Service manual

ManualsBrandsVictory ManualsAutomotiveVegas Jackpot

2008

VEGAS

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 VEGAS LOW

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 VEGAS 8-BALL



KINGPIN



 KINGPIN



TOUR  KINGPIN



8-BALL

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SERVICE MANUAL PN 9921242

FOREWORD

This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept

available for reference in the shop area. All references to left and right side of the motorcycle are from the operator's

perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Read the text and be familiar with the service procedures

before starting the work. Certain procedures will require the use of special tools. Use only the proper tools as specified.

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 above model motorcycles. Comments or suggestions about this manual may be directed to:

Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

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. Any reprinting

or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Summary of content (41 pages)

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2008 VEGAS® • VEGAS LOW™ • VEGAS 8-BALL™ KINGPIN® • KINGPIN® TOUR • KINGPIN 8-BALL™ SERVICE MANUAL PN 9921242 FOREWORD This manual is designed primarily for use by Victory service technicians in a properly equipped shop and should be kept available for reference in the shop area. All references to left and right side of the motorcycle are from the operator's perspective when seated in a normal riding position.
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TRADEMARKS The following are REGISTERED trademarks of Polaris Industries Inc.: POLARIS; POLARIS THE WAY OUT; VICTORY MOTORCYCLES; FREEDOM; 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, is a registered trademark of the William F.
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GENERAL INFORMATION / ROUTING CHAPTER 1 GENERAL INFORMATION / ROUTING 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SERVICE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 UNDERSTANDING SAFETY LABELS & INSTRUCTIONS . . . . . . . . . . . .
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GENERAL INFORMATION / ROUTING SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 GENERAL & PRECISION MEASUREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUNE UP & MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION / ROUTING 1 GENERAL INFORMATION 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.
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GENERAL INFORMATION / ROUTING 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! Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.
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GENERAL INFORMATION / ROUTING 1 GENERAL SPECIFICATIONS - VEGAS Vegas Specifications 2008 Vegas [Vegas 8-Ball] C A P A C I T I E S &D I M E N S I O N S Oil Capacity 5.0 Qt (4.75 ltr) (Approximately 4.65 qts.or 4.25 ltr at oil & filter change) Fuel Capacity 4.5 US Gal (17 ltr) (.8 U.S. gal / 3.0 ltr reserve) Fuel Type / Octane Minimum Premium Unleaded / 92 Octane Wheelbase 66.3 in (168.
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GENERAL INFORMATION / ROUTING Vegas Specifications (cont.) 2008 Vegas [Vegas 8-Ball] D R I V E Transmission Type Manual, 6 Speed Overdrive Constant Mesh [8-Ball - 5 speed] Clutch Type Wet, Multi-Plate Diaphragm Spring Primary Drive Type Wet, Gear Drive w/ Torque Compensator Primary Reduction Ratio Final Drive Type / Final Drive Ratio Gear Shift Pattern S Y Internal Gear Ratios 1st S 2nd T 3rd E 4th M 5th 1.5:1 28mm Carbon Fiber Reinforced Belt / 2.
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GENERAL INFORMATION / ROUTING 1 GENERAL SPECIFICATIONS-KINGPIN Kingpin Specifications 2008 Kingpin [Kingpin 8-Ball] C A P A C I T I E S &D I M E N S I O N S Oil Capacity 5.0 Qt (4.75 ltr) (Approximately 4.65 qts.or 4.25 ltr at oil & filter change) Fuel Capacity 4.5 US Gal (17 ltr) (.8 U.S. gal / 3.0 ltr reserve) Fuel Type / Octane Minimum Premium Unleaded / 92 Octane Wheelbase 65.6 in (166.
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GENERAL INFORMATION / ROUTING Kingpin Specifications (cont.
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GENERAL INFORMATION / ROUTING 1 VEHICLE LOADING WEIGHT CAPACITY - TOP BOX AND SADDLEBAGS When operating a motorcycle with original equipment or accessory saddlebags and / or top box (trunk): • Never ride at speeds exceeding 80 mph (129 km/h). Depending on load and weather conditions, the maximum safe operating speed may be less than 80 mph (129 km/h). Saddlebags and / or top box, combined with the lifting or buffeting effects of wind, can make the motorcycle unstable and cause loss of control.
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GENERAL INFORMATION / ROUTING LOADING EXAMPLES FOR GROSS VEHICLE WEIGHT RATING (GVWR) - KINGPIN® Example 4: Kingpin® with no accessories or cargo (GVWR 1234 lbs / 560 kg) Item Weight Motorcycle - with full capacity of all fluids 704 lbs (319 kg) Operator - with recommended riding apparel 230 lbs (104 kg) Passenger - with recommended riding apparel.
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GENERAL INFORMATION / ROUTING 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.
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GENERAL INFORMATION / ROUTING Paint Colors by Model Refer to www.polarisdealers.com for more information. The 9th letter of the model number designate the color. “P” in the 10th position indicates Premium model. Premium models could be equipped with billet wheels, chrome package, HID headlamp, etc. NOTE: Refer to page 1.14 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. Refer to page 1.
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GENERAL INFORMATION / ROUTING 1 KINGPIN® MODEL YEAR 2008 Model Number Model V08CB26CA, CAP Kingpin, CND, Black V08CB26DA, DAP Kingpin, 49st, Black V08CB26LA, LAP Kingpin, CAL, Black V08CB26CC Kingpin, CND, Midnight Cherry V08CB26DC Kingpin, 49st, Midnight Cherry V08CB26LC Kingpin, CAL, Midnight Cherry V08CB26CD Kingpin, CND, Steel Gray V08CB26DD Kingpin, 49st, Steel Gray V08CB26LD Kingpin, CAL, Steel Gray V08CB26CHP Kingpin, CND, Sands Metallic / Black V08CB26DHP Kingpin, 49st, Sand
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GENERAL INFORMATION / ROUTING PAINT COLOR CODES PAINT COLOR: 2008 PAINT CODE Cruiser Black (PHAT) P-266 Turbo Silver P-445 Flat Black P-463 Sunset Red P-520 Boardwalk Blue P-524 Ness Metallic Purple P-543 Supersteel Gray P-553 Midnight Cherry P-554 Sands Metallic P-555 Anodized Aluminum P-565 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 Clea
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GENERAL INFORMATION / ROUTING 1 VEHICLE INFORMATION Vehicle Identification Number (VIN) See “VIN NUMBER LOCATION” on page 1.16. for location on the vehicle.
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GENERAL INFORMATION / ROUTING VIN NUMBER LOCATION ENGINE NUMBER LOCATION The vehicle identification number (A) is stamped on the right side of the steering head. The engine number (C) is stamped into the right crankcase boss. The stamping identifies the engine model and serial number. A C MANUFACTURER LABEL KEY IDENTIFICATION NUMBER The manufacturer label (B) located on the left frame tube contains the following information: The key identification number (D) is stamped on the key tag.
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GENERAL INFORMATION / ROUTING 1 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.
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GENERAL INFORMATION / ROUTING 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.
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GENERAL INFORMATION / ROUTING 1 EMISSIONS Emission Control Systems The U.S.
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GENERAL INFORMATION / ROUTING INSTRUMENTS A B C D E F Speedometer (A) 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).
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GENERAL INFORMATION / ROUTING 1 INDICATOR LIGHTS 1 2 3 7 4 # 5 6 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.
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GENERAL INFORMATION / ROUTING 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.
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GENERAL INFORMATION / ROUTING 1 ENGINE, CLUTCH, & TRANSMISSION TOOL Clutch Shaft Bearing Support (for clutch shaft installation) Crankcase Assembly Tool (Crankcase Installer) Crankcase Assembly Tool Adapter PART NUMBER PV-47331 PV-46299 (Must be used with PV-45030) and Adapter (Extension) PVX-47429 PVX-47429 Crankshaft Bearing Protector PV-47207 Crankshaft Rotation Tool PV-48736 Crankcase Separator (Crankcase Removal) Engine Hoist or Lift Engine Lock Tool Engine Stand PV-47332-A Commercially Availa
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GENERAL INFORMATION / ROUTING WHEEL & TIRE TOOL PART NUMBER PV-48909 (Victory Air Pump & Gauge) Or Commercially Available Tire Pressure Gauge Air Pressure Gauge 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 Commercially Available FUEL SYSTEM & FUEL INJECTION SPECIAL TOOLS- FUEL SYSTEM/ FUEL INJECTION PA
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GENERAL INFORMATION / ROUTING 1 TRANSPORTING AND SECURING THE MOTORCYCLE 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.
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GENERAL INFORMATION / ROUTING ROUTING DIAGRAMS WIRE HARNESS - RIGHT REAR FRAME = Apply Dielectric Grease P/N 2871329 Harness clip in RH hole Horn Secure purge valve connector to harness (49 State) Harness clip Idle Air Control Harness (IAC) NO DIELECTRIC GREASE OR OTHER CONTAMINANTS ALLOWED ON O2 SENSOR WIRES Secure to brake line bracket (ACC connector) Starter Motor + Cable Route underneath brake clips Route starter cable and voltage regulator bundle inside brake line bracket through suspension pivot
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GENERAL INFORMATION / ROUTING 1 WIRE HARNESS - RIGHT SIDE Clip to frame peg Clip Install harness clip on rear side of bracket Fuel Pump Clip Diagnostic Connector Turn Signal Auto Cancel Module (Under battery box) Rear Brake Light Switch (connect to switch then tie strap to starter cable) Route voltage regulator bundle through clip and insert into hole on bracket Gear Position Switch CPS Wire Guide Speed Sensor P-Clips Tie Strap Starter + Cable 1.
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GENERAL INFORMATION / ROUTING WIRE HARNESS - LEFT SIDE NO DIELECTRIC GREASE OR OTHER CONTAMINANTS ALLOWED ON O2 SENSOR WIRES OR ENGINE HARNESS CONNECTOR Front Coil Wire (Routed through tie strap) Ignition Bundle Routes Through Clip (Dart Clip Secured To Inside Of Bracket) Rear Coil Wire Routed Through Tie Strap Front Coil Wire To Bottom Coil Battery + Battery Circuit Breaker Starter Solenoid Turn Signal Auto Cancel Module Secure battery ground cable and O2 sensor wire in dart strap on front of bracket (S
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GENERAL INFORMATION / ROUTING 1 WIRE HARNESS - UNDER SEAT Chassis Ground (M6x15 Flange Head) 9.6 Nm (85 lb-in) PCM Connector NO DIELECTRIC GREASE OR OTHER CONTAMINANTS ALLOWED ON O2 SENSOR WIRES OR ENGINE HARNESS CONNECTOR Engine Wire Harness Connector RH VIEW Fuse Box HID Module Engine Wire Harness Connector PCM Connector Rear Chassis Wire Harness Connector 1.
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GENERAL INFORMATION / ROUTING WIRE HARNESS CONNECTOR LOCATIONS WIRE HARNESS FRONT VIEW NO DIELECTRIC GREASE OR OTHER CONTAMINANTS ALLOWED ON O2 SENSOR WIRES OR ENGINE HARNESS CONNECTOR = Apply Dielectric Grease P/N 2871329 Speedometer High Beam Front Left Turn signal Left Hand Control Right hand Control Indicator Lamps Overdrive Light Tachometer Horn O2 Sensor Engine Harness Connector Fuse Box Regulator Battery + Starter Relay (Solenoid) Engine Ground Cable (Rear left crankcase) Brake Light Switch
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GENERAL INFORMATION / ROUTING 1 WIRE HARNESS RIGHT SIDE VIEW / TOP VIEW NO DIELECTRIC GREASE OR OTHER CONTAMINANTS ALLOWED ON O2 SENSOR WIRES OR ENGINE HARNESS CONNECTOR = Apply Dielectric Grease P/N 2871329 Fuel Pump / Level Sensor HID Headlamp RIGHT SIDE VIEW Starter Relay Ignition Switch Horn Engine Ground (Rear left crankcase) Turn Signal Auto-Cancel Module (Under battery box) O2 Sensor Rear Brake Light Switch TOP VIEW Regulator Battery + 1.
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GENERAL INFORMATION / ROUTING REFERENCE DECIMAL EQUIVALENTS SAE TAP DRILL SIZES Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.
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GENERAL INFORMATION / ROUTING FAHRENHEIT TO CELSIUS oC o MEASUREMENT CONVERSION CHART to oF: 9 (oC + 40) ÷ 5 - 40 = oF F to C: 5 ( F + 40) ÷ 9 - 40= C o DEGREES F 32 o o DEGREES C UNIT OF MEASURE MULTIPLIED BY CONVERTS TO ft-lb x 12 = in-lb in-lb x.0833 = ft-lb ft-lb x 1.356 = Nm in-lb x.0115 = kg-m 0 Nm x.7376 = ft-lb 41 5 kg-m x 7.233 = ft-lb kg-m x 86.796 = in-lb 50 10 kg-m x 10 = Nm 59 15 68 20 77 in x 25.4 = mm mm x.03937 = in in x 2.
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GENERAL INFORMATION / ROUTING NOTES 1.
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MAINTENANCE CHAPTER 2 MAINTENANCE 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 TUNE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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MAINTENANCE PERIODIC MAINTENANCE (CONT.) HEADLIGHT AIM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLAMP AIM ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND & SPRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND PAD INSPECTION . . . . . .
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MAINTENANCE SERVICE SPECIFICATIONS 2 TUNE UP ITEM SPECIFICATION Specifications apply to Vegas and Kingpin models except Vegas Low where noted Footpegs: (page 2.13): 2-5mm (.080-.200") Brake Pedal Freeplay (Gap at pedal stop) Floorboards: (page 2.16) 1-2mm (.040-.080") Clutch Lever Freeplay .5 - 1.5mm (.020-.060") Compression Pressure (Cylinder) 185-225 (1275-1551) Vegas / KP 12 mm (15/32") with 10 lb force +/- 1.0 mm (+/- 1/32) Drive Belt Deflection (See page 2.
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MAINTENANCE FASTENER TORQUE SPECIFICATIONS MAINTENANCE ITEMS DESCRIPTION APPLY / NOTES TORQUE N-m Lb-ft (Lb-in) Air Filter Cover - (10) Axle Nut, Rear 88 65 Axle Adjuster Lock Nut, Rear (Lock nut style adjusters only) - - Tighten securely after axle is tightened Battery Terminal Bolts & Battery Cover Nuts 4.5 (40) Dielectric Grease Battery Cable To Solenoid or Starter Motor 6.
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