Victory Classic Cruiser (2002-2004) - Workshop Manual

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

- English Workshop 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

INDEX

Victory Classic Cruiser (2002-2004) - Workshop Manual - Wiring Diagrams

inicio - index

coche - car

moto

4x4

quad - buggy

cami?n - truck

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