) 6.8 Nm (60 lb-in)
Ignition Coil to Frame 11 Nm (100 lb-in)
Spark Plug 11 Nm (100 lb-in) Apply Anti-Seize
Timing Wheel Bolt (on RH 28 Nm 17 lb-ft
end of crankshaft)
Rotor (Flywheel) Bolt 102 Nm 75 lb-ft
SPECIAL TOOLS
SPECIAL TOOL PART NUMBER
Connector Test Lead Adapter Kit PV-43526
Fluke 73™ Digital Multimeter PV-43546
Inductive Timing Light PV-43537
TROUBLESHOOTING
BASICS
Before troubleshooting the ignition system, ensure that the engine stop switch is in the run position, that the battery is
fully charged, and that system related fuses are not open (blown). Check visually for corroded, loose, or broken
connections in critical areas such as the sensor connector itself, or at the engine-to-chassis harness 14 pin connector.
Check for loose wire pins in the individual sensor connectors and at the ECM (under the seat).
The Ignition System Troubleshooting flow chart (and the accompanying text) is designed to help you troubleshoot
ignition system problems. It will not lead you to faulty or fouled spark plugs. Always inspect spark plug condition first
(and replace if necessary) when troubleshooting ignition system problems.
Be sure that the spark plugs are the correct heat range and are the specified resistor spark plugs. Non-resistor spark
plugs can introduce electrical problems due to increased Radio Frequency Interference (RFI).
WARNING
Extremely high voltage is present in the ignition system. Do not touch the ignition coil, wires or spark plugs during test
procedures.
17
17.3
IGNITION
IGNITION CIRCUIT DIAGRAM
W / BK
W / GN
VIO / Y
R / BK
VIO / BK
GY
RED
17.4
IGNITION
TEST LEAD ADAPTER KIT

1. Tests in this section may include the testing of voltage and / or resistance at the connectors for various sensor and
system components. Use the appropriate test adapter lead when performing these tests at connector pin(s).
2. Forcing an incorrect or oversized probe into a connector may cause inaccurate test results (due to lack of a solid
mechanical connection to the terminal). It can also damage the connector being probed or the connector housing,
creating another problem which greatly complicates the diagnostic process. Extreme care must be taken not to
introduce problems while probing a connector.
Test Lead Adapter Kit: PV-43526 or suitable Fluke test adapter leads
CAUTION
Once the ECM connector has been disconnected, do not touch the pins on the ECM. Static electricity from your
body can damage the ECM. Do not attempt to perform tests on the ECM. Tests are done on wiring harness side of
ECM connector.
3. The ECM connector is marked 1, 30, 31, and 60 on the wire side of the connector to determine pin location. with
1, 30, 31, and numbers to identify pin terminals. Refer to the diagram below for a description of wire location /
function, and wire colors.
4. Use the information on the following pages to perform ignition system related tests at ECM connector or component.
ECM CONNECTOR MAP

Refer to Chapter 5 to remove connector from ECM.
TOP VIEW - ECM CONNECTOR (WIRE SIDE SHOWN)

IGNITION RELATED ECM CONNECTOR MAP
System related wire color & pin number shown. Refer to wiring diagram for complete information.
1 2 3 4 5 27 28 29
VIO/PK OPEN W / BK W / GN OPEN OPEN GY OPEN
IG COIL IG COIL SIGNAL FUEL PUMP RELAY
VPWR SIGNAL (FRONT) GROUND
(REAR) ECM CONTROLLED
BN = Brown; GN = Green; BK = Black; GY = Gray; PK = Pink; R = Red; VIO = Violet; W = White 17

31 32 33 34 35 56 57 58 59
VIO/PK OPEN BK/W R/BK OPEN OPEN R BK OPEN
ECM IGN
VPWR GROUND SNS CPS + CPS -
VERIFY TERMINAL PINS ARE NOT LOOSE IN CONNECTOR AND WIRE CONNECTION TO TERMINAL PIN IS
SECURE. NOTE: CONNECTOR IS MARKED WITH NUMBERS 1, 30, 31, and 60 ONLY.
17.5
IGNITION
IGNITION SYSTEM TEST FLOWCHART
Before proceeding: 1) Verify battery voltage is at least 12.5 Vdc (Test 1).
2) Check fuel pump fuse (10A) and engine fuse (15A)
3) Turn ignition key and Engine Stop Switch ON and listen for fuel pump. Pump should run
for 2-3 seconds at initial power up. If fuel pump does not run, see Chapter 5.
Check Spark Inspect Compression,

Good Spark
Test 2 Engine & Fuel System
No Spark, Intermittent, or Poor Spark Remove Spark Plug Wires - Test Resistance
2009 - Front 1400-1800 Ohms / Rear 400-600 Ohms
OK 2010 - Front 4360-5780 Ohms / Rear 4080-5050 Ohms (Test 3)
Test Ignition Coil Power Supply (Test 4) No, battery voltage not present during fuel pump cycle
Yes, battery voltage present The Vio/Y wire powers ignition coil and fuel pump. Does the pump run momentarily
(about 2-3 seconds) when ignition key and engine stop switch are first turned ON?
during fuel pump cycle
Check fuel pump power

Yes No
Test ECM Ground Signal to Ignition Coil (Test 4) supply circuit (Chapter 5)
Check for battery voltage on Pin D of the Engine Harness Connector during fuel
pump cycle (remember - voltage will only be present on Vio/Y for 2-3 seconds after
Signal OK No Signal key and stop switches are turned ON).
If voltage is present, repair Vio/Y circuit between Engine Connector & coil connector.
If no battery voltage is present, check Vio/Y splice in Engine Harness (see schematic)
Test Ignition Coil (Test 5)
Inspect Crank Position Sensor and Is resistance within specified range?

Ignition Coil OK Circuit Resistance (Tests 6, 6A, 6B) Is sensor undamaged?
Clean debris from sensor pole.

Check timing wheel on crankshaft Yes No
for damaged teeth.
Re-check all wiring connectors
and harness for damage or poor
connection and re-test for signal. Replace CPS
Incorrect Repair Wiring and/or

Inspect ECM Ground Circuit Connectors
Test 7
Inspect for moisture at 60 pin ECM connector,

Ground Circuit Correct clean and dry if moisture is found
Replace ECM
Note: ECMs rarely fail.
Verify all troubleshooting steps
again before replacing ECM
17.6
IGNITION
BATTERY VOLTAGE INSPECTION - Test 1 SPARK INSPECTION - TEST 2

1. Access battery area at front of motorcycle. 1. Connect an inductive timing light to one spark plug
wire.
2. Set Digital Multimeter (DMM) to DC Volts.
Inductive timing light PV-33277-A
> 12.50 Vdc 2. Turn ignition switch and engine stop switch ON.
3. Shift transmission into neutral and pull in clutch lever.
4. Depress starter button and observe timing light.
3. Inspect battery voltage.

4. If the battery voltage is below 12.5 Vdc, charge or
replace the battery with a fully charged battery. Refer
to Chapter 16 for battery inspection, battery charging 5. Determine if timing light flashes without interruption for
and charging system inspection. both cylinders.
NOTE: When operating the starter with a low battery, the 6. Consistent flashes indicate some secondary voltage is
voltage available for the ignition coils can drop below the present. The likelihood of an ignition related problem
minimum required to produce spark. is reduced but not eliminated. Keep the following points
in mind:
• There is a threshold voltage and amperage
requirement for timing lights below which they will
not trigger and therefore, not flash.
• Fouled spark plugs may drop secondary voltage so
low that a timing light will not trigger and therefore,
not flash.
• With no current flowing (open secondary side of the
ignition coil) the timing light will not flash.
• A faulty high tension lead (plug wire) or poor
connection is one example of an open secondary.
7. Replace spark plugs, connects plug wires and re-test.
8. If timing light does not flash consistently for one or both
cylinders, test high tension leads (Test 3).
NOTE: The plug caps or coil ends are NOT
removable. Wire must be replaced as an assembly. 17
17.7
IGNITION
COIL HIGH TENSION LEADS - Test 3 IGNITION COIL SIGNAL - Test 4

Power To Ignition Coil
CAUTION Battery voltage must be present at the ignition coil during
fuel pump initial cycle, during cranking, and with the
Do not attempt to remove the spark plug caps from the engine running.
spark plug high tension leads. The spark plug caps are 1. Remove ignition switch cover (Chapter 3).
molded to the plug wires and are only available as an
assembly. The specifications given include the 2. Remove ignition coil harness connector from the back
resistance of the spark plug caps. of the coil by pressing tab (A) and gently pulling the
harness connector to remove.
1. Remove high tension leads (HTL) by pulling firmly on
the boots at the coil and spark plug. DO NOT pull on A
the wire or HTL may be permanently damaged.
FRONT TOP VIEW
3. Place the DMM selector dial on the Volts DC scale.

4. Connect the black lead to ground (on the engine).
2. Test each high tension lead with an ohmmeter and
compare to specification. Move wire to detect internal 5. Connect a small thin test adapter lead to the center
breaks or poor connections at terminal ends. terminal of the ignition coil primary connector and the
+ meter lead to the test adapter.
2009 Rear cylinder HTL shown
VIO / Y
A B C
VDC
Test adapter
Engine Ground
High Tension Lead Resistance
6. With engine stop switch OFF, turn the ignition key ON.
2009 - Front: 1400 - 1800  7. Turn the engine stop switch to RUN. Battery voltage
2009 - Rear: 400 - 600  should appear on the center terminal (VIO / Y) for
2-3 seconds until the pump completes its prime cycle.
2010 - Front: 4360 - 5780  8. With transmission in Neutral, crank the engine. Battery
2010 - Rear: 4080 - 5050  voltage should again be present on the center (VIO /
Y) wire terminal.
17.8
IGNITION
Test 4 (Cont.) IGNITION COIL RESISTANCE - Test 5

ECM (Ground) Signal To Ignition Coil
Ignition Coil Primary Winding
ECM ground signal must be present at each of the outer
terminals of the ignition coil primary harness connector.
1. Remove ignition coil (page 17.12).
The signal will appear as a pulse on the meter bar graph
with DMM selector in the OHMs position. 2. Select OHMS function on the DMM.
1. Place the DMM selector dial on the OHMS scale. 3. Measure resistance between terminal 3 and terminal
2. Place a small thin test adapter into one of the outer 2 on the coil. Compare to specification.
terminals of the ignition coil primary connector (either 4. Measure resistance between terminal 1 and terminal
the W/BK or W/GN) and connect one meter lead to the 2 on the coil. Compare to specification.
test adapter.
Primary Windings of
W / BK Ignition Coil
A B
Test each outside
C
terminal to center
terminal

Test adapter
Engine Ground
3. Ground the other lead to the engine.

4. Place transmission in Neutral.
5. Turn the ignition key and engine stop switch ON. Primary Resistance: 0.4 - 0.6 
6. Crank the engine with the electric starter and watch the (Be sure to subtract meter lead resistance
bar graph on the Fluke 73 DMM. The bar graph should from measurement
pulse evenly while engine is cranking, indicating a
ground signal is present.
Ignition Coil Secondary Windings

Bar Graph Pulse
1. Remove ignition coil (page 17.12).
7. Repeat the test on the other outside wire in the 2. Select DIODE CHECK function on the DMM.
connector.
3. Place red DMM lead on center terminal (#2) of coil 17
• If no pulse is present, test the Crankshaft Position primary and black lead on secondary terminal and
Sensor (Test 6). record.
• If the signal is present on one wire and not the
4. Move black DMM lead to the other secondary terminal
other, test related wiring and connections.
and record. (Reading should be the same for both
• If both signals are present and there was battery secondary windings).
voltage on the VIO/Y wire (center terminal) but still
no spark, test the ignition coil windings. (Test 5). (Cont.)
17.9
IGNITION
Ignition Coil Secondary Windings (Cont.) CRANKSHAFT POSITION SENSOR (CPS)

RESISTANCE INSPECTION - Test 6
5. Repeat measurements on each secondary coil with
meter leads reversed. NOTE: This test can also be performed at the ECM
6. Compare readings to specification. Resistance should connector, to test the entire circuit with the sensor.
be low with leads one way and OL with leads reversed. See test 6A (page 17.11).
1. Disconnect the CPS sensor (connector is located at

Secondary Windings rear of engine).
of Ignition Coil 2. Visually inspect the sensor wire harness for damage,
Test each secondary and loose or broken wires or connector pins.
coil in DIODE CHECK
mode with meter leads 3. Select OHMS function on the DMM.
one way, then reverse 4. Measure resistance through the CPS coil by
the leads. connecting a test adapter lead to the sensor wires and
to the meter leads.
Test adapter leads
Meter leads
Specification: 280 @ 20oC, 68oF (+/- 20%)
5. Remove the lower right engine cover.

6. Visually inspect center pole (A) of crankshaft position
sensor for damage or metal particles clinging to the
magnet. Be sure dowel pins (B) are in place on the
Diode inside the secondary coil
requires diode check function of DMM cover (or crankcase) and check for physical damage
to sensor or timing wheel that may affect air gap.
SECONDARY COIL RESISTANCE

USE DIODE CHECK FUNCTION ON DMM
2.0-2.5 Vdc
Open or “OL” with leads reversed
B
17.10
IGNITION
CRANK POSITION SENSOR CIRCUIT and 10. Remove spark plugs from engine. Install spark plugs
SIGNAL Test 6A into spark plug caps and ground the spark plug
electrodes securely to the engine.
NOTE: A test lead adapter kit is required to prevent
11. Measure AC voltage signal from crank position sensor
connector pin, socket, or case damage.
while turning engine over using electric starter with
Connector Test Lead Adapter Kit PV-43526 or suitable spark plugs out and compare to specification.
Fluke test adapter leads
Specification: 2-5 V AC (Spark Plugs Out)
1. Turn ignition key OFF.
2. Remove seat.
3. Remove ECM connector from ECM (Chapter 5).
CRANK POSITION SENSOR CIRCUIT
CONTINUITY Test 6B
4. Select OHMS function on the DMM (
1. Check all pin connectors between sensor and ECM for
5. Connect test adapter leads to the DMM leads.
a good mechanical connection.
6. Place one test adapter lead in pin 57 and the other in
2. Inspect wiring for damage causing an open circuit.
pin 58 of the ECM connector (not the ECM). Compare
resistance to specification.
GROUND CIRCUIT INSPECTION - Test 7
1. Set DMM to DC volts.
2. Connect red meter lead to positive (+) post of battery.
3. Connect black meter lead to several bare metal places
on frame, engine and wiring harness ground
connections while observing meter reading at each.
Red 57 Black 4. At each ground test point, meter should read battery
58
(+) (-) voltage.
5. Low or reduced voltage indicates resistance.
Corrosion, paint, loose or damaged connections, or
broken wires can cause ground problems.
Specification: 280 @ 20oC, 68oF (+/- 20%)
6. Clean battery terminals thoroughly and apply a thin
coat of dielectric grease. The battery ground cable is
CPS AC Signal Test
attached to the engine at the left front corner of
7. With leads connected as for the resistance test (pin 57 crankcase (under the cover with the starter solenoid
and 58 of the ECM connector), select Volts AC function and circuit breaker).
on the DMM.
7. Set DMM to measure resistance. Test for good
8. Turn engine over with electric starter and observe
continuity between the engine crankcase ground and
DMM display.
the chassis grounds. The main chassis grounds are
9. With spark plugs installed voltage reading will be located on the top left fairing shell mounting bolt (B).
erratic due to low rpm and pulsing nature of the signal.
The numerical display will be erratic. Watch bar (A) at
bottom of display to determine if a signal exists. Any
fluctuating AC signal is correct for this test.
17
A
Main Harness Ground

Meter on AC Volts Scale
17.11
IGNITION
IGNITION COIL IGNITION COIL INSTALLATION
IGNITION COIL REMOVAL 1. Installation procedure is the reverse of removal

procedures.
1. Turn ignition switch OFF and remove key. 2. Apply light film of dielectric grease inside the spark plug
2. Remove ignition coil cover (Item A - Chapter 3). boot of high tension leads.
3. Remove both high tension leads (B) from coil. 3. Torque coil mount screw (or screws if coil was removed
with bracket attached) to 9 Nm (84 lb-in).
9 Nm (84 lb-in)
C
9 Nm (84 lb-in)
(All screws shown)
B
4. Remove screw (C) and ignition coil. To remove coil

with bracket, remove 2 screws (D).
5. Press tab (E) to remove primary connector.
FRONT TOP VIEW
6. Remove ignition coil.
17.12
IGNITION
IGNITION SWITCH REMOVAL / CLEARANCE ADJUSTMENT

1. Turn ignition switch OFF and remove key.
2. Remove bridge console (Chapter 3).
3. Lift glove compartment lock cable out of ignition switch bracket. Disconnect inner cable from release arm by carefully
rotating cable to align inner cable wire with slot in the release arm and remove.
4. Lift fuel door lock cable out of ignition switch bracket (Photo 1) and disconnect at panel (B) if required.
5. Rotate fuel door cable to align inner cable wire with slot, slide down to remove cable.
6. Remove switch mounting screws (B).
7. Press the tab on ignition switch harness connector firmly and pull to disconnect switch wire harness from switch.
8. INSTALLATION NOTES: After tightening switch screws, verify clearance between steering stop and switch body
as shown in detail view below. Some 2008 models require a support shim under the ignition switch base. The shim
MUST be re-installed unless the ignition switch is replaced. Refer to Safety Recall Bulletin V-08-01 for more
information.
Refer to the Engine Wiring Diagram for the

Ignition Switch Continuity Table
B
13.5 Nm
(120 lb-in)
B
Photo 1
Photo 2
Switch Detail View

1.5 - 2.5mm Steering Lock Clearance Ignition Switch Shim
(.060 - .100 inch) (2008)
17
17.13
IGNITION
NOTES
17.14
ELECTRIC STARTER
CHAPTER 18
ELECTRIC STARTER
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
STARTER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
STARTER SYSTEM SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
TROUBLESHOOTING FLOW CHART MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
STARTER CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4
TROUBLESHOOTING FLOW CHART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5
TROUBLESHOOTING FLOW CHART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6
TROUBLESHOOTING CHART 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6
BATTERY INSPECTION & CHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 18.7
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
CIRCUIT & SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
STARTER RELAY GROUND BYPASS CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . 18.7
NEUTRAL SWITCH BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.8
CLUTCH SWITCH / CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9
CLUTCH SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.10
CLUTCH SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.10
STARTER RELAY TO STARTER MOTOR POSITIVE CABLE BYPASS TEST . . . . . 18.10
STARTER RELAY POSITIVE CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
STARTER RELAY BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
STARTER RELAY TO STARTER MOTOR POSITIVE CABLE BYPASS TEST . . . . . 18.12
POSITIVE SIDE VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.13
NEGATIVE CABLE BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.15
NEGATIVE SIDE VOLTAGE DROP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.16
STARTER CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.18
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19
STARTER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19
STARTER CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19
18
18.1
ELECTRIC STARTER
GENERAL
SAFETY INFORMATION
WARNING
Always disconnect the battery (negative terminal first) before servicing the starter motor.
• Inspect the condition of the battery before troubleshooting the starter system. Also inspect main engine ground
(on crankcase - upper left rear corner) and battery cable connections.
SPECIFICATIONS
STARTER SPECIFICATIONS
ELECTRIC STARTER & STARTER CLUTCH
Battery Voltage (Open Circuit Voltage) Above 12.5 Vdc -
Commutator Resistance:
Between Any Two Bars Continuity (0 Ohms) -
Any Commutator Bar to Armature Shaft Infinity (OL on Fluke™ 73) -
Battery Input Terminal Resistance to Insulated Brush Continuity (0 Ohms) -
Battery Cable Terminal Resistance to Motor Case Infinity (OL on Fluke™ 73) -
Starter Motor Brush Length 13 mm ± 0.5 mm 6.5 mm
(0.512 ± 0.020") (0.255")
Starter Motor Operating Amp Draw 90-120 Amps Use inductive ammeter
Starter Motor No Load Amp Draw (Bench Test) 30-40 Amps after initial surge -
Starter Torque Limit Clutch Break-Away Torque 50 lb-ft when new 35-45 lb-ft after break-in
Voltage Drop Allowed: Each Connection - Pos Circuit 0.2 V DC (200 millivolts) -
Voltage Drop Allowed: Each Connection - Neg Circuit 0.2 V DC (200 millivolts) -
Total Voltage Drop Allowed - Pos Side Of Starter 0.3 V DC (300 millivolts) -
Total Voltage Drop Allowed - Neg Side Of Starter 0.3 V DC (300 millivolts) -

TORQUE SPECIFICATIONS - STARTER SYSTEM
Description Torque Nm Torque lb-ft (in-lb) & Notes
Bearing Cover Screws (starter gear cover) 10 Nm (85 in-lb)
Electrical Terminal (+) to Starter Motor 6.8 Nm (60 in-lb)
Gear Position Switch (to crankcase) 2.8 Nm (25 in-lb)
Positive Cable (+) to Motor Terminal 6.8 Nm (60 in-lb)
Primary Drive Gear Bolts (to Crankshaft) 41 Nm 30 lb-ft. Clean crankshaft threads
thoroughly. Install new bolts.
Regulator / Rectifier Screws 10 Nm (85 in-lb)
Rotor Bolt (Flywheel) 102 Nm 75 lb-ft
Starter Motor to Crankcase Bolts 30 Nm 22 lb-ft
Starter Motor Case Screws 10 Nm (85 in-lb)
18.2
ELECTRIC STARTER
SPECIAL TOOLS
STARTER SYSTEM SPECIAL TOOLS
SPECIAL TOOL PART NUMBER
Digital Multi-Meter PV-43546
Optional Amp Meter Inductive Clamp PV-39617
Rotor Puller (Flywheel) PV-43533
Engine Stop Tool PV-43502
Connector Test Adapter Kit PV-43526
DIAGNOSTICS
TROUBLESHOOTING FLOW CHART MENU
Symptom Possible Cause Refer To:
Starter motor does not turn with Neutral switch or circuit malfunction Test Neutral Switch (page 18.8)
transmission in neutral. Turns with
clutch pulled in.
Starter motor does not turn with Clutch switch or circuit malfunction, Test Clutch Switch (page 18.9) and
transmission in gear and clutch lever Reverse Switch (if equipped) or reverse switch (page 19.41).
pulled in. Turns with transmission in circuit malfunction.
neutral.
Starter motor will not turn Low battery voltage. Starter button See Troubleshooting Flow Chart 1
faulty. Poor cable connections. Main (page 18.5)
engine ground loose (front left corner
of crankcase under the electrical
cover).
Starter motor turns slowly. Low battery. Faulty starter motor or See Troubleshooting Flow Chart 2
Engine may or may not start. drive mechanism. (page 18.6)
Engine mechanical problem.
Starter motor turns, but engine does Starter torque limit clutch slipping See Troubleshooting Flow Chart 3
not turn. (Chapter 9). (page 18.6)
Starter motor turns at normal speed, Ignition Problem Chapter 17

but engine does not start. Engine Problem Chapter 7-10
Fuel Delivery Problem Chapter 5
18
18.3
ELECTRIC STARTER
STARTER CIRCUIT DIAGRAM
Reverse equipped see

Chapter 19
Connector located
behind rear cylinder
near speed sensor
harness
Not used on 2010

models
18.4
ELECTRIC STARTER
TROUBLESHOOTING FLOW CHART 1

Starter Motor Does Not Turn
Inspect Battery Service battery or replace with known

Battery Condition Poor good battery. Inspect Charging
(page 18.7)
System (Chapter 16)
Battery Condition Good
Does Starter Relay Click Yes

When Button Is Pushed? No
Perform Neutral Switch Test (page 18.8) Starter turns Repair or Replace Switch
& Clutch Switch test (page 18.9)
Bypass starter relay

Starter turns Problem is not in high current portion of starter system.
switch circuit
Inspect switching circuit.
(page 18.11)
Starter doesn’t turn
Bypass starter relay

Starter turns Replace starter relay
(page 18.11)
Bypass positive starter cable Perform voltage drop tests for positive
Starter turns
(page 18.12) high current side of starter system (page 18.13)
Bypass ground side of starter system Perform voltage drop tests for negative
Starter turns high current side of starter system (page 18.16).
(page 18.15)

Engine or starter drive gears are
Inspect starter motor Starter motor O.K. locked up. (High amp draw with no
internal starter problems)
WARNING 18
Ensure that motorcycle is secure and transmission is in neutral for all tests.
CAUTION
Inspect fuses and make sure battery is fully charged before inspecting starter system.
18.5
ELECTRIC STARTER
TROUBLESHOOTING FLOW CHART 2

Starter Motor Turns Slowly, Engine May or May Not Start
Inspect battery: Service battery or replace with

Battery condition poor known good battery. Inspect
(page 18.7)
Charging System (Chapter 16.)
Battery condition good
Perform starter current draw Lower than normal cranking speed

(page 18.18) and lower than normal amp draw
Lower than normal cranking speed Internal starter problem. Remove starter
and high amp draw and inspect.
Perform positive side voltage Voltage drop above Correct problem &
drop. (page 18.13) allowable retest amp draw
Voltage drop within allowable
Perform negative side voltage Voltage drop above Correct problem &
drop. (page 18.16) allowable retest amp draw
Volt drop within allowable
Internal starter problem:

bearings, bushings, shorted Internal starter problem found.
windings, poor brush contact, Rebuild/replace starter motor.
etc. Remove starter & inspect retest amp draw
No internal starter problems found
Carbon build-up in combustion chamber

Engine compression excessive Incorrect valve timing
or internal engine problems Incorrect ignition timing
not allowing parts to rotate freely Internal engine problem
See Engine, Ignition, or Maintenance
chapter
NOTE: Diagnostics require a Digital Multi Meter with a high current shunt or an inductive ammeter clamp.
TROUBLESHOOTING CHART 3
Symptom Possible Cause Possible Reason and/or Inspection
Needed
Starter motor turns, but engine Starter clutch malfunction. Refer To Procedure Chapter 9.
does not turn. The starter motor can Starter torque limit clutch slipping. Refer To Procedure Chapter 9.
be heard spinning. Starter gears damage. Refer To Procedure Chapter 9.
18.6
ELECTRIC STARTER
BATTERY INSPECTION & CHARGING CIRCUIT & SWITCH TESTING

PROCEDURES
STARTER RELAY GROUND BYPASS CIRCUIT
1. Refer to Chapter 16. TEST
BATTERY LOAD TEST
WARNING
1. Load test battery using a commercially available
battery load tester. Follow the battery load tester Verify that motorcycle is secure and that
manufacturer instructions. transmission is in neutral for the following
NOTE: Although not as conclusive, the following inspection.
test can be used to direct troubleshooting efforts if a
battery load tester is not readily available.
2. Charge battery until open circuit voltage is above 12.5

Vdc (page 18.7).
3. Install battery and connect battery cables.
A
4. Connect digital multimeter to battery and keep it
connected for duration of test.
5. Turn ignition key on and move head light high beam
switch to High Beam for 1 minute (without the engine
running).
1. Shift transmission to Neutral.

NOTE: Shifting transmission to neutral or pulling in
the clutch lever provides a ground path for the starter
relay. This test will temporarily bypass these
components. Refer to Starter Circuit Diagram on
page 18.4.
2. Back-probe the Blue / Yellow wire (A) at the solenoid
V DC > 10.5 after connector (shown disconnected) and connect it to a
1 minute ground (Solenoid connector must remain assembled).
3. Turn ignition switch ON and place engine stop switch
in RUN position.
6. Turn ignition off. Measure battery voltage.
4. Press starter button. If starter motor turns, inspect
7. If battery voltage drops below 10.5 Vdc, re-charge and clutch switch (page 18.9) and gear position switch
re-test battery or replace it. page 18.8).
5. If starter motor does not turn, inspect button by
performing the STARTER RELAY POSITIVE
CIRCUIT TEST on 18.11.
18
18.7
ELECTRIC STARTER
NEUTRAL SWITCH BYPASS TEST 5. If the neutral lamp comes on, the gear position switch
or wiring between connector and switch is at fault.
The symptom of a faulty neutral switch circuit is: Continue to Step 6 to test the gear position switch.
• Starter motor will not operate when transmission is 6. Set meter to measure resistance.
in neutral with clutch lever released. 7. Place one meter lead on Black/Pink wire on switch side
of connector.
• Starter will operate when clutch is pulled in.
1. Turn ignition switch on and place engine stop switch
in the RUN position.
2. Shift transmission into Neutral. B
3. Observe neutral indicator light.
4. If indicator is not working with transmission in neutral:
• Disconnect neutral / gear indicator switch (B).

NOTE: 2008-2009 models: When gear position switch
is disconnected, symbol “N” appears on information
display regardless of gear position (with Key ON).
• Connect Black/Pink of harness side connector pin

to ground on engine (not switch side of connector) 8. Connect the other lead to engine ground.
with a jumper lead. This provides a path to ground
for the neutral light. 9. Compare reading to Table 1 below.
10. Replace neutral switch or repair wiring as necessary.
11. If neutral switch is working correctly and neutral
indicator did not light with the harness wire grounded,
inspect neutral lamp circuit wiring and connectors for
B
an open circuit.
If switch is faulty, refer to Gear Position Switch Removal /
Installation (page 19.16).
TABLE 1 - TESTING NEUTRAL PORTION OF GEAR POSITION SWITCH
Gear Position Meter Probe # 1 Meter Probe # 2 Ohmmeter Reading*
Neutral Black/Pink Crankcase (ground) < .5 

(switch side of connector)
Any Gear - Other Than Black/Pink Crankcase (ground) OL

Neutral (switch side of connector)
* Be sure to subtract meter probe resistance from resistance reading
18.8
ELECTRIC STARTER
CLUTCH SWITCH / CIRCUIT TEST 7. If clutch switch does not test as described, inspect
clutch switch, clutch switch wiring or mounting of
Refer to Starter Circuit Diagram on page 18.4. switch to clutch lever for faults.
8. Disconnect switch wiring connector at handlebar.
Symptom of a faulty clutch switch circuit:
• Starter motor will not operate with transmission in
gear and clutch lever pulled in. Starter operates
with transmission in neutral.
Use an ohmmeter to determine if continuity is present
when the switch is closed (lever pulled in).
1. Transmission can be in neutral or in any gear.
2. Separate the 2 pin connector (A) from starter solenoid.
3. Set meter to measure ohms ().
4. Connect red (+) lead of DMM to Blue/Yellow wire in
connector on harness side using a test probe (A) from
Victory Connector Test Kit PV-43526. 9. Connect ohmmeter across the outer 2 terminals of
clutch switch:
5. Connect black meter lead to battery negative post or
ground. • Test for continuity when clutch lever is pulled to
handlebar.
6. Operate clutch lever while observing meter display:
• Pull clutch lever to the handlebar. Meter should • Test for high resistance with lever released.
display continuity or very low resistance (less than
1 ohm) when the clutch switch closes.
• Release clutch lever, meter should display a higher

resistance in the range of 2K - 9K (2000 - 9000). 10. If switch tests correctly at connector, check circuit
between clutch lever switch and starter relay, including
the LH bar switch connector.
11. If switch fails test, inspect mounting of switch.
12. If switch is mounted correctly and physically operates
but does not open and close electrically, replace switch.
A 18
18.9
ELECTRIC STARTER
CLUTCH SWITCH REMOVAL 2. Connect one clamp of a heavy-duty, automotive

1. Disconnect wire harness at the switch (B). remote starter switch to positive terminal lug at starter
2. Remove retaining screw (C). Pull clutch lever and motor.
secure it to the handlebar. Remove switch.
2 pin connector
Starter
B Relay
C 1 Nm (9 lb-in)
CLUTCH SWITCH INSTALLATION

1. Pull clutch lever and secure to handlebar.
2. Install switch and retaining screw. Torque to
Remote Starter Switch
specification.
3. Connect wire harness.
3. Connect other clamp of remote starter switch to
4. Release clutch handle. positive terminal of battery.
5. Verify proper operation.
WARNING
Do not allow any part of the jumper cable clamp to
STARTER RELAY TO STARTER MOTOR touch the chassis or any other ground. Be sure
POSITIVE CABLE BYPASS TEST transmission is in neutral.
4. Make sure transmission is in neutral, key switch off and

WARNING stop switch off.
5. Pull in clutch lever and depress the remote starter
Secure motorcycle and place transmission in
switch momentarily.
neutral for the following test.
6. If starter turns, there is excessive resistance in the
positive, high current side of the starter system. Go to
WARNING Positive Side Voltage Drop Test.
The following test involves high current, heat and 7. If starter does not turn, go to Negative Cable Bypass
possible sparks. Wear a face shield and approved Test.
safety glasses while doing the following test.
1. Place the transmission in neutral.
18.10
ELECTRIC STARTER
STARTER RELAY POSITIVE CIRCUIT TEST STARTER RELAY BYPASS TEST
WARNING WARNING
Secure motorcycle and place transmission in Secure motorcycle and place transmission in
neutral for the following test. neutral for the following test. Be sure the
transmission is in neutral!
Refer to Starter Circuit Diagram on page 18.4.
1. Place the transmission in neutral. WARNING

2. Remove electrical cover. The following test involves high current, heat and
3. Separate connector at starter relay. possible sparks. Wear a face shield and approved
safety glasses while doing the following test. Only
4. Set DMM to DC Volts. use the tool recommended to prevent excessive
5. Check battery voltage by testing across battery heat and possible burns.
terminals. Voltage reading should be at or above 12.5
Vdc.
6. Connect red (+) lead of DMM to the Yellow / White wire
of the starter relay wiring harness connector (A) using
a test probe from Victory Connector Test Kit PV 43526.
2. Remove the electrical cover to access the solenoid on

the back of the battery box.
7. Connect DMM black lead to battery negative post.
3. Connect one lead of a remote starter switch to one of
8. Turn ignition key ON and Engine Stop Switch to RUN the main battery terminal posts on the relay and the
position. other lead to the other main terminal post on the relay.
9. Press starter button. The meter should display battery
voltage. If voltage is more than .2 volts below battery CAUTION
voltage, inspect the power supply circuit.
Do not allow the metal clips of the remote starter relay
10. If no voltage is present on the wire, check for power on switch to touch each other and short out.
pin 3 of the right handlebar switch connector (located
under the console in front of the handlebars). 4. Depress button on remote starter switch.
11. If power is present on the BK/R wire (pin 3) press the 5. If starter motor operates, and the Positive Circuit Test, 18
start button to determine if power is supplied to the Clutch Switch Test, and Neutral Switch Test have
Y/W wire. Check for good continuity through the start passed inspection, replace the relay.
button (pin 3 to pin 4 on the switch side connector) and
for good continuity from switch to starter relay 6. If the starter motor does not operate, inspect cables by
connector on the Y/W wire. performing tests on following pages.
18.11
ELECTRIC STARTER
STARTER RELAY TO STARTER MOTOR 3. Connect other clamp of remote starter switch to
POSITIVE CABLE BYPASS TEST positive terminal of battery.
WARNING
WARNING
Do not allow any part of the jumper cable clamp to
Secure motorcycle and place transmission in touch the chassis or any other ground. Be sure
neutral for the following test. transmission is in neutral.
4. Make sure transmission is in neutral, key switch off and

WARNING stop switch off.
The following test involves high current, heat and 5. Pull in clutch lever and depress the remote starter
possible sparks. Wear a face shield and approved switch momentarily.
safety glasses while doing the following test.
6. If starter turns, there is excessive resistance in the
positive, high current side of the starter system. Go to
Positive Side Voltage Drop Test.
7. If starter does not turn, go to Negative Cable Bypass
Test.
2 pin connector
Starter
Relay
2. Connect one clamp of a heavy-duty, automotive

remote starter switch to positive terminal lug at starter
motor.
18.12
ELECTRIC STARTER
POSITIVE SIDE VOLTAGE DROP TEST 1. Remove spark plug caps.
Symptoms: Starter motor does not turn or turns slowly 2. Install test spark plugs or plugs with the gap CLOSED
when starter relay is bypassed. Starter motor works into plug caps.
correctly when performing Starter Relay Positive Cable 3. Ground spark plug center electrode to engine.
Bypass Test.
NOTE: *The total voltage drop between the battery (+)
and starter motor must not exceed 0.3 Vdc (300 mV).
CAUTION
The ignition system must be disabled when doing
voltage drop tests, if engine starts it will be difficult to
measure voltage drop. To disable ignition system
quickly and safely, observe the following steps.
POSITIVE SIDE VOLTAGE DROP TESTS

Location Allowable Voltage Drop
Battery (+) To Starter (+) 0.3 Vdc (300 mV)
Battery (+) to Battery Side of Relay 0.2 Vdc (200 mV)*
Across Relay 0.2 Vdc (200 mV)*
Starter (+) to Starter Side of Relay 0.2 Vdc (200 mV)*
CAUTION
Only operate starter long enough to stabilize the reading on the DMM (less than 10 seconds). Let starter motor cool
down between each voltage drop test to prevent damage to starter motor.
4. Place transmission in neutral. 7. Place the other lead of the DMM to starter motor
positive terminal screw.
2 pin connector
8. Turn ignition switch on, turn engine stop switch to run
Starter position. Pull in clutch lever.
9. Operate the starter normally (no jumper cables in

place) and observe meter display.
Relay
10. If DMM reads more than 0.3 Vdc (300 mV DC) when
the starter motor is engaged, it indicates that there is
excessive resistance in the starter’s battery positive
path. Continue with the following tests to isolate each
section of the positive path and observe the voltage
drop with DMM leads placed as indicated.
(Cont.)
18
5. Set DMM to DC Volts.
6. Place one lead of DMM to positive battery post.
18.13
ELECTRIC STARTER
11. Place one lead of DMM to positive battery post. Ensure 19. If corrosion is found, wash all connections with a
DMM is set to read DC Volts. solution of baking soda and water, wire brush all
contact areas, apply a light film of dielectric grease to
the hardware and tighten connections. Retest to verify
problem has been corrected.
2 pin connector
Starter
2 pin connector
Starter
Relay
Relay
12. Place other lead of DMM to relay terminal leading to

battery.
13. Engage starter and observe meter display, it should
read less than 0.2 Vdc (200 mV DC). 20. Place one lead of DMM to battery side of relay. Reset
DMM to read DC Volts if necessary.
14. If voltage drop is observed, the cable, connection at the
battery or connection at the relay is causing resistance 21. Place other lead to starter motor side of relay.
and must be corrected. 22. Engage starter and observe meter display; it should
15. Inspect cable ends for corrosion where cable is read less than 0.2 Vdc (200 mV DC).
connected to terminal lugs. 23. If voltage drop is observed, remove cables and clean
16. Remove cable. Set the DMM to read Ohms. cable terminals and relay terminals. Reattach cables.
Retest voltage drop.
17. Place DMM leads at both ends of the cable and
measure the cable’s resistance. The resistance should 24. If voltage drop is still observed through the relay,
be 0 ohms. Replace cable if necessary. replace relay.
18. Inspect battery post, battery cable lug and relay lug for (Cont.)
corrosion or looseness.
NOTE: Corrosion has resistance that limits or stops the
flow of current to the starter motor.
18.14
ELECTRIC STARTER
25. Place one lead of DMM to starter motor side of relay. NEGATIVE CABLE BYPASS TEST
Ensure DMM is set to read Volts DC.
1. Place transmission in neutral.
Starter 2 pin connector Starter 2 pin connector
Relay
Relay
Jumper Cable
Starter Motor Case
26. Place other lead of DMM to starter motor positive 2. Remove electrical cover.
terminal.
3. Connect one clamp of an automotive type jumper cable
27. Engage starter and observe meter display. (heavy gauge jumper cable) to battery negative post.
28. If voltage drop is observed, cable connection at relay 4. Connect other end of jumper cable to a good ground
or connection at starter motor is causing resistance location on starter motor body.
and must be corrected.
5. Make sure transmission is in neutral. Turn ignition key
29. Inspect cable ends for corrosion where cable is and stop switch on. Pull clutch lever in and attempt to
connected to terminal lugs. start motorcycle.
30. Remove cable. Set DMM to read Ohms. 6. If starter motor turns, there is excessive resistance in
31. Place DMM leads at both ends of cable and measure the negative, high current side of the starter system.
cable resistance. The resistance should be 0 ohms. Perform Negative Side Voltage Drop Test.
Replace cable if necessary. Remember to subtract test 7. If starter does not turn and all troubleshooting steps
lead resistance. have led to this test, replace starter motor.
32. Inspect starter cable lug and relay lug for corrosion or
looseness.
33. If corrosion is found, wash all connections with a
solution of baking soda and water, wire brush all
hardware and tighten connections. Retest to verify 18
18.15
ELECTRIC STARTER
NEGATIVE SIDE VOLTAGE DROP TEST

NEGATIVE SIDE VOLTAGE DROP TESTS
Location Allowable Voltage Drop
Battery (-) To Starter Body (-) 0.3 Volts DC (300 mV)
Battery (-) to Battery Cable Ground Connection At Engine 0.2 Volts DC (200 mV)*
Battery Cable Ground Connection To Starter Body (-) 0.2 Volts DC (200 mV)*
NOTE: *The total voltage drop of these two items must 4. Place other lead of DMM to a clean ground on starter
not exceed 0.3 Volts DC (300 mV). motor body.
5. Turn ignition switch ON and engine stop switch to RUN
CAUTION position. Pull clutch lever in.
Only operate the starter long enough to stabilize the 6. Operate starter normally (no jumper cables in place)
reading on the DMM (less than 10 seconds running time). and observe meter display.
Let starter motor cool down between each voltage drop 7. If DMM reads more than 0.3 Volts DC when starter
tests to prevent damage to starter motor. motor is engaged, it indicates that there is excessive
resistance in the starter’s battery negative path.
Disable the ignition system so engine will not start during Continue with the following tests to isolate each section
this test. of the negative path and observe the voltage drop with
• Remove spark plug caps. DMM leads placed as indicated.
8. Place one lead of the DMM to the negative battery post.
• Install test spark plugs or plugs with the gap closed Ensure that the DMM is set to read DC Volts.
into plug caps.
9. Place the other lead of the DMM to the battery cable
• Ground center electrode of spark plugs to engine. engine ground connection.
1. Place transmission in neutral. (Cont.)
2 pin connector
Starter
Relay
2. Set DMM to DC Volts.

3. Place one lead of DMM to negative battery post.
18.16
ELECTRIC STARTER
10. Engage the starter and observe the meter display, it 18. Place the other lead on starter motor body.
should read less than 0.2 Volts DC (200 mV DC).
19. Engage the starter and observe the meter display, it
should read less than 0.2 Volts DC (200 mV DC).
20. If voltage drop is observed, there is resistance between
Starter 2 pin connector the battery cable connection at engine and the
mounting surfaces of the starter motor. While this
would be unusual, it is possible.
Relay
Starter 2 pin connector
Relay
Battery Ground Located at rear

left side of engine.
11. If voltage drop is observed, the cable, connection at the

battery, connection at the engine or mounting surface
of the starter motor body is causing resistance and
must be corrected.
12. Inspect the cable ends for corrosion where cable is Battery Ground Located at rear
left side of engine.
connected to battery or engine.
13. Remove the cable. Set the DMM to read Ohms. 21. Remove and clean the connection between ground
battery cable and engine.
14. Place the DMM leads at both ends of the cable and
measure the cable’s resistance. The resistance should 22. Remove the starter and ensure that the starter is
be 0 ohms. Remember to subtract meter lead making firm contact with engine. Ensure that the starter
resistance. Replace the cable if necessary. mounting bolts are tight.
15. Inspect the battery post, battery cable lug and engine 23. If corrosion is found, wash all connections with a
battery cable mount for corrosion or looseness. solution of baking soda and water, wire brush all
16. If corrosion is found, wash all connections with a the hardware and tighten connections. Retest to verify
solution of baking soda and water, wire brush all problem has been corrected.
contact areas, apply a light film of dielectric grease to 18
the hardware and tighten connections. Retest to verify
17. Place one lead of DMM to battery cable mount at
engine. Reset the DMM to read DC Volts if necessary.
18.17
ELECTRIC STARTER
STARTER CURRENT DRAW TEST 4. Set DMM to Volts DC scale and connect red lead of
meter to positive post of battery.
WARNING 5. Connect black lead of meter to negative post of battery.

6. Turn ignition switch on and observe ammeter. It should
Do not allow any part of the jumper cable clamp to register negative amps. If it does not, turn the ammeter
touch the chassis or any other ground. probe around.
7. Make sure ignition switch is on, engine stop switch is
CAUTION in the run position, transmission is in neutral, clutch
lever pulled in and that the ignition system is disabled.
Disable the ignition system so that the engine will not
8. Press starter switch and crank starter for about 5
start during this test. seconds and observe both meters and the tachometer.
Remove spark plug caps. 9. The battery voltage should remain above 9.6 volts.
10. The amperage draw of the starter should not exceed
Install test spark plugs into plug caps. 130 amps. See page 18.18 for Starter Current Draw
chart.
Ground spark plugs against engine.
1. Inspect the battery (see procedure). Charge or

replace battery as necessary before proceeding.
2. Place transmission in neutral.
3. Position an inductive ammeter clamp on battery
positive cable.
Starter
< 130 amps
18.18
ELECTRIC STARTER
STARTER CURRENT DRAW RESULTS (Good Battery Condition Verified)

Amperage Draw Battery Voltage Engine RPM Possible Problem
90 to 120 amps 9.6 Volts DC or Greater Greater Than 400 rpm Normal
Less Than 90 amps 9.6 Volts DC or Greater Less Than 400 rpm Internal starter problems
Greater Than 130 amps Less Than 9.6 Volts DC Less Than 400 rpm Inspect for voltage drops on
positive or negative side of starter
circuit.
Greater Than 130 amps Less Than 9.6 Volts DC Less Than 400 rpm Voltage drops within acceptable
limits.
Remove starter & inspect.
Greater Than 130 amps Less Than 9.6 Volts DC Less Than 400 rpm Voltage drops within acceptable
limits.
No internal starter problem.
Engine compression is excessive
or internal engine problems not
allowing parts to rotate freely.
STARTER MOTOR REMOVAL STARTER MOTOR INSTALLATION
WARNING WARNING
Ensure that the ignition switch is turned off. Make sure that the ignition switch is turned off and
Remove the negative cable at the battery before that the negative cable is disconnected from the
removing the starter motor. battery before installing the starter.
1. Remove exhaust system. (Refer to Chapter 3) 1. Place starter into the engine case while aligning the
starter mounting lugs as closely as possible during the
2. Remove regulator/rectifier assembly.
installation process.
3. Remove cable from starter terminal.
2. Rotate the starter to align starter mounting lugs with
bolt holes in engine cases.
3. Install starter mounting bolts and tighten to
specification.
30 Nm (22 lb-ft)
4. Connect starter motor cable and cable nut. Torque
cable nut to specification.
6.8 Nm (60 in-lb)
5. Install regulator/rectifier assembly.
10 Nm (85 in-lb)
6. Install exhaust system. Refer to Chapter 3.
4. Place drain pan under starter.
7. Connect negative battery cable.
5. Remove 2 starter motor mounting bolts and remove
starter.
STARTER CLUTCH REMOVAL
18
1. Refer to Chapter 9.
18.19
ELECTRIC STARTER
NOTES
18.20
WIRING / LIGHTING SYSTEMS
CHAPTER 19
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2
FUSE BOX LOCATION / FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2
ABS FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2
PRIMARY HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
HEADLAMP CIRCUIT - LOW BEAM (2008-2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4
HEADLAMP CIRCUIT - HIGH BEAM (2008-2010). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5
HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010) . . . . . . . . . 19.6
TURN SIGNAL SYSTEM (2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
TURN SIGNAL SYSTEM WIRING DIAGRAM (2008) . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
TURN SIGNAL AUTO CANCEL MODULE OVERVIEW (2008) . . . . . . . . . . . . . . . . . . . 19.8
AUTO CANCEL TURN SIGNAL SYSTEM SELF-DIAGNOSTICS - 2008 . . . . . . . . . . . 19.9
TURN SIGNAL DIAGNOSTIC BLINK CODES - 2008 . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
TURN SIGNAL SYSTEM (2009-2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.11
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.13
SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.14
CRUISE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.17
OPERATION OVERVIEW - SETTING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.17
OPERATION OVERVIEW - RESUME / ACCELERATE. . . . . . . . . . . . . . . . . . . . . . . . 19.17
OPERATIONAL OVERVIEW - DECELERATE / CANCEL . . . . . . . . . . . . . . . . . . . . . . 19.17
CRUISE CONTROL DIAGNOSTIC BLINK CODES (OVERVIEW) . . . . . . . . . . . . . . . 19.18
CRUISE CONTROL DISENGAGE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.18
CRUISE MODULE INPUT / OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.18
CRUISE CONTROL SWITCH DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.19
CRUISE CONTROL CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.20
CRUISE CONTROL CABLE “LASH LEARN” PROCEDURE . . . . . . . . . . . . . . . . . . . . 19.21
HORN RELAY CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.23
WINDSHIELD / TRUNK LAMP CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.24
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.25
SYSTEM DIAGRAM (2008 - 2010). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.25
INSTRUMENT CLUSTER 24 PIN CONNECTOR INPUT / OUTPUT (2008-2009) . . . 19.26
INSTRUMENT CLUSTER 24 PIN CONNECTOR INPUT / OUTPUT (2010) . . . . . . . . 19.27
HEATERS (SEAT / HANDGRIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.28
CONSOLE SWITCH WIRE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.29
TIPOVER SENSOR (2009-2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.30
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.31
AUDIO SYSTEMS CONTROL SWITCH ON-BOARD DIAGNOSTICS . . . . . . . . . . . . 19.33
NAVIGATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.35
GPS NAVIGATION & NAV MP3 PLAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.35
AUDIO SYSTEM REPROGRAMMING (AUXILIARY CONTROLLER REFLASH) . . . . 19.36
REVERSE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.39
WIRING DIAGRAM / REVERSE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.39
REVERSE SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.40-19.41
REVERSE SYSTEM SAFETY & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.42
REVERSE MODULE / FUSE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.42
TACHOMETER SIGNAL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.43
GROUND LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.44
WIRE HARNESS VIEWS, ELECTRICAL CONNECTOR LOCATION. . . . . . . . . 19.45-19.47
19
19.1
FUSES FUSE REPLACEMENT

FUSE BOX LOCATION To access relays and fuses:
There are two fuse boxes under the windshield access
panel. Remove the panel to access fuses, auto-reset circuit 1. Remove windshield access panel (page 3.6).
breakers, and relays. Use a fuse puller to remove a fuse if
necessary. 2. Push center pin of each dart upward and remove darts
and cover panel(s).
LEFT FUSE BOX (DECAL PN 7174111) 2008-2010
3. Pull tabs away from cover(s) to release.
IGNITION
10A HEADLIGHT
HORN SECONDARY LIGHTS
POWER
RELAY RELAY 4. Refer to label on cover for fuse application and rating.
HEADLIGHT RELAY
20A
GAUGES RADIO HORN

5A 25A 20A
TURN SIGNAL/BRAKE
SECONDARY RELAY
SPARE TS/BRAKE
LIGHTS
FUSE 20A
20A
RIGHT FUSE BOX (DECAL PN 7174112) 2008
FUEL PUMP/
FOG LIGHTS ENGINE CHASSIS ELECTRICAL
IGNITION COIL
RELAY RELAY RELAY
RELAY
Right Fuse Box Left Fuse Box
SPARE ENGINE FP/IGN COIL
FUSE 15A 15A
HEADLIGHT CONTROL
RELAY
SPARE WINDSHIELD CHASSIS
FUSE 20A 20A
RIGHT FUSE BOX (DECAL PN 7175380) 2009

ABS FUSE
ABS fuses (A) are located under the windshield access
panel (if equipped). The ABS warning lamp will stay on if
fuses are removed or open (blown). ABS system
information begins on page 15.32.
19.2
PRIMARY HEADLIGHTS
ASSEMBLY VIEW
HID WIRING HARNESS CONNECTOR
HID BALLAST MODULE
6.1 Nm (54 lb-in)
RUBBER BOOT
2.7 Nm (24 lb-in) HALOGEN BULB
COCKPIT SUB-FRAME
TAB
HID WIRING HARNESS CONNECTOR
HID DRIVING LAMP BULB

2.7 Nm (24 lb-in)
HALOGEN DRIVING LAMP BULB
19
19
19.3
HEADLIGHT CIRCUIT - LOW BEAM (2008-2010)
The starter button must be pressed to power the headlight circuit on 2009-2010 models.
See “HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010)” on page 19.6 for operation of the
power and control relay.
2008 ONLY
19.4
HEADLIGHT CIRCUIT - HIGH BEAM (2008-2010)

The starter button must be pressed to power the headlight circuit on 2009-2010 models.
See “HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010)” on page 19.6 for operation of the
power and control relay.
2008 ONLY
19
19
19.5
HEADLIGHT POWER AND CONTROL RELAY OPERATION (2009-2010)
Starter
Solenoid
B
A
2009-2010 Models - The starter button must be pressed to power the headlight circuit.
When the starter button is pressed, the pull-in coil of the Headlight Control Relay stays energized
by the output current (A).
The diode (B) prevents current back flow through the starter solenoid circuit when the relay is energized.
19.6
TURN SIGNAL SYSTEM (2008)

TURN SIGNAL SYSTEM WIRING DIAGRAM (2008)
Auto Cancel Module
19
19
19.7
TURN SIGNAL AUTO CANCEL MODULE OVERVIEW (2008)
AUTO CANCEL MODULE INPUT / OUTPUT - 2008

Pin Overview of Operation
Function / Name Wire Color
Number (See page 19.12 for 2009-2010 module)
1 Switched Power Y / VIO Switched battery voltage supplied by turn signal / brake relay.
Brake Input Power When the front or rear brake is applied, the module receives power on this wire
2 W / PINK
(+12Vdc) from the brake switch(es).
Supplies power to rear RH turn signal relay. Module powers relay
whenever the left or right turn signals are activated. When the relay is
3 RH Turn Relay BLUE / BRN powered, the rear middle marker lamp ground circuits are opened and
the marker lamps turn off. This action visually separates the upper turn
signal lamp from the bottom brake lamp.
ECM Protection Diode
4 Violet +12Vdc side of ECM Protection Diode. Prevents voltage spikes to ECM.
Input
ECM Protection Diode
5 VIO / WHITE “Negative” side of ECM Protection Diode. Prevents voltage spikes to ECM.
Output
Grounded when clutch lever switch is closed so engine can be stared in gear
6 Neutral Light Diode Input BLUE /YEL when lever is pulled in. Diode prevents neutral light from illuminating when
clutch lever is pulled in with transmission in gear.
7 Neutral Light Diode Output BK / PINK Ground path through neutral light switch when transmission is in neutral.
Module sends power to the right turn signals on this wire when RIGHT turn is
8 Right Turn Signal Output BLUE / RED selected (module pin 14 receives a ground from the turn signal switch) or when
HAZARD switch is on (module pin 12 grounded by hazard switch).
9 Switched Power Y/VIO Switched battery voltage supplied by turn signal / brake relay.
Supplies power to rear LH turn signal relay. Module powers relay
whenever the left or right turn signals are activated. When the relay is
10 LH Turn Relay BLUE / VIO powered, the rear middle marker lamp ground circuits are opened and
the marker lamps turn off. This action visually separates the upper turn
signal lamp from the bottom brake lamp.
0-1700 Hz Square Wave, 0-12Vdc received from speed sensor for vehicle
11 Speed Sensor Input GRN / BLU
speed / cancel information.
This wire is grounded through the hazard switch when the switch is closed, and
12 Hazard Switch Input BLU / WHT
the module flashes all turn signals (through pin 8 and pin 15).
Left Turn Signal Switch This wire is grounded when the left turn signal switch is closed (left turn
13 VIO / BLU
Input selected). The module flashes LH signals through pin 15.
Right Turn Signal Switch This wire is grounded when the right turn signal switch is closed (right turn
14 VIO / RED
Input selected). The module flashes RH signals through pin 8.
Module sends power to the left turn signals on this wire when LEFT turn is
15 Left Turn Signal Output BLUE selected (module pin 13 receives a ground from the turn signal switch) or when
HAZARD switch is on (module pin 12 grounded by hazard switch).
16 Module Ground BLK / WHT Grounds the module.
NOTE: When the turn signal manual cancel button is pushed, both left and right turn signal inputs (Pins 13 and 14 of
the module) are grounded at the same time. The module cancels output on pin 13 and 14 when a cancel command is
received.
19.8
AUTO CANCEL TURN SIGNAL SYSTEM Turn Signal Switch Mode:

SELF-DIAGNOSTICS - 2008 5. Perform Steps 1-4 to enter the diagnostic mode.
The auto cancel module on 2008 models (located under 6. When codes are blinking on rear turn signals, turn the
the console) contains a self-diagnostic feature. The self- hazard switch OFF. The system will finish the code
diagnostics can be activated to run a test of the turn display sequence then enter the Turn Signal Switch
signal circuits, turn signal switch (left handlebar switch), diagnostic mode.
and the auto-cancel module power supply.
Turn Signal Switch Tests:
To enter the diagnostic mode: 7. Move the turn signal switch to the LEFT TURN position
1. Turn ignition key OFF. and HOLD. Both left turn signal lamps should light.
2. Turn hazard switch ON. 8. Move the turn signal switch to the RIGHT TURN
position and HOLD. Both right turn signal lamps should
3. Turn ignition key ON. light.
4. Pull and release the front brake lever (or rear brake 9. Push the switch in to the CANCEL position. All 4 turn
pedal) 3 times within a 3 second period to enable the signal lamps should light, indicating the cancel switch
diagnostic mode. is working properly.
• All 4 turn signal bulbs will illuminate for 1 second and
then go out, to indicate the diagnostic mode has been
enabled. (Only bulbs in working order will illuminate)
• The “blink codes” now start flashing on the rear turn
signal bulbs.
Notes about the blink codes:

• Refer to the chart on page page 19.10 for a list of
codes and what they mean.
• Code 12 will always be present; alone if there are no
faults in the system, or with other codes following if
there is a fault. Code 12 marks the beginning of the
code display sequence.
• There is a 2 second pause between blinked codes.
• Each code will blink twice before the next code is
displayed. Example: If a code 13 is present, the
indicator lamp will flash code 12 (1 long pulse, then 2
short), then repeat the code 12, then code 13, and
repeat code 13.
• The blink codes will flash until cancelled by turning
the key OFF or by turning the hazard switch OFF.
Turning the hazard switch OFF before turning the key
OFF will change the diagnostic mode to the next level,
which is “Turn Signal Switch” diagnostic mode.
19
19
19.9
TURN SIGNAL DIAGNOSTIC BLINK CODES - 2008
BLINK CODE EXAMPLES

One long pulse then two short pulses 2 second
pause
12 on
off
Time
One long pulse then three short pulses
13
on
off
Time
BLINK CODE TABLE
NOTE: Fault codes (13 and above) will only appear when actually present. A separate “code clearing” operation is not required.
When a problem is corrected, the code will not be displayed when the sequence repeats.
CODE Code Description / Possible Cause Diagnostic Steps
12 Self Check Complete Normal - always displayed as first code
13 Left Hand Circuit Over-Current To determine if front or rear left signal circuit is at fault: 1) Remove
Possible Causes: seat. 2) Disconnect rear wire harness 8-pin connector. 3) If code
Shorted bulb (filament has shorted across filament 13 is no longer displayed, cause of overcurrent is in rear left signal
posts) Action: replace bulb. unit or circuit. If code 13 remains, fault is in front left signal unit or
Short to ground at socket or in related wiring. System circuit. IMPORTANT: The system will now detect undercurrent
will interrupt power to the shorted circuit. Left side due to the open rear connector, and display code 14 and code 16.
bulbs will not be illuminated. These codes will disappear after rear harness is re-connected.
Action: Determine front or rear. Inspect wiring.
14 Left Hand Circuit Under Current (Open Bulb, No Inspect / replace bulb; inspect socket or connections to bulb that
Bulb, faulty connection, etc.) is not lit.
15 Right Hand Circuit Over-Current To determine if front or rear right signal circuit is at fault: 1)
Possible Causes: Remove seat. 2) Disconnect rear wire harness 8-pin connector.
Shorted bulb (filament has shorted across filament 3) If code 15 is no longer displayed, cause of overcurrent is in rear
posts) Action: replace bulb. right signal unit or circuit. If code 15 remains, fault is in front right
Short to ground at socket or in related wiring. System signal unit or circuit. IMPORTANT: The system will now detect
will interrupt power to the shorted circuit. Right side undercurrent due to the open rear connector, and display codes
bulbs will not be illuminated. 14 and 16. These codes will disappear after rear harness is re-
Action: Determine front or rear. Inspect wiring. connected.
16 Right Hand Circuit Under Current (Open Bulb, No Inspect / replace bulb; inspect socket or connections to bulb that
Bulb, faulty connection, etc.) is not lit.
17 Low Module Voltage Check for battery voltage to module (Pin 9, Violet)
(Must be >12 VDC)
18, 19, & 20 Not Used N/A
19.10
TURN SIGNAL SYSTEM (2009-2010)

TURN SIGNAL SYSTEM DIAGRAM (2009-2010)
Under LH Side
Cover
Flasher Module (auto cancel

is controlled by ECM) 19
19
19.11
TURN SIGNAL FLASHER MODULE (2009-2010)

On 2009-2010 models, auto-cancel turn signal functions are performed in the ECM, not in the Auto Cancel Module as
on 2008 models. The 12 pin module (was 16 pin on 2008) is used to flash the turn signal and hazard circuits, and also
contains clutch circuit and ECM protection diodes (see wiring diagram). The flasher module is located under the console.
2009-2010 FLASHER MODULE INPUT / OUTPUT

Pin
Function / Name Wire Color Overview of Operation
Number
Turn Signal Indicator
1 - (This pin not used)
Light Output
Switched Power Input
2 VIOLET +12Vdc From turn signal / brake relay. Supplies battery voltage to module.
(+12Vdc)
BLACK / From Pin 14 of ECM. (Through Pin 15 of Chassis-to-Engine Harness
3 Left Turn Input
BLUE Connector).
BLACK / From Pin 15 of ECM. (Through Pin 16 of Chassis-to-Engine Harness
4 Right Turn Input
RED Connector).
BLACK /
5 Ground Flasher Module Ground.
WHITE
BLUE / This wire is grounded through the hazard switch when the switch is closed, and
6 Hazard Switch Input
WHITE the module flashes all turn signals (module outputs 12V to Pin 7 and Pin 12).
Flasher Module sends power to right turn signals on this wire when it receives
7 Right Turn Signal Output BLUE / RED
RH turn signal (ground) input from ECM on Pin 4 (BK/R).
8 Engine Diode Anode VIOLET “Negative” side of ECM Protection Diode. Prevents voltage spikes to ECM.
Engine Diode VIOLET /

9 +12VDC side of ECM Protection Diode. Prevents voltage spikes to ECM.
Cathode WHITE
Grounded when clutch lever switch is closed so engine can be started in gear
Neutral Light Diode BLUE /
10 when lever is pulled in. Diode prevents Neutral light from illuminating when
Anode YELLOW
clutch lever is pulled in with transmission in gear.
Neutral Light Diode BLACK /
11 Ground path through neutral light switch when transmission is in neutral.
Cathode PINK
Flasher Module sends power to left turn signals on this wire when it receives LH
12 Left Turn Signal Output BLUE
turn signal input (ground) from ECM on Pin 3 (BK/BU).
Flasher Module
19.12
SPEEDOMETER
SPEEDOMETER
Speedometer Troubleshooting Flowchart
No Speed Perform Speed Sensor Test Replace

Indication below (see page 19.21) Is Sensor OK? NO Speed
Sensor
YES
Check wiring (continuity) & connectors

between ECM PIN 42, the Cruise
Control Module, and the Speed Sensor
connector
YES
Test constant power (on Pin 1) and

(at Pin 2) of speedometer connector
Replace
Test constant power supply and Power at speedo.
switched power supply wiring NO YES
speedo? Document
mileage.
SPEED SENSOR TEST

The speed sensor can be tested using the Cruise Control System Switch Diagnostics (page 19.19). You must perform
the entire test in proper sequence to complete the speed sensor portion (Test 5).
NOTE: The signal from the speed sensor is supplied to the ECM on Pin 42, and distributed or used by the
ECM to operate the speedometer, the cruise control module, and the auto cancel feature of the turn signal
system. If any one of these components is functioning properly (for example, the speedometer works, the
turn signals cancel normally, or the cruise control will accept a set speed) then the speed sensor itself is
functional and supplying a signal to the ECM. Diagnostics should be focused on the non functional circuit,
not on the speed sensor itself.
19
19
19.13
SWITCH TESTING
REAR BRAKE LIGHT SWITCH TEST FRONT BRAKE LIGHT SWITCH TEST
1. Remove electrical cover. 1. Disconnect wires (B) from switch.
2. Connect ohmmeter to switch contacts and test for good
continuity through switch when front brake is applied.
SPECIFICATION: Continuity When Brake Applied
2. Disconnect the rear brake light switch wires (A). The

switch is located just below the starter solenoid.
3. Connect ohmmeter to switch contacts and test for good

continuity through switch when rear brake is applied.
SPECIFICATION: Continuity When Brake Applied
Rear brake
B Front brake hydraulic
micro switch pressure
located on front switch
brake lever perch located above oil filter
19.14
CLUTCH SWITCH TESTING 4. Perform the resistance tests in the table below and
compare results.
1. Refer to page 18.9 to test the clutch switch and circuit.
5. 2008-2009: Ground path for the switch is through the
GEAR POSITION SWITCH TESTING shift drum detent roller. Wait for the reading to stabilize
before recording the resistance in each gear. It may be
1. Refer to bench testing (page 19.16) if switch is necessary to shift multiple times into and out of the
removed. gear being tested in order to get a stable resistance
2. Remove side covers (page 3.27). reading.
3. Disconnect gear position switch 2 pin connector. 2010: Ground path is through switch to ground wire
and then the case.
BN BK/Y
View from open

end of connector
TABLE 1 - TESTING NEUTRAL SIDE OF GEAR POSITION SWITCH (Switch Installed)

Gear Meter lead connections Ohmmeter Reading*
(switch side of unplugged connector)
RED LEAD (+) BLACK LEAD (-) +/- 20%
Neutral Brown < 1.0 
Crankcase (Ground)
Any gear (except Neutral) Brown  (OL or “overload”)
* Subtract meter lead resistance from result
TABLE 2 - TESTING GEAR INDICATOR SIDE OF GEAR POSITION SWITCH (Switch Installed)
Gear Meter lead connections Resistance: Resistance:
(switch side of unplugged connector) 2008-2009 Models 2010 Models
RED LEAD (+) BLACK LEAD (-) +/- 10% +/- 10%
1ST 330  470 
Neutral  (or “OL”) DIODE CHECK function.
Continuity one way and no
continuity with leads reversed.
2ND 825  1750  (1.75 K

Black / Yellow Crankcase Ground
3RD 1500 1.5 K 2860  (2.86 K
4TH 2740 2.74 K 4710  (4.71 K
5TH 6810 6.81 K 7242  (7.24 K
19
19
6TH 15,000 15.0 K 13,950  (13.95 K
19.15
GEAR POSITION SWITCH REMOVAL 8. 2008-2009: Test the ground path between the spring
hole in the shift drum and engine ground (to a good
Removal / Bench Test ground on crankcase. Resistance should be less than
one Ohm. Ground path is through shift drum to shift
1. Remove mufflers (page 3.47).
star and detent roller to crankcase ground.
2. Loosen head pipes (page 3.48) and move outward
2010: Ground path is through center switch contact to
until drive sprocket cover can be removed. Complete
BK wire to crankcase ground.
head pipe removal is not required.
3. Remove switch screws and wire harness clamps.

2008-2009: Black
4. Remove switch.
5. Test each switch contact to the BK/Y wire in the

connector as shown below and compare to resistance
table on page 19.15.
NOTE: On 2010 models, also test the ring terminal (BK
wire) to center contact of switch.
6. If switch resistance is within specified range, inspect 2010: 2 springs and

2 contact plungers
the spring and plunger (Step 7).
BN BK/Y
2010: White
View from open
end of connector
2010: Ground Wire
N 1
2
6 (OD)
3
4 5
Installation
1. Replace sealing O-ring on switch body and lubricate

with a light film of grease.
2010: Test center contact to BK wire
from switch (the ring terminal ground). 2. Clean sealing surface on crankcase.
Resistance = less than 1.0 
3. Install switch.
4. Torque mounting screws to 4.9 Nm (43 lb-in).

7. Remove and inspect each spring and plunger.
5. Install wire harness clamps to crankcase. Torque
mounting screws to 87 lb-in.
19.16
CRUISE CONTROL OPERATION OVERVIEW - RESUME /

ACCELERATE
OPERATION OVERVIEW - SETTING SPEED
Review Cruise Control Safety & Operation in the Rider’s Manual
Resume
before operating the Cruise Control.
To set the cruise control (if equipped):

Right Handlebar
Accelerate Decelerate
RESUME
Pressing the Resume button (RES) will reset the cruise to
On Set the memorized speed after braking or disengaging the
cruise control with either brake, throttle, or clutch.
NOTE: Pressing the cruise control OFF button will
erase the SET speed from memory and disengage the
cruise control.
ACCELERATE
Press and release (tap) the Accelerate (ACC) button to
increase speeds in approximately 1 mph increments.
OFF Press and hold the ACC button to accelerate the vehicle
to a new SET speed until released, or until a maximum
1. Press the ON button to activate Cruise Control. increase of approximately 10 MPH is achieved
2. Accelerate to desired speed and press SET button. (whichever comes first).
This speed will be logged in memory. NOTE: If you use throttle to accelerate and then
3. The CRUISE indicator lamp on the instrument cluster release it, cruise will resume original SET speed.
will illuminate.
OPERATIONAL OVERVIEW - DECELERATE /
CANCEL
DECELERATE
Press and release (tap) the Decelerate (DEC) button to
decrease speeds in approximately 1 mph increments.
Press and hold the DEC button to reduce SET speed to
• Cruise control can be set in any gear. desired speed, then release to enter a new SET speed. If
• The cruise control can be activated between you hold the DEC button, the vehicle continues to
speeds of 25-95 mph (40-153 kph). decelerate to the 25 MPH minimum cruise speed.
• Set speed will vary slightly in hilly terrain. TO CANCEL THE CRUISE CONTROL
• The cruise control will not resume a pre-set speed if the To cancel the cruise control, do one of the following:
resulting accel / decel rate is too high or too low. Example: If • Apply the front or the rear brake or both.
you are in 6th gear and try to resume a set speed from • Close the throttle completely with the twist grip.
40mph, the cruise may disengage. • Pull the clutch lever in.
• Brake lights must be working properly. • Turn the cruise control master switch to OFF.
NOTE: Pressing the OFF button will erase the SET
19
19
4. Push the OFF button to turn the cruise control system
off and erase the memory set speed. speed from memory.
19.17
CRUISE CONTROL DIAGNOSTIC BLINK CRUISE CONTROL DISENGAGE CODES

CODES (OVERVIEW)
FLASH SEQUENCE DESCRIPTION
The eight most recent causes for cruise control 111 Initial state / No dropout
disengage (“drop out”) are stored in the cruise control
112 Throttle grip at zero (throttle cable switch)
module memory. Each cause is assigned a diagnostic
blink code consisting of three primary digits, which can be 113 ON - OFF state (OFF button pressed)
viewed on the instrument cluster by watching the cruise
Cancel Disengage - SET and RESUME buttons
indicator lamp. Each digit is flashed with .25 seconds 121
pushed simultaneously.
between flashes and a 1 second delay between primary
122 Brake Lamps (Brake switch disengage)
digits.
211 Coast (DEC) Disengage
212 Low Speed Inhibit Disengage
1 1 2 213 Hi speed, Low speed, or overspeed disengage

ON
221 Underspeed disengage
222 Hi acceleration / deceleration speed disengage
223 Loss of vehicle speed sensor
231 High RPM Disengage

OFF
1 sec. 1 sec. .25 sec. 232 Loss of RPM signal
EXAMPLE OF FLASH CODE = 112 242 High rate of RPM change detected
Some 300 series codes may be displayed until at

least 8 disengage codes have been logged.
311 (or any 300 code)
Example: A new motorcycle or if a new module
has been installed.
1. With the ignition key in the OFF position, press and
HOLD the SET button.
2. Turn the ignition key to the RUN position. Do not start CRUISE MODULE INPUT / OUTPUT
the engine. Disconnect harness from module. Test Input / Outputs with
a 12V test light or a multimeter and compare to table below.
3. Release the SET button on the cruise control
handlebar switch. The most recent diagnostic code will Cruise Module Wire Harness Connector
begin flashing.
WIRE
PIN CRUISE CONTROL FUNCTION
4. Press and release the resume (RES) button to review COLOR
the code again.
A W / BU ON / OFF (+12 Vdc)
5. To view the next code, press and release the SET B W / OR SET / COAST INPUT (+12 Vdc)
button.
C W / VIO RESUME / ACCEL INPUT (+12 Vdc)
6. When all 8 codes have been displayed, the cruise
D W/R THROTTLE SAFETY SW IN (+12 Vdc)
indicator on the instrument cluster will remain
illuminated. E BK GROUND
7. To exit the diagnostic code lamp flash mode, turn the F LB / PK SWITCHED POWER (+12 Vdc)
ignition key to OFF.
G W / PK STOP LAMP INPUT (+12 Vdc)
ENGINE RPM INPUT (TACH SIGNAL

H GN / W FROM PIN 22 of ECM)
J W / BN IDICATOR LAMP OUTPUT
VEHICLE SPEED INPUT (FROM PIN

K GN / BU 21 ECM - Does speedometer work?)
19.18
CRUISE CONTROL SWITCH DIAGNOSTICS Test 4

(Brake Switch)
The sensors and switches that supply information to the
cruise control module can be tested to verify proper 14. Continuing from Test 3, apply the front or rear brake
operation. lever. The lamp should illuminate.
15. Release the front or rear brake lever and the lamp
NOTE: Test 1 is the only diagnostic test that can be should go out. If the lamp illuminated in Step 1 of this
repeated. Repeating any other test will cause the test, then went out when the lever was released, the
system to exit the diagnostic test mode. brake switch is functioning properly. NOTE: Only one
switch (front or rear) can be tested during one test
Test 1 cycle.
(SET / DEC Button)
16. Apply the front brake lever for 5 seconds. The lamp will
1. Press and hold the cruise control ON and SET illuminate for 5 seconds, then go out.
buttons.
17. Release the brake lever and the lamp should
2. Turn the ignition key to ON, but do not start the engine. illuminate.
The cruise control indicator should illuminate on the NOTE: The cruise control module will cycle the cable
instrument cluster. stroke briefly which may be felt at the throttle grip. If
3. Release both buttons. Indicator lamp should go out. the actuator does not pull the cable after releasing
the brake, there is a problem with the cable or
4. Press the SET button. The indicator lamp should actuator. Proceed to Test 5.
illuminate. The lamp will go off when the button is
released. If the lamp illuminated, the SET / DEC button Test 5
circuit is functioning properly. (Speed Sensor Input)
NOTE: Continue to press and release the SET button
to repeat the test if desired. 18. Roll the motorcycle forward while observing the
indicator lamp. If the vehicle speed signal is present,
5. Perform Test 2. the lamp will flash rapidly for a sufficient test distance
(5 to 10 feet / 2 to 3 meters) and then go off.
Test 2
(Resume / Accelerate Button) 19. Push the cruise control OFF button.
6. Continuing on from Test 1, press the RES / ACC 20. Turn the ignition switch to the OFF position.
button. The cruise indicator lamp should illuminate. 21. Perform Test 6.
7. Release the button, and the lamp should go out. If the
lamp illuminated, the RES / ACC button circuit is Test 6
functioning properly. (RPM Signal)
8. Do not repeat this test. Doing so will exit the system 22. Press and hold the RES / ACC button.
from the diagnostic test mode. 23. Turn the ignition key to the ON position while holding
9. Perform Test 3. the RES / ACC button. The indicator lamp should
illuminate. Do not release the RES/ACC button until
the following Step is completed.
Test 3
(Throttle Grip) 24. While still holding the RES/ACC button, start the
engine. The cruise control indicator lamp should
10. Continuing from Test 2, close the throttle grip firmly
illuminate and flash with the RPM pulses until button
(throttle switch closes). The lamp should illuminate.
is released.
11. Release the throttle (throttle switch opens) and the NOTE: Starting the engine may cause the system to
lamp should go off. If the lamp illuminated, the throttle exit the diagnostic mode if the battery voltage drops
cable switch circuit is functioning properly. too low during cranking.
12. Do not repeat this test. Doing so will exit the system
from the diagnostic test mode. 25. Turn the ignition key to the OFF position. All tests are
complete.
19
19
13. Perform Test 4.
19.19
CRUISE CONTROL CABLE REPLACEMENT 5. Locate cruise control cable at throttle body.
NOTE: Always perform the “Lash Learn” procedure

THROTTLE BODY
after replacing the cruise control cable.
1. Locate cruise control module under the seat.
REAR FRAME ASSEMBLY
CRUISE CONTROL CABLE
CABLE BRACKET THROTTLE LINKAGE FITTING
CABLE 6. Disconnect cable from bracket and throttle linkage

ADAPTER
fitting.
CRUISE 7. Install a new cruise control cable using same routing

MODULE
and tie strap locations. Verify cable snaps securely into
CRUISE MODULE BRACKET
place on bracket.
8. Be sure drive ribbon is straight as shown in Step

2. To remove cable, grasp and firmly turn cable adapter
2 (not twisted). Connect cable to buckle.
counterclockwise.
9. Pull throttle body end of cable to draw cable adapter
CABLE ADAPTER toward module. The buckle must slide freely into cable
CONNECTION adapter.
Drive ribbon straight
(not twisted) 10. Install cable adaptor in module.
11. If module was removed from bracket, torque fasteners

to 10 lb-ft. (12 Nm).
BUCKLE 12. Perform “Lash Learn” procedure (page 19.15).

CRUISE ACTUATOR MODULE
3. Pull adapter back to reveal cable buckle. Remove

cable from buckle.
4. Remove tie strap securing cable to frame.
19.20
CRUISE CONTROL CABLE “LASH LEARN” 3. PRESS and HOLD both Resume (RES) and ON
PROCEDURE buttons on cruise control switch.
The cruise control actuator cable has no manual cable

free play adjuster, so a “Lash Learn” procedure must be
initiated by the Victory technician. This simple, automated
process allows the cruise control module to take up any
slack in the cruise cable which will ensure a smooth
transition to SET speeds, and quicker reaction to
changes in load (hills) and speeds. Perform the following
procedure:
• After installing an accessory Cruise Control kit.
• After replacing any component that affects cruise
control cable free play (cruise cable, cruise module, or
throttle body assembly).
Failure to perform this procedure could result in erratic
cruise control operation such as “hunting” around a SET
speed or a sluggish reaction to load and speed changes.
NOTE: Performing the “lash learn” procedure is not
required when adjusting or replacing the throttle
open / close cables. The Lash Learn procedure can
be performed at any time and multiple times without PRESS and HOLD
causing any problems.
1. With engine at operating temperature, turn ignition key
OFF.
4. Turn ignition key ON (while holding Resume and ON
buttons).
2. Place transmission in NEUTRAL.
5. Continue to HOLD both Resume (RES) and ON

buttons and START THE ENGINE.
19
19
19.21
6. After engine starts, watch cruise indicator lamp on 9. Listen for a brief increase in engine RPM as the cruise
indicator display until it turns OFF. (If indicator lamp control module takes up any cable lash (free play) and
does not illuminate and remain illuminated when the completes the Lash Learn process. The cruise control
engine starts, repeat steps 1 through 5). lamp will go off during this part of procedure.
Idle is stabilized
Light goes out
7. When the cruise control lamp turns OFF, RELEASE

both Resume and ON buttons. 10. When engine RPM drops down to idle speed and the
cruise indicator lamp goes out, RELEASE the resume
(RES) button.
8. PRESS and HOLD the Resume (RES) button. The

cruise control indicator lamp should illuminate.
11. Turn the engine off; the process is complete.
12. Test cruise control operation by test riding the

motorcycle.
19.22
HORN RELAY CIRCUITS

SYSTEM DIAGRAM
19
19
19.23
WINDSHIELD / TRUNK LAMP CIRCUITS

SYSTEM DIAGRAM
NOTE: Trunk lamp operation can be viewed by

removing the seat and backrest pad from
the front of the trunk.
19.24
INSTRUMENT CLUSTER
SYSTEM DIAGRAM (2008 - 2010)
Reverse (2009 only)
SEE CHAPTER 5 FOR INFORMATION ON

“ERR” CODES DISPLAYED ON LCD SCREEN
NOTE: INSTRUMENT CLUSTER SOFTWARE

CAN BE REPROGRAMMED IF UPDATES
ARE RELEASED BY VICTORY. FOLLOW
AUXILIARY CONTROLLER REFLASH
PROCEDURE IN THIS CHAPTER OR IN
DIGITAL WRENCH.
19
19
19.25
2008-2009 VISION INSTRUMENT CLUSTER CONNECTOR PIN FUNCTION

INSTRUMENT CLUSTER 24 PIN CONNECTOR INPUT / OUTPUT (2008-2009)
OR / BN
OR / W
2009 Only
“R” displayed when reverse switch
is open (lever in Reverse).
Ambient Air See fuel sensor test
Temp Chapter 5
19.26
30K Ohm
Behind LH Mirror
19
19
19.27
2010 VISION INSTRUMENT CLUSTER CONNECTOR PIN FUNCTION

INSTRUMENT CLUSTER 24 PIN CONNECTOR INPUT / OUTPUT (2010)
OR / BN
OR / W
PIN 20 not used on 2010 models.
“R” signal to Instrument Cluster is
controlled by the ECM (on the CAN
See Chapter 5
Ambient Air
Temp
30K Ohm
Behind LH Mirror
HEATERS
HEATED SEAT & HANDGRIP WIRING DIAGRAM
HEATED SEAT GRID TROUBLESHOOTING:
Disconnect 2-Pin connector (under seat).
Connect Ohmmeter to LT BU/PK and BK wires on seat side
of 2-Pin connector. Turn both seat heater switches OFF.
Test each switch / grid separately (turn other switch OFF).
Compare to specifications below (all specs +/- 20%).
2010 NOTE: High and low grid resistance measured
will be the same approximate value.
GRIP RESISTANCE
(EACH)
2008-2009 Driver: 2008-2009 Pass

OFF: O.L. () OFF: O.L. ()
LOW: 21.5  LOW: 21.5 
HIGH: 5.3  HIGH: 5.3 
2010 Driver 2010 Pass
OFF: O.L. () OFF: O.L. ()
HIGH or LOW: HIGH or LOW:
2M -12M 2M-12M
HEATED SEAT POWER SUPPLY TROUBLESHOOTING: Disconnect 2-Pin connector (under seat).
Turn key ON. Check for battery voltage on LT BU/PK wire on main harness side of connector.
Turn key OFF. Check for a good ground (less than 1 Ohm) on BK wire (on main harness side of 2-Pin).
HEATED HAND GRIP TROUBLESHOOTING:

This test measures the resistance of both hand grip heater grids at the switch:
SWITCH CONTACT
Wire Color BN Lt BU/Pk BU
Disconnect BU (High) and BN (Low) wires from switch (under front of console).
Measure resistance between BU wire and ground: 4 Ohms HIGH
Measure resistance between BN wire and ground: 6.5 Ohms
If resistance is out of range, test each grip resistance individually (see test this page). OFF
LOW
19.28
CONSOLE SWITCH WIRE CONNECTIONS

Wire connections for console switches are shown below.
FRONT OF CONSOLE
ACC
DRIVING
LAMP
PK/GN & GN/PK
Hand Warmer
HAZARD Power Lt BU / PK
BU/W & BK/W
Hand Warmer
Hand Warmer LOW - Brown
High - Blue on front tab
on rear tab
19
19
19.29
TIPOVER SENSOR (2009-2010) LOCATION

The tipover sensor is mounted on the cruise control
OVERVIEW OF OPERATION
module bracket near the rear wheel closeoff panel.
The Tipover Sensor (TOS) is used to disable the fuel
Access the sensor by removing the right lower access
pump, fuel injector, and ignition circuits in the event of a
panel. To disconnect the wire harness, insert a small flat
crash or tipover condition.
screwdriver in the slot (A) on the left side of the
The ECM sends a 5VDC reference to the sensor and connector.
monitors the output voltage. From the output signal, the
ECM can tell whether the TOS system is in normal
operation, if the vehicle is tipped over, or if there is an
open or short in the system wiring. Only a tipover voltage
from the sensor will cause the ECM to disable the fuel A
pump and ignition circuits. If the TOS system wiring is
disconnected (open / high) the ECM will set a trouble code
(and subsequent CHK ENG light) but will not disable the
engine’s operational circuits. The same is true for a TOS
system short to ground (low).
Only in the event of an actual tipover condition is the
voltage output within a range that will cause the ECM to
disconnect the fuel and ignition circuits as well as the
internal drivers that control them.
TIPOVER SENSOR RESET

After a Tipover Condition Has Occurred:
1. Return the motorcycle to the upright position and
place it on the side stand.
2. Be sure the Engine Stop (kill) switch is in the RUN
position.
3. Turn the ignition key OFF.
4. Turn the ignition key ON. The fuel pump should cycle
and the system should return to normal operation.
DIAGNOSTICS
1. If the tipover sensor was activated (vehicle was
actually tipped over) reset the system as outlined
above. If the tipover condition trouble code (P1504) is
still present, continue.
2. Remove the right side cover and right lower access
panel (Chapter 3).
3. Visually inspect the sensor. Be sure it is mounted
securely to the cruise module bracket and the bracket
is secure in the chassis. The word “UP” must be visible
on the top of the sensor and the sensor should be level
relative to the motorcycle.
4. Disconnect the sensor from the main wire harness and
look at connector pins for signs of corrosion or
misalignment that would cause a poor connection.
5. Connect Digital Wrench for further diagnosis of the
tipover sensor circuit.
19.30
AUDIO SYSTEMS
AUDIO SYSTEM DIAGRAM
NOTE: DO NOT INSTALL 2008-2009 RADIO, CB RADIO, OR XM RADIO ON 2010 MODEL VISION (OR 2010
EQUIPMENT ON 2008-2009). FOR AUDIO / COM SYSTEM OPERATION, REVIEW INFORMATION IN
CHAPTER 1. SEE TROUBLESHOOTING ON PAGE 19.39.
(10th Anniversary or Accy)
NOTE:
Remove 25A fuse
for 15 seconds to
re-boot radio.
19
19
19.31
AUDIO SYSTEMS DIAGNOSTIC SCREENS Example - Screen 2:

On-board diagnostics and systems information are Audio / COM switch button diagnostics. This screen and
available on the radio display. Follow procedure below to button diagnostics are described on page 19.33.
enter Diagnostic Mode and view information. Only the
main radio screen categories are shown here. Information 2008 Display Shown
screen and diagnostic screens will only appear if the
motorcycle is equipped with that device (CB, XM, etc.)
1. Turn ignition switch to ACC.
2. Turn radio OFF (Victory, Victory Motorcycles or Ness
Signature Series is shown on display). SCREEN 2 - Button Diagnostics
3. Turn ignition switch OFF.
4. Turn ignition switch back to ACC. Example - Screen 3:
Tuner location screen displays which band frequency
5. Press & HOLD #1 preset button and MODE button on
package is in use. To change country, press the “+” or “-”
console while turning radio power ON.
button on the radio console. When finished, press MODE
button again to continue to the next screen.
VICTORY
TUNER LOCATION
USA (Europe, etc.)
Hold #1
Preset SCREEN 3 - Tuner Location
and Mode
Then press Example - Screen 4:

the power Amplifier error screen displays “No Errors” as shown or
button an error fault if one exists.
6. The diagnostics mode is entered. Screens 1-5 and a

description of each follows.
AMP: NO
NOTE: A “Watchdog Error Cleared” message will ERRORS
occasionally appear as the first thing displayed. This can
be ignored, it is an internal software notification.
SCREEN 4 - Amp error display
Example - Screen 1:
Software and hardware versions. Refer to Digital Wrench
to see if software updates have been released. To view Example - Screen 5:
the CB and XM radio software versions, continue to
The speed signal screen displays speed of the vehicle in
toggle with the MODE button until CB or XM information
mph or kph to verify speed signal is reaching the radio.
is displayed.
Speed
SW VER: x.xxx
HW VER: x 0 mph 0 kph
SCREEN 1 - Software & Hardware SCREEN 5 - Speed signal
19.32
AUDIO SYSTEMS CONTROL SWITCH ON-

BOARD DIAGNOSTICS On 2008 models, be sure the correct input is being
“seen” by the radio. To do this, press a button and
Both the left handlebar audio control switch and console note the location (address) of the “1” when it
audio control buttons should be tested with on-board appears in the display, then verify it is in the correct
diagnostics if possible. A bench test procedure location using the table on the following page.
(page 19.35) can be performed if necessary. This is especially important if the radio does not
To activate audio switch on-board diagnostic mode: respond correctly to commands from a switch.
Verify switch connector pins are clean (use electrical
1. Turn ignition switch to ACC. contact cleaner) and that the connector is latched
2. Turn radio OFF (Victory Motorcycles or Ness together securely before replacing a switch.
Signature Series is shown on display). A loose connection or even a small amount of
contamination or corrosion can affect switch function.
3. Turn ignition switch OFF.
4. Turn ignition switch back to ACC.
console while turning radio power ON.
VICTORY
Handlebar buttons Passenger buttons
No button
pressed
Hold #1
preset
and Mode
button down
Button
pressed
Then press
power button
2008 Models - 2 rows of zeros.
(See Table 1 on following page for position)
6. The diagnostics mode is entered. Press MODE to
toggle to the second screen - button diagnostics. See
for description of screens 1, 3, 4, & 5. 1 16
NOTE: A “Watchdog Error Cleared” message will
occasionally appear as the first thing displayed. This can
be ignored, it is an internal software notification.
7. 2008 Models - display contains two lines of “zeros”. 17 32
Each location corresponds to a radio button on the Display address - 2008
radio, handlebar switches, or passenger control
switches. (See page 19.34 for position).
A zero (0) represents a button not being pressed.
A one (1) represents a button being pressed.
If a “1” appears at the proper address on the display, VOLUME UP
the button and circuit wiring are functioning correctly.
2009* and 2010 Models - the display shows the name
2009-2010 Models - Display shows
of the button that is pressed.
name of button pressed. 19
19
* Software version 5.05A and later
19.33
AUDIO / COM BUTTON LOCATION TABLE - 2008 MODELS

TABLE 1 - 2008 Model Audio / Com Control Input Location
POSITION ON DISPLAY POSITION ON DISPLAY
BUTTON FUNCTION TOP ROW BOTTOM ROW
(POSITIONS 1-16) (POSITIONS 17-32)
NOT DEFINED 1
SOURCE (on both radio console and handlebar audio switch) 2
MODE (on radio console button) 3
“+” (on radio console) 4
“-” (on radio console) 5
PRESET 1 6
PRESET 2 7
Position 1 Position 16 PRESET 3 8

PRESET 4 9
2008 Display - Top Row
PRESET 5 10
PRESET 6 11
PRESET 7 12
PRESET 8 13
PRESET 9 14
PRESET 10 15
PRESET 11 16
PRESET 12 (on radio console) 17
PTT (Push to Talk) (on rear control) 18
VOLUME “+” (on rear control) 19
VOLUME “-” (on rear control) 20
ICOM (on handlebar com switch) 21
COM (on handlebar com switch) 22
VOLUME “+” (on handlebar audio switch) 23
2008 Display - Bottom Row VOLUME “-” (on handlebar audio switch) 24
Position 17 Position 32 MUTE (on handlebar audio switch) 25
TUNE “+” (on handlebar audio switch) 26
TUNE “-” (on handlebar audio switch) 27
PTT (Push to Talk) (on handlebar com switch) 28
SQUELCH “+” (on handlebar com switch) 29
SQUELCH “-” (on handlebar com switch) 30
NOT DEFINED 31 & 32
19.34
AUDIO SYSTEMS CONTROL SWITCH -

BENCH TEST
On-board switch diagnostics should be used if available,
however, the audio control switches can be bench tested
with an Ohmmeter. Use extra care with the meter leads to
ensure connector pins are not damaged when testing.
1. Connect Ohmmeter leads to each of the two wires Diagnostic resistor in parallel with switch resistors
leading from the Audio Switch or CB / ICOM switch.
2. Press each button and refer to the chart below for
resistance values.
NOTE: The self-diagnostics built in to the radio use
the 15 K diagnostic resistor (in parallel with all
Actual resistor values shown. Use resistance
button resistors) to verify the switch is connected. from table when testing switch with an Ohmmeter.
The switch wire resistance will reflect this 15 K
resistor value when none of the buttons are pushed.
AUDIO SWITCH RESISTANCE

RESISTANCE (+/- 10%)
BUTTON
Wire Colors: WHITE, ORANGE
MUTE 99
SOURCE 325
VOLUME UP 940
VOLUME DOWN 1920(1.92K)
TUNE UP 3095(3.09K)
TUNE DOWN 4680(4.68K)
DIAGNOSTIC
(No Button 15,000 (15.0K
Pushed)
CB / ICOM SWITCH RESISTANCE

RESISTANCE (+/- 10%)
BUTTON
Wire Colors: BLUE, YELLOW
PTT (Top) 99
PTT (Bottom) 325
ICOM 940
COM 1920(1.92K)
SQUELCH (-) 3095(3.09K)
SQUELCH (+) 4680(4.68K)
DIAGNOSTIC
19
19
15,000 (15.0K
(No Button Pushed)
19.35
AUDIO SYSTEM REPROGRAMMING ...or go to www.polarisdealers.com and click on the Digital

(AUXILIARY CONTROLLER REPROGRAM) Wrench Updates link under the Service and Warranty
drop down menu...
The current radio software and hardware versions are
displayed on Screen 1 when the radio is in diagnostic
mode. Follow the instructions on page 19.32 to access
radio diagnostic screens and record the version that is
currently installed.
If software updates become available for the audio

system (Radio, XM, CB/COM, etc.), the radio can be
reprogrammed using Digital Wrench. The procedure is
similar to a fuel / ignition map calibration reprogramming
procedure.
If you have questions about:

• Connecting Digital Wrench to the vehicle
• Troubleshooting communication errors ...either of these will get you to the most up-to-date
diagnostic troubleshooting help and FAQs available.
• How to test your Digital Wrench interface cable
• Downloading the most recent reprogramming file set REPROGRAMMING PROCEDURE
• Virtually anything related to Digital Wrench!
1. Connect the Digital Wrench Smartlink to the
visit www.diagsys.com... diagnostic port in the left saddlebag.
2. Start Digital Wrench, select appropriate vehicle
information, and click NEXT.
...and click on Digital Wrench Home. Then select a

diagnostic category... 3. Click the red tool box to open the Special Tests menu.
4. Select “Auxiliary Controller Reprogramming”.
19.36
5. Select the item you want to re-program from the list. 8. Go to the dealer web site (www.polarisdealers.com).
9. Select the Service and Warranty drop-down menu.
10. Select “Reflash Authorization”.

5
10
11
6. Follow instructions on screen and click CONTINUE.
11. Paste the Request Code copied in Step 7 into the

Request Code box (right click in the box then select
paste).
6 12. Click CONTINUE.
12
13
7. Highlight the Request Code that appears in the box.

(Hold “Ctrl” and press “C” to copy the code). 13. Enter the information in the boxes and click
“Authorize”. Click only ONCE as indicated on the
NOTE: DO NOT shut down or exit Digital Wrench
screen!
until reprogramming is complete or the Authorization
Key will be lost! 14. A screen will pop up. Click OK to get the reflash
Authorization Key.
14
19
19
19.37
15. Highlight the Authorization Key. 21. Once reprogramming is complete, follow all steps on
the screen, then click FINISH.
16. Right click and select COPY to copy the key.
16
23
17. Click in the Authorization Key box.

22. Cycle the ignition switch to restart the audio
18. Hold “Ctrl” and press “V” to paste the key. components.
19. Click CONTINUE. 23. Repeat this procedure for other components that need
reprogramming.
24. Always verify the software version of all audio

components (radio, CB/ICOM, XM, etc.) is at the most
current level, by performing the following steps:
25. Turn ignition switch to ACC and turn radio OFF.

20 (VICTORY or VICTORY MOTORCYCLES is shown on
19
display)
26. Turn ignition switch to OFF and then back to ACC.

console then turn radio power ON.
VICTORY
20. This screen will appear when reprogramming is taking

place. Do not disturb the motorcycle, computer, or Hold #1
mouse while reprogramming is in process. Preset
and Mode
buttons
Then press
power button
The diagnostics mode is entered. Record the radio

software version, then use the MODE button to toggle to
the CB and XM radio screens to view the software version
of each.
SW VER: x.xxx
HW VER: x
19.38
AUDIO TROUBLESHOOTING TIPS NAVIGATION SYSTEM
Possible Cause/ GPS NAVIGATION & NAV MP3 PLAYER

Symptom Action
Refer to the Garmin® zumo® 660 Operator’s Manual and
to page 1.52 of this manual for more information.
Re-boot the radio:
Remove radio fuse (25A)
for 15 seconds. Reinstall Changing the Active Source to NAV MP3: page 1.37
and test.
Before you begin: page 1.52
No radio display, partial
display, or system
“locked up”. If a re-boot (above) does Operation tips and Volume Settings: page 1.52
not restore the system,
temporarily disconnect
the entertainment Changing the Aux Mode to NAV MP3: page 1.53
harness and any
accessories and test. Switching from radio to MP3 Player: page 1.54
System does not Test hand control

respond correctly to switches with on-board Other notes:
hand control button diagnostics (begins on
inputs. page 19.33) The GPS system audio will override all other audio
functions except for the CB (transmitting and receiving).
Software (SW) versions
of system components The GPS will not provide audio commands if the radio is
CB / ICOM or XM radio OFF.
(radios) are at different
does not interact levels. Reprogram
properly with main (reflash) ALL radios to the
radio. To disable the GPS audio, turn volume on GPS unit to
same level. See
page 19.36. zero.
The volume level through the speaker is based on the

NEVER use aftermarket volume setting in the GPS unit along with the volume
speaker in the audio setting of the radio.
system. Damage can
Speakers not genuine occur to the radio due to
Victory. overheating. Install
genuine Victory (4 Ohm)
speakers.
Headsets are not

Headsets work only in genuine Victory. Replace
entertainment modes
with genuine Victory
and not in ICOM.
headsets.
19
19
19.39
Y
19.40
W
W GN/W
GN
Reverse
Harness PK
BU/Y
GY/R
Black wire in Pin B
on 2009 model only
BU
REVERSE SYSTEM
Chassis
Harness
PK
Y/W
R/BK
R
WIRING DIAGRAM / REVERSE HARNESS
OR
IC = Instrument Cluster
Under seat / left side inner saddlebag
Under seat / left side cover

Under electrical cover
(front of engine)
REVERSE SYSTEM DIAGNOSTICS

OVERVIEW OF OPERATION
In a Reverse system, the electric starter button serves a dual purpose. When the starter button is pressed, battery
voltage is sent through the Reverse wiring harness to the Reverse Module. The module then decides whether to send
power to the electric starter solenoid (for engine starting) or to the Reverse Drive Motor (for reverse operation). This
decision is based on information the module receives from the reverse switch and a few other inputs such as the
neutral switch and tachometer signal.
MECHANICAL SYSTEM BASIC FUNCTION
When the Reverse Lever is lifted UP (Reverse) a cam-actuated linkage rod pulls the Reverse Idler Gear inward,
directly coupling the Pinion Gear to the Reverse Driven gear (mounted to the belt drive sprocket). The Reverse Switch
is now OPEN, which takes the ground away from Pin C of the module, and the module will supply power to the
Reverse motor when the starter button is pressed.
REVERSE MODULE INPUT TESTING
To test the various inputs to the reverse module, disconnect the harness from module (page 19.43) and test with a
12V test light or multimeter. Tests are outlined in the table below.
NOTE: The engine must be running to test the tachometer signal to the module on Pin A. If the tachometer
works, perform tests on the other inputs first, then if necessary, test the tach input on Pin A.
REVERSE MODULE INPUT / OUTPUT
Pin Wire Pin Function / Test Connections / Normal Result
Function / Name
Number Color (All input tests performed on connector pins; harness disconnected from module)
SIGNAL: 9Hz square wave. FUNCTION: tells module engine is running.
TEST: Set meter to Hz A/C or Vdc. Start engine first, then disconnect harness
connector from module. Connect red (+) meter lead to PIN A. Connect black (-)
A Tachometer Input GN
meter lead to engine ground or Pin F (if ground at Pin F has been tested).
RESULT: Approximately 9 Hz or a pulsating DC indicated on the bar graph of the
meter, indicating that a signal is present (voltage reading will vary).
SIGNAL: +12 Vdc. FUNCTION: Battery voltage into module when starter button
is pressed. TEST: Set meter to Vdc. Connect red (+) meter lead to PIN B. Connect
B Start Switch Input BU / Y
black (-) meter lead to engine ground (or Pin F). Turn ignition switch ON and stop
switch to RUN. RESULT: Battery voltage present when starter button is pressed.
SIGNAL: Open to ground. FUNCTION: Tells module Reverse has been selected
(Pin C has no ground). TEST: Set meter to (Ohms). Connect one meter lead to
C Reverse Switch Input W PIN C. Connect other meter lead to engine ground (or Pin F). Move reverse lever
to Reverse. RESULT: OPEN (OL) with lever in Reverse (UP). Good continuity to
ground ( 1)with lever in Forward (down).
D Not Used - Pin D not used
SIGNAL: +12 Vdc. FUNCTION: Battery voltage into module.
TEST: Set meter to Vdc. Connect red (+) meter lead to PIN E. Connect black (-)
E Switched Power PK
meter lead to engine ground (or Pin F). Turn ignition switch ON and stop switch
to RUN. RESULT: Battery voltage present when key is turned ON.
Module ground. TEST: Set meter to (Ohms). Connect one meter lead to PIN F.
F Ground BK
Connect other meter lead to engine ground. RESULT: Continuity to ground ( 1)
SIGNAL: +12 Vdc. FUNCTION: Power supply from load side of 40A circuit
G Battery Voltage R
breaker. Module switches power to Pin J in Reverse. TEST: +12 Vdc constant.
Power out of module to engine starter solenoid when starter button is pressed
H Starter Output Y
(and reverse lever is not in Reverse).
J Reverse Output GY/R

Power out of module to reverse drive motor when starter button is pressed (and
reverse lever is in Reverse).
19
19
K Not Used - Pin K not used
19.41
REVERSE SYSTEM DIAGNOSTICS (Cont.)
REVERSE SYSTEM TROUBLESHOOTING

Problem Possible Cause / Remedy Reference
Reverse switch contacts closed.

See below for switch contact test.
Check reverse switch function and
Adjust linkage rod (page 11.12).
linkage adjustment.
Reverse system inoperative.
25A fuse open (blown). Replace fuse
“R” not indicated on display. See page 19.43
and determine cause.
Poor wiring connection. Verify all

wiring is connected and clean.
Reverse lever in “Reverse” position

Engine starter inoperative* (UP). Move lever to forward (DOWN)
position.*
*NOTE: If the 25A fuse is blown, the
25A fuse open (blown). Replace fuse.
engine starter motor will not operate See page 19.43
Determine cause of failure.
even if the reverse lever is in the
forward (down) position. Poor wiring connection. Verify all
wiring is connected and clean.
Reverse linkage adjustment incorrect.

“R” Displayed too early or too late in See below for switch contact test.
reverse lever travel range Reverse switch malfunction or switch Adjust linkage rod (page 11.12).
mounting bracket bent.
Reverse switch contacts open (no

Move lever back to the Forward
Engine kills when transmission shifted ground on Pin C at module). Reverse
position (down) or adjust shift
into gear. lever in Reverse position or linkage
linkage (page 11.12).
adjustment incorrect.
Difficulty moving lever into or out of Reverse gear idler shaft dirty.
Lubricate idler shaft (page 2.7)
Reverse position Lubricate shaft at every oil change.
Reverse Switch Inspection
In Reverse (switch arm is up) - No continuity 1. Disconnect switch (under left side cover).
Switch mounted
in reverse gear case 2. Connect one lead of Ohmmeter to switch
wire and the other to engine ground.
3. Place Reverse lever in forward (Down).
4. Resistance should be less than 1 Ohm
to ground (good continuity).
5. Slowly lift reverse lever while observing
the Ohmmeter reading. Lever must move
In Forward - continuity through switch
Connected to reverse harness at least 6mm (1/4 inch) and no more than
grounds Pin C of module
(under LH side cover) 12mm (1/2 inch) before the switch opens
(no continuity).
6. If switch opens and closes out of the range
above, adjust linkage rod (page 11.12).
Replace switch if always grounded or open.
19.42
REVERSE SYSTEM SAFETY

NOTE: Do not attempt to engage or disengage the
reverse system when the motorcycle is moving.
BEFORE operating in reverse NEVER operate in reverse
Always sit on the motorcycle with legs astride and both When not properly seated.
feet on the ground.
When in an area where obstacles or bystanders are
Always check for obstacles or people behind the present.
motorcycle.
With a passenger on board. A passenger can obstruct
Always retract the sidestand fully. your view and maneuverability.
Always make sure the motorcycle is completely stopped. On loose or slippery surfaces. Loss of foot traction could
cause a tip-over.
While the motorcycle is moving forward.
When on a grade or uneven surfaces.
OPERATING THE REVERSE SYSTEM NOTE: The engine will stop if you shift into forward gear
before disengaging the reverse lever.
1. Check the area behind and around the motorcycle for
obstacles or people. Be aware that the front wheel REVERSE MODULE / FUSE ACCESS
may travel outward and require a larger operating
area.
2. Make sure the motorcycle is stationary.
2. Reverse module is located between the left inner
3. Dismount any passenger.
saddlebag and the frame. Fuse (A) is attached.
4. Straddle the motorcycle and bring it to the fully upright
position. Sit in a normal riding position with legs
astride and both feet on the ground. A
5. Retract the sidestand.
6. Place the transmission in neutral. Start the engine and

allow it to idle.
7. Lift the reverse lever and verify that the reverse
indicator (R) displays in the Information Display.
8. Recheck the area behind and around the motorcycle
to ensure a clear operating area.
9. While balancing the motorcycle with your legs and 3. Lift tab and separate connector from module.
feet, press and hold the START button to begin
moving in reverse. Release the button to stop moving. NOTE: The starter system will not function with the
reverse module disconnected, or if the 25A fuse (A)
10. When completely stopped, move the reverse lever is open. On models equipped with Reverse, the
down to the disengaged position. Verify that the tachometer signal test (page 19.44) can be
neutral indicator (N) displays before stopping the
engine.
performed at this connector, but the engine must be 19
19
started BEFORE disconnecting the harness from the
reverse module.
19.43
TACHOMETER SIGNAL TEST TESTING AT THE REVERSE MODULE:

A tachometer signal is sent out of ECM (Pin 22) on the
Green / White wire. The signal can be tested at the cruise 2. Shift transmission into NEUTRAL.
control module connector GN/W wire (2008-20010), the 3. Set digital volt meter to measure Frequency (Hz AC
reverse harness connector on the chassis harness GN/W scale). If your meter does not have frequency
wire (2009-2010 not equipped with reverse), or at the measurement capability, set the meter to measure DC
reverse module GN wire (2009-2010 with reverse). Volts (Vdc).
NOTE: The Instrument Cluster receives a tachometer 4. Start engine and let it idle.
input on the CAN line on Pins 4 and 5 of the 24-Pin 5. Disconnect reverse module wire harness connector
Instrument Cluster connector. A multimeter cannot be (page 19.43).
used to check the tach signal at the Instrument Cluster. If
the tachometer (gauge) does not function properly, inspect
the connector for corroded, loose, or damaged pins.
TESTING AT THE CRUISE CONTROL CONNECTOR:

1. Remove the seat (page 3.27).
2. Shift the transmission into NEUTRAL.
3. Set digital volt meter to measure Frequency (Hz AC
scale). If your meter does not have frequency
measurement capability, set the meter to measure DC
Volts (Vdc).
4. Use a screwdriver through the opening in the frame
and carefully pry back the latch of the cruise control
connector while pulling lightly on the connector 6. Connect Red meter lead (+) to Pin A of reverse module
harness. DO NOT pull forcefully on the wires. connector (GN wire).
5. Connect Red meter lead (+) to Pin H of cruise control 7. Connect Black (-) meter lead to engine ground.
module connector (GN/W wire).
6. Connect Black (-) meter lead to engine ground. 8. Compare measurement to specification.
7. Start engine and let it idle. 9. If no tach signal is present, inspect GN/W wire in the
Engine-to-Chassis harness connector (A).
8. Compare measurement to specification.
9. If no tach signal is present, inspect GN/W wire in the
Engine-to-Chassis harness connector (A).
19.44
GROUND LOCATIONS ECM ground (C).

Front left ECM mounting bolt (under seat).
Symptoms of a loose, corroded, or broken ground wire
vary depending on the wire and the location. Most often, a
problem with a main ground wire location will affect
multiple circuits. Inspect the grounds to be sure they are
clean and tight.
Engine ground (A).

Left rear corner of crankcase.
Chassis grounds (D).

Left upper frame-to-fairing support bracket bolt (near air
filter).
Engine harness grounds (B).

Front left corner of crankcase under electrical cover.
19
19
19.45
WIRE HARNESS (TOP VIEW)
= Apply Dielectric grease P/N 2871329 DO NOT apply dielectric grease to sealed connectors
or to O2 sensor connectors or wires.
P-Clip for main chassis wire harness bundle
is attached to lower right instrument panel
mounting bolt. Opening faces up and to rear.
Attach (4) clips to rib on underside

of leg fairing support.
Engine harness
Engine to chassis
harness connector
Slide clip onto rib on

inner saddlebag Tie straps include main wire harness
and rear lighting harness.
Diagnostic connector grommet

Tie strap includes main chassis wire
ECM ground ring terminal on harness bundle
front left bolt.
9.6 Nm (85 lb-in) Rear lighting wire harness routed
under body panel on this side of clips.

harness bundle
19.46
= Apply Dielectric grease P/N 2871329

DO NOT apply dielectric grease to sealed connectors
or to O2 sensor connectors or wires.
Ambient Air
Temp Sensor
Black 3-Pin to
driving light Main harness routed
through tie straps
attached to clips
Natural 3-Pin to main

lights (upper 2)
WIRE HARNESS (SIDE & FRONT VIEW)
Clip secures engine

harness bundle Brake switch
jumper
FRONT VIEW
Main chassis ground
9.6 Nm (85 lb-in)
Brake light relay location:

P-Clip attached to forward relay
fastener. Relay wire bundle
routes up through P-clip.
Circuit breaker
2.8 Nm (25 lb-in)

Clips in mounting holes
O2 sensor connection
must be inboard of bumper
19.47
19
19
ELECTRICAL CONNECTOR AND COMPONENT LOCATION
Halogen Driving Light

LH Headlight RH Headlight
Windshield Control RH Fuse Box

LH Fuse Box Fuel Pump
Ambient Air
Park Lamp
Temp
RH Turn Signal
Park Lamp
RH Speaker + / -
LH Turn Signal
LH Speaker + / - AM/FM Antenna
LH Control Switch
Instrument 2.8 Nm (25 lb-in)
Cruise Hand
Cluster Control
RH Control Switch
RH Illuminated
Audio Controls Badge
Ignition Switch
LH Illuminated
Badge
ABS Radio
(capped if not equipped)
Reverse Connector
(capped if not equipped)
(In front frame opening
under seat)
Engine-to-Chassis
Harness Connector
Cruise Control
(In front frame opening
under seat)
Trunk
Heated Seat (capped if not equipped)
= Apply thin film of dielectric
grease PN 2871329
DO NOT apply dielectric grease to sealed

connectors or to oxygen sensor wiring.
19.48
ELECTRICAL CONNECTOR AND COMPONENT LOCATION
= Apply thin film of dielectric

grease PN 2871329
DO NOT apply dielectric grease to sealed

connectors or to oxygen sensor wiring.
Instrument Cluster Driving Light Switch

Hazard Switch
Fog Lights
HID Ballast Power

Heated Grip Switch
ACC Power Heated Grip Ground
Radio
AM/FM Antenna
GPS
+12V Powerlet
(Accessory)
iPod
AUX
Main Chassis Flasher

Harness Ground
+12V Powerlet Throttle
(Glove Box) Safety Switch
Reverse (front frame opening

under seat)
Horn
Circuit Breaker
Rear Lighting
Cruise Control
(front frame opening under seat)
O2 Sensor Rear Brake Light Engine-to-Chassis Harness

(under LH side cover)
No grease!
Starter Solenoid
19
19
19.49
NOTES
19.50
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Chapter 15

2009-2010 CHASSIS WIRING DIAGRAM

$36*4&$0/530-
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le
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2009-2010 ENGINE HARNESS WIRING DIAGRAM
Slide Lock End
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View From
Wire Side
la
Po
09
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Wire Harness End
ECM CONNECTOR
(Under Seat)
Antenna wire: Antenna tube on RH leg fairing
routed in tube
Attached to windshield
access panel
Connector between RH fuse box and

RH speaker volume. Must not contact metal.
2008 - 2010

INFORMATION / ENTERTAINMENT
.
nc
WIRING DIAGRAM
sI
Connect Antenna to CB radio
le
before connecting the radio harness
Sa
ris
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Po
09
20
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WP
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ECM
CONNECTOR
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le
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09 Slide Lock End
20
Under LH Side Cover
©
9LHZIURP
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HOHFWULFDOFRYHU
In Left Saddlebag (&0&RQQHFWRU

8QGHU6HDW
"VUP$BODFM.PEVMF 7*$503:7*4*0/ UN $IBTTJT8JSJOH%JBHSBN
6OEFS$POTPMF
2008 CHASSIS WIRING DIAGRAM

$SVJTF$POUSPM
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nc
INSTRUMENT CLUSTER
sI
8JSF&OE7JFX
le
3BEJP
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8JSF&OE 7JFX
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09
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Under LH
Side Cover
2008 VICTORY VISION CHASSIS WIRING DIAGRAM
UN
"VUP$BODFM.PEVMF 7*$503:7*4*0/ $IBTTJT8JSJOH%JBHSBN
6OEFS$POTPMF
.
nc
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INSTRUMENT CLUSTER
le
8JSF&OE7JFX
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is
l ar
8JSF&OE 7JFX
Po
09
20
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2008 VICTORY VISION ENGINE WIRING DIAGRAM
WP
9,&725<9,6,21
(QJLQH:LULQJ'LDJUDP
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nc
ECM CONNECTOR
sI
(Under Seat)
le
Wire Harness End
Sa
is
l ar
Po
09 Slide Lock End
20
Under LH Side Cover
©
9LHZIURP
ZLUHVLGH
)URQWRIHQJLQHXQGHU
HOHFWULFDOFRYHU
(In Left Saddlebag) (&0&RQQHFWRU

8QGHU6HDW
2009 - 2010 VICTORY VISION CHASSIS WIRING DIAGRAM
'MBTIFS.PEVMF 6OEFS$POTPMF
"#4 4FF"#4
5P$"/)JHI

5P$"/-PX

8JSF)BSOFTT
Chapter 15
4XJUDIFE1PXFS

.
nc
$36*4&$0/530-
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le
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*/4536.&/5$-645&3
Sa
3"%*0
is

ar

l
Po
09
20
©
-)1PXFS
%JTUSJCVUJPO
3)1PXFS
%JTUSJCVUJPO
$)"44*450&/(*/&)"3/&44
$0//&$503
6OEFS-FGU4JEF$PWFS
2009 - 2010 VICTORY VISION ENGINE WIRING DIAGRAM
ECM CONNECTOR
.
(Under Seat)
nc
Slide Lock End
sI
le
Sa
is
ar
View From
Wire Side
l
Po
09
20
Under LH Side Cover
©
Wire Harness End
ECM CONNECTOR
(Under Seat)
(In Left Saddlebag)
2008 - 2010 VICTORY VISION INFORMATION / ENTERTAINMENT WIRING DIAGRAM
Antenna wire routed in tube Antenna tube on RH leg fairing
Attached to windshield
access panel
Connector located between RH fuse box and RH speaker volume.

Must not contact metal.
.
nc

sI
le
Sa
is
l ar
Po
09
20
©

2010 Victory Vision Tour Service Manual

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SPECIFICATIONS / GAUGE / AUDIO

Polaris acknowledges the following products mentioned in this manual:

XM, a registered trademark of XM Satellite Radio, Inc.

Always stop the engine and refuel outdoors or in a

Care should be taken to be sure the motorcycle NOTICE

• operator body weight

VICTORY Type: Color Indicator

VIN NUMBER / MANUFACTURER LABEL VECI / NECI / TIRE INFORMATION LABELS 1

The Manufacturer Information Decal also includes the

PUBLICATIONS & TECHNICAL LITERATURE

VICTORY SERVICE MANUAL PART NUMBERS

MATERIAL SAFETY DATA SHEET (MSDS)

VICTORY DETAIL & FINISH RESTORER KITS AND PRODUCTS

VICTORY VISION STREET MODEL YEAR 2008

• Avoid prolonged full throttle operation.

NOISE EMISSION CONTROL SYSTEM

CRANKCASE EMISSION CONTROL

EVAPORATIVE EMISSION CONTROL

SPECIAL SERVICE TOOLS 1

TUNE UP & MAINTENANCE TOOLS

STEERING & SUSPENSION TOOLS

WHEEL & TIRE TOOLS 1

FUEL SYSTEM & FUEL INJECTION TOOLS

TOOL ORDERING INFORMATION

TRANSPORTING, ELEVATING, AND SECURING THE MOTORCYCLE

If you must transport the motorcycle or secure it to a lift table:

Platform jack To shock/strut mount, or rear tip-over bar

INSTRUMENTATION / CONTROLS IGNITION SWITCH 1

INSTRUMENT CLUSTER VOLT METER

(1a) The light sensor port is located on the speedometer

(2) The tach displays current engine speed in revolutions

5. Indicator Lamp Display

CLOCK GEAR POSITION 1

1 • Turn the key ON and toggle to the trip meter to

To RESET the above items, tap MODE button until desired

CHANGING INFORMATION DISPLAY UNITS CONSOLE MOUNTED SWITCHES

2008 Standard Metric

2008-2009 Models: HAND GRIP HEATER SWITCH

2010 Models: Grip Heat Hazard

• Turn ignition key to ON or ACC.

Indicator Lamp Function Indicator Lamp Function

SEAT HEATER HEADLAMP HIGH / LOW BEAM SWITCH

LEFT Handlebar Switch

LEFT HANDLEBAR SWITCH

LEFT Handlebar Switch

MANUAL WINDSHIELD ADJUSTMENT TURN SIGNAL MOMENTARY FEATURE 1

Never start the motorcycle in gear with the clutch

RIGHT HANDLEBAR CONTROLS MIRRORS

RIGHT LINKED BRAKE SYSTEM

AUDIO / COM / CRUISE CONTROL BUTTONS

FRONT BRAKE LEVER REACH FOOT CONTROL ADJUSTMENT 1

3. Install the screw and torque to 96 lb-in. (11 Nm).

5. Loosen both jam nuts (4).

6. Turn linkage rod (5) until peg on shift pedal is about

7. Tighten jam nuts to 96 lb-in. (11 Nm).

FUEL DOOR GLOVE COMPARTMENT

• Refer to loading information beginning on page 1.9.

RADIO / AUDIO SYSTEM MAIN USER INTERFACE

• FM 87.5 to 108.00 MHz 2

LOWER LEFT HAND CONTROL REAR PASSENGER CONTROL 1