Victory Vegas Jackpot Service manual

Cvr_9920340
2/1/06
3:53 PM
Page 1
2005-2006 HAMMER
TM
2006 VEGAS JACKPOT
& NESS SIGNATURE SERIES VEGAS JACKPOT
SERVICE MANUAL
TM
2005-2006 HAMMER / 2006 VEGAS JACKPOT
TM
TM
SERVICE MANUAL
9920340
PN 9920340
Printed in USA
31
2005-2006 Hammert
2006 Vegas Jackpott
2006 Ness Signature Series Vegas Jackpott
SERVICE MANUAL
Part Number 9920340
Foreword
This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept
available for reference in the shop area. All references to left (LH) and right (RH) side of the motorcycle are from the
operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures
in order to perform the work safely and correctly. Read the text and be familiar with the service procedures before starting
the work. Certain procedures will require the use of special tools. Use only the proper tools as specified. If you have any
doubt as to your ability to perform any of the procedures outlined in this service manual, contact an authorized Victory
dealer for service.
This manual includes procedures for maintenance, component identification and repair, along with service specifications
for the models listed above. Comments or suggestions about this manual may be directed to: Service Publications Dept.
@ Polaris Sales Inc. 2100 Hwy 55 Medina, Minnesota 55340. Victory dealers can also use the on-line feedback forum
located at:www.polarisdealers.com under News, Forms & Links/Service & Warranty/Polaris Manual Feedback link and fill
out the information on the form.
E 2005 Polaris Industries. All information contained in this publication is based on the latest product information available at the time of
publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and /or procedures in this publication are intended
for reference use only. No liability can be accepted for omissions or inaccuracies in this publication. Any reprinting or reuse of the depictions
and/or procedures contained in this publication is expressly prohibited. Printed in U.S.A.
GENERAL &
MAINTENANCE
GENERAL
1
MAINTENANCE
2
3
4
5
6
FRAME/BODY/EXHAUST
LUBRICATION & COOLING
FUEL SYSTEM/FUEL INJECTION
ELECTRICAL
CHASSIS
ENGINE
ENGINE REMOVAL & INSTALLATION
7
CYLINDER & PISTON
8
CLUTCH, PRIMARY, & SHIFT
9
TRANSMISSION & CRANKSHAFT
10
DRIVE LINE
11
FRONT WHEEL & SUSPENSION 12
REAR WHEEL & SUSPENSION 13
TIRES
14
BRAKES
15
CHARGING SYSTEM
16
IGNITION SYSTEM & BATTERY 17
ELECTRIC STARTER
18
LIGHTING & INSTRUMENTATION 19
CYLINDER HEAD & VALVES
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TRADEMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SERVICE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
UNDERSTANDING SAFETY LABELS & INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 1.4
REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
VICTORY TOUCH-UP AND REFINISHING PAINT / DETAIL & FINISHING KITS . . . . . 1.5
PAINTING TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PAINT COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
VEHICLE IDENTIFICATION NUMBER (VIN) & MODEL NUMBER DESCRIPTIONS . . . 1.8
VIN NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
MODEL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
KEY IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
PUBLICATIONS & TECHNICAL LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MATERIAL SAFETY DATA SHEET (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
EMISSION CONTROL SYSTEMS / EMISSION SOURCES . . . . . . . . . . . . . . . . . . . . . 1.11
EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
NOISE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
EVAPORATIVE EMISSION CONTROL (CALIFORNIA MODELS) . . . . . . . . . . . . . . . . 1.12
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
TRIP ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
GENERAL & PRECISION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
TUNE UP & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
ENGINE, CLUTCH, & TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
STEERING & SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
WHEEL & TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
FUEL SYSTEM & FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
TRANSPORTING AND SECURING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . 1.18
ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
WIRE HARNESS - LEFT REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
WIRE HARNESS - RIGHT REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
WIRE HARNESS - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21
WIRE HARNESS - UNDER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
1.1
GENERAL INFORMATION
WIRE HARNESS CONNECTOR LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
TOP VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
LEFT SIDE VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25
RIGHT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
FUEL TANK VENT AND DRAIN HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27
2005 HAMMER - 49 STATE, CANADA, UK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27
2006 - ALL EXCEPT CALIFORNIA MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
CALIFORNIA MODELS (ALL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METRIC TAP DRILL SIZES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASUREMENT CONVERSION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
1.30
1.30
1.30
1.31
1.31
GENERAL INFORMATION
1
GENERAL INFORMATION
TRADEMARKS
Victory acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
SERVICE RULES
In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual
and familiarize themselves with the procedures before beginning. Notes, Cautions and Warnings have been included
for clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are
necessary to perform some procedures in this manual safely and correctly.
Use only genuine Victory service parts, including fasteners that require replacement if removed. Do NOT substitute
fasteners or hardware.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause
damage to precision parts. Clean the motorcycle before beginning service. Clean all parts before installing.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found.
If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or in the case of steering, driveline, and chassis components, can result in loss of control during
operation of the motorcycle, which may result in severe personal injury or death.
If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand
tighten. Following the method and sequence indicated, tighten evenly to the specified torque value. When removing
nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn before removing them
to prevent distortion of that component.
Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating
surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances.
Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore,
they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand
or compress them beyond what is required for installation.
Victory lubricants and greases have been specially formulated to provide maximum performance and protection when
applied properly. In some applications, warranty coverage may be void if improper lubricants are used.
Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating
grease loses lubricity and may contain abrasive foreign matter.
Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or
any other fasteners as noted in this service manual with genuine Victory hardware from an authorized Victory dealer.
Working with batteries can be hazardous. Review all battery warnings and cautions. See “BATTERY SAFETY” on
page 16.2.
1.3
GENERAL INFORMATION
SAFETY INFORMATION
UNDERSTANDING SAFETY LABELS & INSTRUCTIONS
READ AND BECOME FAMILIAR WITH ALL WARNING AND CAUTION SYSMBOLS AND STATEMENTS
LISTED BELOW AND IN THE TEXT OF THIS MANUAL BEFORE YOU BEGIN WORK.
DANGER, WARNINGS, & CAUTION SYMBOLS
This is the safety alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
Gasoline is extremely flammable and explosive
for personal injury. Your safety is involved!
under certain conditions.
Indicates a potential hazard which could result in severe
injury or death.
Indicates a potential hazard which may result in minor personal
injury or damage to the motorcycle.
CAUTION
Indicates a situation that can result in damage to the motorcycle.
NOTE:
The word “NOTE:”in this manual will alert you to key
information or instructions.
The engine exhaust from this product
contains chemicals known to cause cancer,
birth defects or other reproductive harm.
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.
Engine exhaust fumes are poisonous and can cause
loss of consciousness or death in a short time.
Improper repairs or service can create
unsafe conditions that may cause severe
personal injury or death.
Never run the engine in an enclosed area
Modifications to this motorcycle not approved
by Victory may cause loss of performance,
without a properly functioning exhaust gas
evacuation system connected to the product. excessive emissions, and make the machine
unsafe for use.
Wear insulated protection for hands and
arms or wait until hot components have
cooled sufficiently before working on the
product.
Brake fluid is poisonous. Do not ingest or
allow brake fluid to contact eyes. Always
wear eye protection when working with
brake fluid.
The engine and exhaust components on this
product become very hot during operation
and remain so for a period of time after the
engine is stopped.
Brake fluid is poisonous.
KEEP OUT OF REACH OF CHILDREN.
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing.
CAUTION
Brake fluid will damage plastic, painted and rubber parts. Protect
these surfaces whenever the brake system is being serviced.
1.4
GENERAL INFORMATION
1
REFINISHING
VICTORY TOUCH-UP AND REFINISHING PAINT
Service Paint products are available in three different sizes and applications. Some paint colors require up to 3 components to create a color. Prices subject to change without notice. Dealer is responsible for freight on paint and paint
products.
.6 ounce bottle: (Order Multiple of 2) For brush touch-up of small nicks.
10 ounce aerosol can: (Order Multiple of 2)
Apply light even coats for best results. Recoat time is from 30-60 minutes or after 4 days of drying to prevent lifting.
Quarts: (Sold as each)
For repaint of properly prepared plastic components or metal substrates.
Paint is a high quality acrylic urethane manufactured by U.S. Paint.
Mix as indicated on back of paint can. Paint can be recoated after paint is tack free or has ”flashed off”.
Paint finish may be wet sanded and buffed after coating has cured.
How to order:
Authorized Victory Dealers only. Place your order via the dealer web site at :
www.polarisdealers.com / News Forms & Links / Pure Polaris
Note: There will be a 25% service fee charged for all returns. Polaris dealer will be responsible for return freight.
VICTORY DETAIL AND FINISH RESTORER KITS
A Detail Kit (polish, wax, and dressing) and a Restore Kit (polish, and swirl / scuff remover) is available from the Victory parts department for painted surface protection and to remove minor surface imperfections.
Detail Kit: 2872195 (Includes Non-Abrasive Wash, Swirl Remover / Polish, Polywax Final Finish, Vinyl / Rubber
Protector, Applicator and Cloth.
Restore / Polish: 2872192 (12 oz. Aerosol)
PAINTING TERMS
The following terms describe the general operations referred to in the Paint Color Code chart on page 1.7.
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.
1.5
GENERAL INFORMATION
PAINT COLORS BY MODEL
NOTE: Refer to www.polarisdealers.com for more information.
NOTE: The 9th letter of the model number designate the color. “P” in the 10th position indicates Premium model.
Refer to page 1.7 for paint color code. Detailed paint ordering information is available on the dealer web site at News,
Forms & Links / Pure Polaris / Paint Codes & Part Numbers.
HAMMER™ MODEL YEAR 2005
Model Number
Model
Description / Color
V05HB126/226 (Feature & Option)
Hammer
Toxic Green w/ Tribal Tattoo
V05HB26 CA, CAP, DA, DAP, LA, LAP, UA
Hammer
Cruiser / PHAT Black
V05HB26 CK, DK, LK
Hammer
Flame Yellow
V05HB26 CL, DL, LL
Hammer
Indy Red
V05HB26 CM, DM, LM
Hammer
Cosmic Sunburst
V05HB26 CSP, DSP, LSP, US
Hammer
Indy Red w/ Tribal Tattoo
HAMMER™ MODEL YEAR 2006
Model Number
Model
Description / Color
V06HB26 CA, CAP, DA, DAP, LA, LAP, UA
Hammer
Cruiser / PHAT Black
V06HB26 CB, DB, LB,
Hammer
Indy Red
V06HB26 CJ, DJ, LJ,
Hammer
Supersonic Blue w/ Clear Pearl
V06HB26 CK, DK, , LK, UK
Hammer
Flame Yellow w/ Tribal Tattoo
V06HB26 CLP, DLP, LLP, UL
Hammer
Nuclear Sunset w/ Tribal Tattoo
VEGAS JACKPOT™ / NESS SIGNATURE SERIES VEGAS JACKPOT™ MODEL YEAR 2006
Model Number
Model
Description / Color
V06XB26 CA, CAP, DA, DAP, LA, LAP
Vegas Jackpot
Cruiser / PHAT Black
V06XB26 CM, CMP, DM, DMP, LM, LMP
Vegas Jackpot
Cruiser Black w/ X Graphics
V06XB26 CN, CNP, DN, DNP, LN, LNP, UN
Vegas Jackpot
Sunset Red w/ X Graphics
V06XB26 CP, CPP, DP, DPP, LP, LPP
Vegas Jackpot
Competition Yellow w X Graphics
V06BC26 CR, DR, LR
Ness Signature
Cruiser Black w/ Ness Flames
V06BC26 CS, DS, LS
Ness Signature
Supersonic Blue w/ Ness Graphics
V06XB26 CT, CTP, DT, DTP, LT, LTP
Vegas Jackpot
Sunset Red
1.6
GENERAL INFORMATION
1
PAINT COLOR CODES
PAINT COLOR - 2005 and 2006
PAINT CODE
NOTES
Cruiser Black (PHAT)
P-266
Indy Red
P-293
Flame Yellow
P-388
Turbo Silver
P-445
Paint kits require base coat with a topcoat of Clear Metallic (CM)
Cosmic Sunburst
P-446
Clear coat (C) required
Toxic Green Pearl
P-491
Aerosols, Kits, and Touch-Ups require a white base (WU). Toxic
Green Pearl.
Nuclear Sunset
P-493
Competition Yellow
P-517
Sunset Red
P-520
Aerosols and Touch-Ups require base coat of Indy Red with
topcoat of Clear Metallic (CM). Paint kits require white
undercoater (WU).
Nuclear Sunset w/ Tribal Tattoo P-1210
P-493 w/ X Graphic
Flame Yellow w/ Tribal Tattoo
P-1214
P-388 w/ Tribal Tattoo
Sunset Red w/ X Graphics
P-1223
P-520 w/ X Graphic
Black w/ X Graphics
P-1224
P-266 w/ X Graphic
Competition Yellow w/ X
Graphics
P-1227
P-517 w/ X Graphic
Supersonic Blue / Clear Pearl
P-1231
Aerosols, Kits, and Touch-Ups require a white base (WU).
Supersonic Blue (P-499) and Clear Pearl topcoat (CP).
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
(Base Coat Only)
WU, OWU,
PWU, VVU
WU=White Undercoater; OWU=Off-White Undercoater;
PWU=Pearl White Undercoater; VVU=Victory Violet
Undercoater
1.7
GENERAL INFORMATION
VEHICLE INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
See “VIN NUMBER LOCATION” on page 1.9 for location on the vehicle.
SAE-assigned
World Manufacturing
Identifier
Chassis:
A = 8-Ball
B = Ness Jackpot
C = Kingpin
D = Ness Kingpin (05)
E = Ness Vegas (05)
G = Vegas
H = Hammer
N = Ness Vegas (04)
T = Touring Cruiser
X = Jackpot
Type:
B = Base Model
C = Custom
D = Deluxe
Series:
C = Canada
D = Domestic (49 State)
L = California
U = United Kingdom
Serial Number
*5VPHB26D062000000*
Engine Size:
1 = 1507 cc
2 = 1634 cc
Engine HP:
6 = 78-94
Check Digit
(May be a number
or a letter)
Model Year:
5 = 2005, 6 = 2006 etc.
Plant/ Line
Code
MODEL NUMBER
See “MODEL NUMBER LOCATION” on page 1.9 for location on vehicle. See “PAINT COLORS BY MODEL” on page 1.6
for color.
Chassis:
A = 8-Ball
B = Ness Jackpot
C = Kingpin
D = Ness Kingpin (05)
E = Ness Vegas (05)
G = Vegas
H = Hammer
N = Ness Vegas (04)
T = Touring Cruiser
X = Jackpot
Engine Size:
1 = 1507 cc
2 = 1634 cc
Engine HP:
6 = 78-94
Series:
C = Canada
D = Domestic (49 State)
L = California
U = United Kingdom
P = Premium Model
(Billet Wheels, HID Headlight,
Other options as specified)
V05XB26DAP
Victory
Model Year:
05=2005; 06=2006, etc.
1.8
Type:
B = Standard
C = Custom
D = Deluxe
Color Indicator
GENERAL INFORMATION
1
VIN NUMBER LOCATION
A
The vehicle identification number (A) is stamped on the right side of the
steering head.
MODEL NUMBER LOCATION
B
The model label (B) is located on the left side of the steering head.
ENGINE NUMBER LOCATION
The engine number label (C) is attached to the horizontal crankcase
surface (2005 Hammer) or stamped into the right crankcase boss (D)
(2006 models). The label or stamping identifies the engine model and
serial number.
D
C
KEY IDENTIFICATION NUMBER
The key identification number (E) is stamped on the key tag. If the key
and the identification number are lost or misplaced, the lock set (ignition
switch / fuel cap) must be replaced.
E
Key blanks are available from service parts. Locksmiths familiar with the
motorcycle industry will be able to cut a replacement key with the key
I.D. number and a Victory key blank.
1.9
GENERAL INFORMATION
PUBLICATIONS & TECHNICAL LITERATURE
PUBLICATION PART NUMBERS
The following chart lists the part numbers for Owner’s Manuals, parts books, and parts microfiche.
OTHER VICTORY PUBLICATIONS
Year / Model
Publication Part Numbers U.S. and (Canada)
Owner’s Manual
Parts Book
Microfiche
2003 Vegas
9918231 (Canada 9918232)
9918368
9918369
2004 Vegas / Ness Vegas
9918115 (Canada 9918116)
9918954
9918955
2004 Kingpin
9918948 (Canada 9918949)
9918956
9918957
2005 Vegas / Ness Vegas
9919441 (Canada 9919442)
9919623
9919624
2005 Kingpin / Ness Kingpin
9919441 (Canada 9919442)
9919625
9919626
2005 Vegas 8-Ball
9919441 (Canada 9919442)
9919623
9919624
2005 Hammer
9919443 (Canada 9919444)
9919629
9919630
2006 Vegas
9920119 (Canada 9920120)
(California 9920563)
9920335
9920336
2006 Kingpin
9920119 (Canada 9920120)
(California 9920563)
9920308
9920339
2006 8-Ball
9920119 (Canada 9920120)
(California 9920563)
9920335
9920336
2006 Touring Cruiser
9920117 (Canada 9920118)
9920343
9920344
2006 Hammer
9920121 (Canada 9920122)
(California 9920564)
9920341
9920342
2006 Vegas Jackpot /
2006 Ness Signature Series Jackpot
9920327 (Canada 9920328)
9920345
9920346
OTHER VICTORY SERVICE MANUALS
2003-2006 Vegas / Kingpin / 8-Ball / Ness
Signature Series Vegas & Kingpin
9920337
2002 - 2006 Classic & Touring Cruiser
Service Manual 9919632
MATERIAL SAFETY DATA SHEET (MSDS)
To review or print a Material Safety Data Sheet for Victory maintenance products, chemicals or lubricants visit:
www.polarisdealers.com / news forms & links / pure polaris
OR: Contact Dealer Support (Victory Dealers)
Non-Dealers contact Customer Service at 763-417-8650
1.10
GENERAL INFORMATION
1
BREAK IN PERIOD
BREAK-IN PROCEDURE
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
Position
Notes
0-90 miles
0-1/3
Avoid prolonged operation above 1/3 throttle. Stop engine and let it cool
following every hour of operation. Vary speed of motorcycle. Do not
operate machine at one set throttle position.
90-300 miles
0-1/2
Avoid prolonged operation above 1/2 throttle. Stop engine and let it cool
following every hour of operation. Vary speed of the motorcycle. Do not
operate machine at one set throttle 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.
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.
1.11
GENERAL INFORMATION
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. Except for TPS adjustments as required by the Periodic
Maintenance Interval Table on page 2.11, or if components are replaced that affect idle speed, no adjustments should
be made to the 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)
A vacuum hose connects the purge port manifold to the charcoal canister. Evaporated fuel vapor passes from the fuel
tank, along the vent hose , and to the charcoal canister. Activated charcoal in the canister filters the regulated
elements of the vapor for storage until the engine is started and the motorcycle is driven. The canister and liquid trap
are cleaned as part of the engine's ordinary combustion cycle. Inspect the evaporative control system clamps, hoses,
fittings, canister and other hardware for wear or damage during each maintenance period of the motorcycle. Refer to
the owner's manual for emission system warnings and instructions.
1.12
GENERAL INFORMATION
1
INSTRUMENTS
1. Speedometer
2. Tachometer
3. Odometer / 4. Trip Odometer
5. Reset Button
JACKPOT / NESS JACKPOT
6. Overdrive Light (Tachometer equipped only)
HAMMER
SPEEDOMETER (1)
The speedometer receives an input signal from the speed sensor located on top of the crankcase behind the rear
cylinder. Pulse signals from the speed sensor are converted inside the speedometer to speed and distance outputs in
miles (kilometers in Canada). These outputs are displayed by the analog needle (speed) or in the LCD window
(distance). The speedometer operates only when the ignition switch is in the On position and the speed sensor has
an input (vehicle is moving). Refer to Chapter 19 for speedometer or sensor diagnostics.
TACHOMETER (2)
The tachometer reports current engine speed in revolutions per minute (RPM). A red line on the gauge indicates
maximum safe engine RPM. The tachometer may be standard equipment or an accessory on some models.
WARNING
Do not operate the engine over 5600 RPM. Excessive RPM could cause engine damage or failure that could result
in you losing control of the motorcycle.
ODOMETER (3)
The odometer is the default mode of the speedometer LCD after starting the engine and displays the total miles
traveled (km in Canada).
To toggle the display between Odometer and TRIP Odometer, the ignition switch must be in the ON position. Press
the reset button (5). The display changes to TRIP".
TRIP ODOMETER (4)
The trip odometer shows total distance traveled since the trip odometer was reset.
To toggle the display between Odometer and TRIP Odometer, the ignition switch must be in the ON position. Press
the reset button. The display changes to TRIP".
To reset the trip odometer, the ignition switch must be in the ON position with the display in trip odometer mode. Press
and hold the reset button (5) until the TRIP odometer display resets to zero.
1.13
GENERAL INFORMATION
INDICATOR LIGHTS
7
1
2
4
3
5
6
Table 1-1:
#
Symbol / Function
NEUTRAL INDICATOR
1
HEADLAMP HIGH BEAM
2
Operation
The neutral indicator illuminates when the transmission is in Neutral, and the
ignition key is ON.
The headlamp high beam indicator illuminates when the headlamp switch is set to
High and the ignition key is ON.
3
The check engine indicator will illuminate any time the ignition key is ON and the
engine control module sensors report abnormal sensor or engine operation. The
check engine indicator will continue to illuminate as long as the fault condition
exists. It also illuminates momentarily when the ignition key is ON and the engine is
not running. This demonstrates that the indicator is functioning properly.
4
The low oil pressure indicator illuminates when engine oil pressure drops below
safe operating pressure. If this indicator illuminates while the engine is running, turn
the engine off immediately and check the oil level. Add oil if necessary. If the oil level
is correct and the indicator remains illuminated after the engine is restarted, turn the
engine off immediately.
The low oil pressure indicator also illuminates when the ignition key is ON and the
engine is not running. This demonstrates that the indicator is functioning properly.
CHECK ENGINE INDICATOR
LOW OIL PRESSURE
INDICATOR
TURN SIGNAL INDICATOR
5
LOW FUEL INDICATOR
6
OVERDRIVE INDICATOR
7
1.14
The turn signal indicator flashes when the left, right, or both turn signals are active.
If a turn signal bulb has failed, or if there is a short circuit in the turn signal system,
the turn signal indicator flashes at more than twice the normal rate.
This indicator is also used as the output display for the diagnostic “blink codes”
when using the self-diagnostic feature of the Auto-Cancel Turn Signal system. Refer
to Chapter 9 for more information on the self diagnostic feature.
The low fuel indicator illuminates when approximately 0.6 gallons (2.27 liters) of fuel
remains in the fuel tank and the ignition key is ON.
On vehicles equipped with a tachometer, the overdrive indicator is illuminated when
the transmission is in Overdrive (6th gear) and the ignition key is ON.
GENERAL INFORMATION
1
SPECIAL SERVICE TOOLS
GENERAL & PRECISION MEASUREMENT
TOOL
PART NUMBER
Bearing & Seal Driver Set
PV-43558
Bore Gauge Set, 50-100mm
PV-3017
Decal, Service Bulletin Completion
Dial Caliper (Metric, 0-150mm)
Dial Caliper (Electronic Conversion. English 0-6” / Metric 0-150mm)
Dial Indicator, Adjustable (Metric. 10mm travel)
7170107
(Order from Victory Parts Dept.)
PV-26900-7
PV-39776
PV-26900-12
Dial Indicator Stand, Flexible. Magnetic Base
PV-34481
Engine Ear Listening Device
PV-39565
Feeler Gauge Set
Outside Micrometer (0-25 & 25-50mm)
Outside Micrometer Set (0-100mm)
PV-26900-8 or PV-26900-9
PV-3006, PV-3007
PV-3009
Plastigauge®
Commercially Available
Small Hole Gauge Set
Commercially Available
Straight Edge, Precision
Surface Plate
PV-34673
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
TOOL
Belt Tension Gauge
PART NUMBER
PV-43532
Cylinder Leakdown Tester
PV-35667-A
Compression Gauge Set
PV-33223
Oil Pressure Gauge Set
PV-43531
Oil Filter Wrench
65mm/2.5in. Commercially available
ELECTRICAL
TOOL
PART NUMBER
Ammeter Inductive Clamp for Fluke 73™ Multimeter
PV-39617
Electrical Connector Test Adapter Kit
PV-43526
Inductive Timing Light
PV-43537
Multimeter, Fluke 73™
PV-43546
Speedometer Signal Tester (Requires Adaptor PV-47303)
PV-43544
Speedometer Signal Test Adapter 2001-Current
PV-47303
1.15
GENERAL INFORMATION
ENGINE, CLUTCH, & TRANSMISSION
TOOL
PART NUMBER
Clutch Hub Holding Tool
PV-43518
Clutch Shaft Holder
PV-45028
Clutch Shaft Bearing Support
(for clutch shaft installation)
PV-47331
Crankcase Assembly Tool (Same as Mainshaft / Crankcase
Installer)
Crankcase Assembly Tool Adaptor
PV-46299 (Must be used with PV-45030) and
Adaptor (Extension) PVX-47429
PVX-47429
Crankshaft Bearing Protector
PV-47207
Crankshaft Rotation Socket
PV-46988
Crankcase Separator (Crankcase Removal)
PV-47332
Engine Hoist or Lift
Engine Lock Tool
Engine Stand
Flywheel Puller
Mainshaft / Crankcase Installer (Crankcase Assembly)
Moly Assembly Paste (Premium Starter Grease)
Mainshaft (Output Shaft) Seal Installation Tool
Piston Ring Compressor (97mm +)
Split Gear Line-Up Tool
Valve Spring Compressors (Adapter is PV-43513-A)
Commercially Available
PV-43502-A
Commercially Available
PV-43533
PV-46299 (Must be used with PV-45030)
PN 2871460
(Order from Victory Parts Dept.)
PV-43505
Includes PV-43570-1 Pliers, PV-43570-2 Band
(3 5/8” to 3 7/8”)
Any 1/4” shaft: Example: 1/4” drill bit shank.
PV-1253 or PV-4019 (Quick Release)
STEERING & SUSPENSION
TOOL
Blind Bearing Remover Set
Cartridge Shaft Holder (Kingpin / Hammer)
Damper Rod Holder (Vegas)
Fork Oil Level Gauge
Fork Seal Driver 43mm, Inverted (Kingpin / Hammer)
Fork Seal Driver, 43mm, Conventional (Vegas)
Fork Seal Guide Tool, 43mm (KP, Hammer, Vegas)
Steering Bearing, Wheel Bearing Installation Set
Steering Stem Bearing Removal Tool (Lower)
Steering Stem Bearing Adjustment Socket
Steering Stem Bearing Spanner Wrench
Shock Absorber Pre-Load Adjustment Spanner
Shock Spring Compressor
1.16
PART NUMBER
PV-43551
PV-47060
PV-43517
PV-59000-A
PV-47035
PV-47036
PV-47037
PV-43515
PV-44683
PV-43508
PV-43509
PV-46993
PV-43571
GENERAL INFORMATION
1
WHEEL & TIRE
TOOL
PART NUMBER
Air Pressure Gauge
Commercially Available
Tire Bead Breaker
( May be part of the tire removal equipment being used)
Commercially Available
Tire Mounting Lubricant
Commercially Available
Tire Removal Equipment
Commercially Available
Rim Protector
PV-43536
Wheel Balancing/Truing Stand
TBA
FUEL SYSTEM & FUEL INJECTION
SPECIAL TOOLS- FUEL SYSTEM/ FUEL INJECTION
PART NUMBER
Victory/Polaris Diagnostic Tool Kit w/ Diagnostic Software
PV-46085 (See Chapter 5)
PV-46085 Kit Contents
(The items at right are included in main kit above and can
also be ordered separately)
Interface Cable PU-47151
Victory Interface Cable Adapter
PV-46085-2
Kit - Air / Fuel Ratio Monitor (Includes components below)
PV-45410 (See Chapter 5)
Tube, Air/Fuel Monitor Sensor PV-45410-1 (not required for Hammer / Jackpot)
O2 Sensor (with wire harness and connector) PV-45410-2
Cable, Air/Fuel Monitor Power & Volt Meter PV-45410-3
Instruction Sheet, Air/Fuel Monitor PV-45410-4
Fuel Pressure Gauge
Laptop Computer (Refer to diagnostic software user
manual or HELP section for minimum specifications
PV-43506
Commercially Available
TOOL ORDERING INFORMATION
NOTE: Not all special tools listed here are applicable to models covered in this manual. Order Special Service Tools
from SPX Corp. (Phone 800-328-6657 / FAX 586-578-7375) except where noted to order from Victory or as
“Commercially Available”.
1.17
GENERAL INFORMATION
TRANSPORTING AND SECURING THE MOTORCYCLE
GENERAL GUIDELINES
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.
Loosen screw and slide
turn signal mount up
Both sides
Both sides
Both sides
Hammer
1.18
Jackpot
GENERAL INFORMATION
1
ROUTING DIAGRAMS
WIRE HARNESS - LEFT REAR FRAME
Tie Strap Includes:
Frame Tube
Main Bundle
Regulator / Rectifier Harness
Crankshaft Position Sensor (CPS) Harness
Tie Strap Includes:
Starter Cable
Regulator / Rectifier Harness
Crankshaft Position Sensor (CPS) Harness
! Starter cable to be routed on outside of CPS
and Voltage Regulator wiring
Rear Brake Light Switch
Oil Pressure Switch
= Apply Dielectric Grease
P/N 2871329
1.19
GENERAL INFORMATION
WIRE HARNESS - RIGHT REAR FRAME
MAP Sensor
Tie Strap: Place between fuel pump harness
and main harness clip
Gear position switch harness connector
1.20
GENERAL INFORMATION
1
WIRE HARNESS - RIGHT SIDE
Harness Route
OBD ll Diagnostic Port
Fuse Box
Speed Sensor
Harness Clip
Speed Sensor
Throttle Position Sensor (TPS)
Horn
Front Injector Jumper
Gear Position Switch
1.21
GENERAL INFORMATION
WIRE HARNESS - UNDER SEAT
Rear Harness Connector
Chassis Ground
! Do not ground other items to
this terminal
ECM Connector (Access by
removing battery box)
1.22
HID Kit Connectors
GENERAL INFORMATION
1
REAR FENDER
Refer to Chapter 3 for fender removal
Stop / Tail Lamp Connectors
Secure wires in guides
Turn Signal Connectors
License Plate Lamp Connectors
Secure wires in guides
1.23
GENERAL INFORMATION
WIRE HARNESS CONNECTOR LOCATIONS
TOP VIEW
Indicator Lights
Front Left Turn Signal
Left Hand Controls
Inside Headlamp
Speedometer
Front Right Turn signal
Right Hand Controls
Tachometer (or Accy Tach)
Horn
= Apply a light film of
Dielectric Grease 2871329
Regulator/Rectifier
Crankshaft Position Sensor
(CPS)
Dart
Voltage Regulator
Battery Positive (+)
Circuit Breaker
Power Out
Starter Relay (Solenoid)
Chassis Ground
! Do not add
other grounds here
Oil Pressure
Battery Negative
Battery Positive (+)
1.24
Battery Positive (+)
Circuit Breaker
Power In
GENERAL INFORMATION
1
LEFT SIDE VIEW
= Apply a light film of
Dielectric Grease 2871329
Air Temperature Sensor
Front Fuel Injector Jumper
Ignition Coils
High Intensity
Discharge
HID Ballast Power
HID Ballast Output
Horn
Chassis Ground
! Do not add
other grounds here
Ignition Switch
Output
Oil Temperature Sensor
(Rear cylinder head LH side)
Starter Relay
Tie Strap
Speed Sensor
(Rear top of Crankcase)
Crank Position Sensor (CPS)
On front left primary cover
Engine
Control
Module
(ECM)
Engine Ground
(Rear left crankcase)
Rear Brake
Switch
Regulator/Rectifier
Oil Pressure Switch
ALONG LEFT LOWER FRAME CRADLE
1.25
GENERAL INFORMATION
RIGHT SIDE VIEW
= Apply a light film of
Dielectric Grease 2871329
Harness Clips (to frame)
Air Temperature
Sensor
Horn
Rear Fuel Injector
Ignition Switch
Starter Solenoid
Speed Sensor
Crankshaft Position
Sensor (CPS)
Gear Position
Switch
Engine Ground
Tie Strap
Route starter motor cable outside
of these
Regulator/Rectifier
Rear Brake Light Switch
1.26
GENERAL INFORMATION
1
FUEL TANK VENT AND DRAIN HOSE ROUTING
2005 HAMMER - 49 STATE, CANADA, UK
NOTE: On 2005 Hammer 49 State, Canada, or UK models,
the fuel cap is vented.
Drain hose fitting for cap
area on left side of tank
Clamp
22 in. lbs.
(2.5 Nm)
Tanks with a single hose (water drain) must
have a vented fuel cap. See Chapter 5 to test cap vent.
Tie Strap.
Do not crimp.
A
49 State, Canada, UK Models
One side of “Y” connection is plugged
or may be a straight single connection.
Tie Strap.
Do not crimp.
Cap area drain hole
B
Tie Strap.
Do not crimp.
C
Water Drain/Hose Inspection
1.
Disconnect drain hose from junction at rear left side of fuel tank (A). Open fuel cap and inspect drain hole (B). Pump low pressure air
into bottom of drain hose at the junction and listen for air escaping from the drain hole. Verify drain hose below “Y" fitting at (A) is clear
to the end of hose at (C).
1.27