Victory Classic Cruiser (2002-2004) - Repair, Service Manual and Electrical Wiring Diagrams

CLICK HERE FOR SAMPLE MANUAL

VICTORY CLASSIC CRUISER (2002-2004) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING

- English Service Manual and Wiring Diagram to motorcycles Victory Classic Cruiser (2002-2004).

CONTENTS:

INTRODUCTION

TABLE OF CONTENTS

CHAPTER 1-GENERAL

- Understanding Safety Labels and Instruction
- Danger, Warnings, & Caution Symbols
- General Safety / Service Rules
- Victory Touch Up Paint and Refinishing Kits
- Victory Paint Colors and Paint Codes
- Vehicle Identification Number (VIN)
- Key Identification Numbers
- Model Identification Number
- Engine Number Decal
- Break-in Procedures
- Publication Part Numbers
- Emission Control Systems
- Emission Sources
- Exhaust Emmision Control
- Noise Emmision Control System
- Evaporative Emission Control Control (CA Models)
- Crankcase Emission Control
- Multi-Function Display (MFD)
- MFD Function Flow Chart
- Special Service Tools
- Cable & Harness Routing

CHAPTER 2-MAINTENANCE

- General Specifications, 2002 Models
- General Specifications, 2003-2004 Models
- Periodic Maintenance Interval Chart
- Tune-up Specifications
- Fastener Torque Specifications, Tune-up
- Maintenance Products
- Oil Level Inspection / Oil and Filter Change
- Control Lubrication
- Brake Pedal / Brake Lever Freeplay Inspection
- Brake Fluid Level Inspection
- Brake Pad Inspection
- Clutch Lever Freeplay
- Fast Idle Lever Freeplay Adjustment
- Throttle Cable Freeplay Adjustment
- Sidestand Pivot / Sidestand Pad Inspection
- Air Filter Inspection / Replacement
- Fuel Pre-Filter and Fuel Line Inspection
- Fuel Tank Vent / Crankcase Ventilation
- Spark Plug
- Battery, Battery Storage, Inspection
- Battery Removal / Installation
- Compression Test
- Fuses / Fuse Box
- Headlight Aim Adjustment
- Drive Belt Inspection / Tension Inspection
- Drive Belt Tension Adjustment
- Drive Belt / Rear Wheel Alignment
- Drive Sprocket Inspection
- Front Fort Inspection
- Suspension Inpection
- Shock Spring Preload Inspection
- Steering Head Bearing Inspection
- Tire Inspection / Tire Pressure Table
- Cleaning
- Storage

CHAPTER 3-FRAME, BODY, EXHAUST

- Warnings / Troubleshooting
- Exhaust Exploded Views and Fastener Torque Values
- Windshield and Deflector Exploded View
- Seat Removal and Installation
- Seat Base Removal, Passenger, (STD, DLX, Classic Cruiser)
- Side Cover Removal
- Muffler Removal and Installation (STD, DLX, Classic Cruiser)
- Exhaust Pipe Removal and Installation (Touring Cruiser)
- Saddlebag Removal and Installation
- Rear Fender Removal & Installation
- Windshield (Touring Cruiser)
- Saddlebag Exploded View, Touring Cruiser
- Fender Tip Installation

CHAPTER 4-LUBRICATION & COOLING

- General
- Specifications
- Special Tools
- Troubleshooting
- Oil Pressure Inspection
- Oil Pump Removal
- Oil Pressure Relief Values
- Oil Pump Inspection
- Oil Pump Disassembly
- Oil Pump Assembly
- Oil Pump Installation
- Oil Cooler Inspection
- Oil Cooler Removal
- Oil Cooler Installation

CHAPTER 5-FUEL SYSTEM / FUEL INJECTION

- General
- Specification, Special Tools, Troubleshooting
- Evaporative Emmisions Routing, TC, CA
- Evaporative Emissions Routing, STD, DLX, Classic
- Fuel Injection Servicing Procedures
- Fuel Delivery Assembly View
- Fuel Tank Removal
- Fuel Level Sender Removal
- Fuel Pump Removal
- Fuel Pump Installation
- Fuel Level Sender Installation
- Fuel Sender Resistance Test (Fuel Tank Installed)
- Fuel Sender Resistance Test (Bench Test)
- Fuel Tank Installation
- Fuel Tank Vent Inspection
- Fuel Pump Priming Procedure
- Fuel Pump Electrical Diagnostics
- Fuel Pump Current Draw
- Fuel Pump Pressure Inspection
- Throttle Body Removal and Installation
- Fuel Injector Removal
- Throttle Cable / Fast Idle Cable Adjustment
- Fuel Injection Component Location
- Fuel Injection Exploded View
- Self Diagnostic Function
- Sensor and Fuel Injection Diagnostics
- Fault Code Overview
- Fault Codes (Listing)
- Barometric Pressure (Map) Sensor Diagnostics
- Air Temperature Sensor (ATS) Diagnostics
- Throttle Position Sensor (TPS) Diagnostics
- Oil Temperature Sensor (OTS) Diagnostics
- Crankshaft Position Sensor Diagnostics
- Vehicle Speed Sensor Diagnostics
- Memory Check Sum Error
- Battery Voltage AT ECM Diagnostics
- Battery Voltage Testing
- ECM Connector Map / ECM Harness Testing
- Overview of Operation-Fuel Injection System
- TPS Calibration Notes / Tools Needed
- TPS Calibration Procedure
- Re-flash Software Essentials
- Troubleshooting

CHAPTER 6-ENGINE REMOVAL & INSTALLATION

- Engine Mounting Exploded View / Fastener Torque
- Specifications
- Fastener Size and Torque Charts
- Engine Removal
- Engine Installation

CHAPTER 7-CYLINDER HEAD & VALVE TRAIN

- General
- Specifications, Cylinder Head & Valve Train
- Exploded View & Torque Specs, Cam Drive / Valve Cover
- Exploded View, Cam Carrier & Rocker Arm
- Exploded View & Torque Specs, Cyl Head & Cam Carrier
- Cam Timing Quick Reference
- External Inspection
- Cam Drive Cover Removal
- Valve Cover Removal
- Cam Chain Tensioner Removal
- Cam Chain Tensioner Inspection
- Camshaft Chain & Sprocket Removal
- Rocker Arm Removal
- Rocker Arm and Shaft Inspection
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Disassembly
- Cylinder Head Inspection
- Valve Spring Free Length Inspection
- Valve Inspection
- Valve Guide Removal and Installation
- Valve Seat Inspection
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Cylinder Head Installation
- Camshaft and Rocker Arm Installation
- Camshaft Timing, Rear Cylinder
- Camshaft Timing, Front Cylinder

- Valve Cover Installation
- Troubleshooting

CHAPTER 8-CYLINDER & PISTON

- General
- Torque Values
- Piston Ring Profile and Orientation
- Specifications
- External Engine Inspection
- Cylinder Removal
- Cylinder Inspection
- Cylinder Bore Measurement
- Piston to Cylinder Clearance Worksheet
- Cylinder Warpage Measurement
- Piston and Piston Ring Removal
- Piston and Piston Ring Inspection
- Piston Pin Bore Inspection
- Cylinder Stud Replacement
- Piston Ring Installation
- Piston Installation
- Cylinder Installation
- Troubleshooting

CHAPTER 9-CLUTCH, PRIMARY DRIVE, & SHIFT LINKAGE

- General
- Specifications
- Primary Cover Exploded View
- Shift Mechanism Exploded View
- Cap Plate & Cap Plate Seal Removal
- Clutch Pinion Shaft Removal & Installation
- Clutch Pinion Shaft Seal Replacement
- Shift Lever Arm Removal
- Primary Cover Removal
- Clutch Pinion Shaft Bearing Inspection
- Shift Ratchet Removal & Inspection
- Shift Ratchet Installation
- Shift Shaft Bearing & Seal Replacement
- Primary Cover Installation
- Clutch Exploded View
- Clutch Removal
- Clutch Disassembly
- Clutch Inspection
- Clutch Pressure Plate Inspection
- Rack Insert Disassembly & Inspection
- Clutch Assembly
- Clutch Installation
- Primary Drive / Torque Compensator Exploded View
- Torque Compensator Removal
- Torque Compensator Inspection
- Torque Compensator Installation
- Flywheel Removal / Installation
- Split Gear Removal
- Split Gear Inspection
- Split Gear Installation
- Starter Gear Removal
- Starter Gear Inspection
- Starter Slip Clutch Removal and Installation
- Starter Gear Installation
- Troubleshooting

CHAPTER 10-TRANSIMISSION & CRANKSHAFT

- General / Specifications
- Connecting Rod and Crankhaft Specifications
- Torque and Locking Agent, Crankcase Components
- Torque and Locking Agent, Crankshaft, Crankcase
- Crankcase Separation
- Exploded View, Transmission Assembly
- Exploded View, Mainshaft
- Exploded View, Countershaft
- Exploded View, Shift Drum and Shift Fork Inspection
- Power Delivery through Transmission
- Transmission Removal
- Transmission Inspection
- Shift Drum Inspection
- Crankshaft Assembly / Clutch Shaft Installation
- Transmission Installation
- Crankshaft Removal
- Rod Side Clearnace Inspection
- Connecting Rod Removal & Identification
- Crankshaft Inspection
- Crankshaft Cleaning
- Connecting Rod & Road Bearing Inspection (Big End)
- Main Bearing Inspection
- Connecting Rod Bearing Clearance Inspection
- Connecting Rod Bearing Selection
- Main Bearing Oil Clearance Inspection
- Crankshaft Installation
- Crankcase Reed Valve Assembly Removal & Inspection
- Balance Shaft Removal , Inspection & Installation
- Crankshaft Assembly & Sealing
- 5th Gear Seal Installation (Engine in Frame)
- Troubleshooting, Transmission & Crankshaft

CHAPTER 11-DRIVE LINE

- General
- Special Tools
- Specifications
- Drive Line Fastener Torque Specifications
- Drive Line Fastener Torque Specifications
- Belt Inspections
- Belt Removal
- Belt Inspection
- Drive Sprocket Removal
- Drive Sprocket Inspection
- Drive Sprocket Installation
- Rear Sprocket Removal
- Rear Sprocket Inspection
- Rear Sprocket Installation
- Troubleshooting

CHAPTER 12-FRONT WHEEL & SUSPENSION

- General
- Specifications, Front Wheel and Suspension
- Special Tools
- Fastener Torque Specifications Table

- Exploded View & Torque-Handlebar & Fork (2003 Classic)
- Exploded View / Torque-Handlebar & Fork (Touring Cruiser)
- Exploded View / Torque-Front Wheel and Brake
- Handlebar Removal
- Handlebar Installation
- Lower Handlebar Clamp (Riser) Removal
- Lower Handlebar Clamp (Riser) Installation
- Front Wheel Removal
- Front Axle Inspection
- Front Brake Disc Removal / Installation
- Front Wheel / Wheel Bearing Inspection
- Front Wheel Bearing Removal / Installation
- Front Wheel Installation
- Front Fork Removal
- Front Fork Disassembly
- Front Fork Inspection
- Front Fork Assembly
- Front Fork Installation
- Triple Clamp Removal
- Outer Race Removal
- Lower Steering Stem Bearing Removal
- Steering Stem Bearing Installation
- Steering Head Bearing Adjustment
- Triple Clamp Assembly
- Steering Bearing Inspection
- Steering Bearing Preload Measurement
- Troubleshooting

CHAPTER 13-REAR WHEEL & SUSPENSION

- General
- Specifications
- Fastener Torque Specifications
- Special Tools
- Rear Wheel / Suspension Fastener Torques
- Rear Wheel Removal
- Rear Axle Inspection
- Rear Wheel Inspection
- Rear Wheel Bearing Inspection
- Whhel Bearing Removal
- Wheel Bearing Installation
- Brake Disc Removal
- Brake Disc Installation
- Rear Sprocket Removal
- Rear Sprocket Installation
- Rear Wheel Installation
- Shock Absorber Removal
- Shock Absorber Inspection
- Forward Shock Mount Removal
- Forward Shock Mount Installation
- Shock Absorber Installation
- Shock Absorber Expolded View (2003 Classic Cruiser)
- Shock Absorber Exploded View (2003 Touring Cruiser)
- Shock Absorber Technical Data (2003 Classic Cruiser)
- Shock Absorber Technical Data (2003 Touring Cruiser)
- Shock Rebuilding
- Swing Arm Removal
- Swing Arm Bushing Removal
- Swing Arm Pivot Parts Inspection
- Swing Arm Installation
- Troubleshooting

CHAPTER 14-TIRES / WHEELS

- General
- Specifications
- Special Tools
- Tire Wear Patterns & General Causes
- Ozone Cracking
- Front Tire Cupping
- Tire Removal-General
- Tire Removal
- Wheel Inspection
- Tire Valve Inspection
- Tire Installation
- Tire Inflation Precautions
- Tire Balancing
- Wheel Lacing

- Wheel Offset
- Wheel Truing
- Troubleshooting

CHAPTER 15-BRAKES

- General
- Specifications-Brake System
- Fastener Torque Specifications
- Brake Fluid Replacement and Bleeding
- Brake Fluid Filling & Bleeding
- Front Brake Pad Replacement
- Rear Brake Pad Replacement
- Brake Disc Inspection (Front & Rear)
- Front Master Cylinder Removal
- Front Master Cylinder Installation
- Front Caliper Removal
- Front Caliper Installation
- Rear Master Cylinder Removal
- Rear Master Cylinder Installation
- Rear Brake Fluid Reservoir Removal
- Rear Reservoir Installation
- Rear Caliper Removal
- Rear Caliper Installation
- Rear Brake Pedal Removal
- Rear Brake Pedal Installation
- Troubleshooting-Brake System

CHAPTER 16-CHARGING SYSTEM & BATTERY

- General
- Charging System and Battery Precautions
- Specifications
- Special Tools
- Troubleshooting
- Initial Battery Service
- Charging New Maintenance Free Batteries
- Charging Maintenance Free Batteries (General)
- Battery Inspection
- Battery Load Test
- Current Drain Inspection
- Regulated Voltage and Amperage Output Inspection
- Voltage Drop Rectifier Regulator to Battery (+)
- Stator AC Voltage Output Inspection
- Stator Resistance Inspection
- Stator Windings to Ground Inspection
- Stator Removal
- Stator Installation
- Flywheel Removal
- Flywheel Installation
- Rectifier / Regulator Inspection &
- Rectifier / Regulator Replacement

CHAPTER 17-IGNITION

- General
- Specifications
- Fastener Torque Specifications
- Special Tools
- Ignition System Troubleshooting Flow Chart
- Spark Inspection: Test 1
- Battery Voltage Inspection: Test 2
- Battery Voltage Inspection (engine misfires): Test 3
- Crank Position Sensor Resistance Inspection: Test 4
- Crank Position Sensor AC Output: Test 4A
- Ground Circuit Inspection: Test 5
- Ignition Coil Inspection: Test 6
- Ignition Coil Removal
- Ignition Coil Installation
- Ignition Switch Removal
- Flywheel Timing Gear Removal
- Flywheel Timing Gear Installation
- ECM Circuit Tests
- ECM Connector Map
- Electrical Testing at ECM Wiring Harness Connector

CHAPTER 18-ELECTRIC STARTER

- General
- Starter Specifications
- Specifications
- Special Tools
- Troubleshooting Flow Chart Menu
- Troubleshooting Flow Chart One
- Troubleshooting Flow Chart Two
- Troubleshooting Flow Chart Three
- Battery Inspection & Charging Procedures: Test 1
- Battery Load Test: Test 1 A
- Starter Relay Ground Circuit: Test 2
- Neutral Switch Inspection: Test 2 A
- Neutral Switch Removal & Bench Testing: Test 2 B
- Neutral Switch Installation
- Clutch Switch: Test 2 C
- Clutch Switch Removal
- Clutch Switch Installation
- Starter Relay Positive Circuit: Test 3
- Starter Relay Bypass: Test 4
- Starter Relay to Starter Motor Positive Cable Bypass: Test 5
- Positive Side Voltage Drop Test: (Test 5A)
- Negative Cable Bypass (Test 6 of Flow Chart Troubleshooting)
- Negative Side Voltage Drop Test (Test 6A)
- Starter Amp Draw Test: (Test 7)
- Starter Motor Removal
- Starter Motor Installation
- Starter Clutch Removal
- Starter One Way Clutch Inspection
- Starter Idler Gear Removal
- Starter Slip Clutch Inspection
- Starter Slip Clutch Cover Bearing Removal
- Starter Slip Clutch Cover Bearing Installation
- Starter Slip Clutch Cover Installation
- Starter Idler Gear Installation

CHAPTER 19-LIGHTING SYSTEMS

- Lighting Wiring Diagram
- Automatice Turn Signal Cancel
- Turn Signal Set / Reset Switch Function
- Set / Reset Test
- Vehicle Speed Sensor Test (Speed Sensor to Speedometer Signal)
- Vehicle Speed Input Signal
- Auto Cancel / Hazard System Block Diagram
- Speedometer Connector Pin Descriptions
- Speedometer Signal Descriptions
- Left Handlebar Switch Wiring Diagram
- Right Handlebar Switch Wiring Diagram