Description
2008 Victory Vision Street & Tour Service Manual PN 9921254 PDF
The 2008 Victory Vision Street & Tour Service Manual PN 9921254 PDF is a comprehensive 511-page workshop reference for the Victory Vision Street and Victory Vision Tour. It was prepared primarily for Victory service technicians working in a properly equipped shop and combines maintenance procedures, component identification, repair information, service specifications, diagnostic routines, assembly views and electrical circuit material for these motorcycles.
Coverage is built around the 2008 Vision platform and its Victory Freedom V-Twin powertrain. The general specifications identify a 50-degree SOHC V-Twin four-stroke engine with 1737cc / 106 cubic-inch displacement, air/oil cooling, closed-loop sequential electronic fuel injection, a six-speed overdrive constant-mesh transmission and a carbon-fiber-reinforced final drive belt. The manual then moves well beyond basic specifications into complete workshop procedures for the engine, chassis, fuel system, driveline, brakes and electrical systems.
File Details
- Manual type: Service Manual
- Brand / models: Victory Vision Street / Victory Vision Tour
- Model year: 2008
- Manual part number: 9921254
- Language: English
- Page count: 511 pages
- File format: PDF
Workshop Coverage Built Around the 2008 Victory Vision
This manual is structured for practical service work rather than simple owner-level operation. Routine jobs such as engine oil and filter changes, air-filter service, tire inspection, cable free play, brake-fluid checks, brake-pad inspection, battery care, drive-belt tension and suspension inspection sit alongside major disassembly work such as engine removal, cylinder-head and valve-train service, piston and cylinder inspection, clutch disassembly, crankcase separation, transmission service and crankshaft work.
The diagnostic content is equally substantial. Fuel-injection coverage includes fuel-pump testing, pressure inspection, component locations, PCM connector information, fault-code access and sensor diagnostics. Separate chapters cover battery and charging-system tests, ignition troubleshooting, starter-circuit flow charts, switch and voltage-drop tests, and wiring/lighting circuits. This makes the 2008 Victory Vision Street & Tour Service Manual PN 9921254 PDF useful both when a fault must be traced systematically and when a known component needs removal, inspection or replacement.
Chapters Covered
- Chapter 1 – Specifications / Gauge / Audio
- General information, safety, general specifications and vehicle identification
- Instrumentation / controls, instrument cluster and indicator lamps
- Radio / audio system, CB / ICOM, AUX / iPod, XM satellite radio and CD changer
- Chapter 2 – Maintenance
- Service specifications, fastener torque specifications and periodic maintenance
- Engine oil and filter, tires, cables, brake and clutch fluid, brake pads and battery
- Engine compression, drive-belt inspection / adjustment, suspension, headlamp and storage
- Chapter 3 – Frame-Body-Exhaust
- Front and rear body assembly views and removal / installation procedures
- Windshield, console, fairings, trunk, saddlebags and floorboards
- Exhaust system assembly, muffler removal and head-pipe removal
- Chapter 4 – Lubrication & Cooling
- Oiling-system operation, troubleshooting, specifications and oil-flow diagram
- Oil cooler inspection / removal / installation and oil-pressure inspection
- Oil-pump removal, relief valves, inspection, disassembly, assembly and installation
- Chapter 5 – Fuel System / Fuel Injection
- Fuel-system specifications, troubleshooting and EFI service precautions
- Fuel tank, fuel pump, fuel-pressure inspection and fuel-system electrical diagnostics
- Fuel-injection components, self-diagnostics, fault codes and sensor tests
- Chapter 6 – Engine Removal & Installation
- Engine-removal overview, specifications, special tools and mounting torque values
- Preparation, removal procedure, injector removal and engine installation
- Chapter 7 – Cylinder Head & Valve Train
- Cylinder-head data, cam drive, rocker arms and camshaft timing
- Cam-chain tensioner, cylinder-head disassembly / inspection and valve service
- Cylinder-head assembly / installation and valve-train troubleshooting
- Chapter 8 – Cylinder & Piston
- Cylinder removal, bore measurement and piston-to-cylinder clearance
- Piston, piston rings, piston pin, cylinder inspection and installation
- Cylinder and piston troubleshooting
- Chapter 9 – Clutch, Primary, & Shift Linkage
- Hydraulic clutch, shift linkage, primary cover and shift mechanism
- Clutch removal, disassembly, inspection, assembly and installation
- Torque compensator, flywheel, split gear, starter drive and primary drive gear
- Chapter 10 – Transmission & Crankshaft
- Crankcase, crankshaft and connecting-rod specifications
- Transmission, mainshaft, countershaft, shift drum and shift-fork assembly views
- Crankcase separation, transmission / crankshaft service, bearings and balance shaft
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “2008 Victory Vision Street & Tour Service Manual PN 9921254 PDF” are as follows:
+FOREWORDp. 1
FOREWORDp. 1
TRADEMARKSp. 2
+SPECIFICATIONS / GAUGE / AUDIOp. 3
+GENERAL INFORMATIONp. 5
TRADEMARKSp. 5
SERVICE RULESp. 5
+SAFETY INFORMATIONp. 6
Understanding Safety Labels & Instructionsp. 6
+GENERAL SPECIFICATIONSp. 7
Victory Vision‰ Street / Victory Vision‰ Tour Specificationsp. 7
Victory Vision‰ Street / Victory Vision‰ Tour Specifications (cont.)p. 8
+VEHICLE LOADINGp. 9
GROSS VEHICLE WEIGHT RATINGp. 9
LOADING EXAMPLES FOR GROSS VEHICLE WEIGHT RATING (GVWR)p. 9
+VEHICLE INFORMATIONp. 10
VEHICLE IDENTIFICATION NUMBER (VIN)p. 10
MODEL NUMBERp. 10
VIN NUMBER / MANUFACTURER LABELp. 11
ENGINE NUMBER LOCATIONp. 11
VECI / NECI / TIRE INFORMATION LABELSp. 11
KEY IDENTIFICATION NUMBERp. 11
+PUBLICATIONS & TECHNICAL LITERATUREp. 12
PUBLICATION PART NUMBERSp. 12
MATERIAL SAFETY DATA SHEET (MSDS)p. 12
+BREAK IN PERIODp. 13
+EMISSIONSp. 14
EMISSION CONTROL SYSTEMSp. 14
EMISSION SOURCESp. 14
EXHAUST EMISSION CONTROLp. 14
NOISE EMISSION CONTROL SYSTEMp. 14
CRANKCASE EMISSION CONTROLp. 14
EVAPORATIVE EMISSION CONTROLp. 14
+SPECIAL SERVICE TOOLSp. 15
GENERAL & PRECISION MEASUREMENTp. 15
TUNE UP & MAINTENANCEp. 15
ELECTRICALp. 15
ENGINE, CLUTCH, & TRANSMISSIONp. 16
STEERING & SUSPENSIONp. 16
WHEEL & TIREp. 17
FUEL SYSTEM & FUEL INJECTIONp. 17
TOOL ORDERING INFORMATIONp. 17
+TRANSPORTING, ELEVATING, AND SECURING THE MOTORCYCLEp. 18
+REFERENCEp. 19
SAE TAP DRILL SIZESp. 19
METRIC TAP DRILL SIZESp. 19
DECIMAL EQUIVALENTSp. 19
FAHRENHEIT TO CELSIUSp. 20
MEASUREMENT CONVERSION CHARTp. 20
+INSTRUMENTATION / CONTROLSp. 21
IGNITION KEYp. 21
IGNITION SWITCHp. 21
INSTRUMENT CLUSTERp. 22
SPEEDOMETERp. 22
TACHOMETERp. 22
FUEL GAUGEp. 22
VOLT METERp. 22
INDICATOR LAMP DISPLAYp. 22
INFORMATION DISPLAYp. 22
CLOCKp. 23
GEAR POSITIONp. 23
TRIP ODOMETERp. 23
TEMPERATUREp. 23
ODOMETERp. 23
TO CHANGE DISPLAY UNITS (MILES TO KILOMETERS)p. 23
CONSOLE MOUNTED SWITCHESp. 24
HAND GRIP HEATER SWITCHp. 24
HAZARD SWITCH (Emergency Flashers)p. 24
DRIVING LAMP SWITCHp. 24
NEUTRAL, GEAR POSITION, & HIGH BEAM INDICATOR LAMPSp. 25
SEAT HEATERp. 26
LEFT HANDLEBAR SWITCHp. 26
MODE BUTTONp. 26
HEADLAMP HIGH / LOW BEAM SWITCHp. 26
WINDSHIELD ADJUSTMENT SWITCH (Motorized)p. 26
MANUAL WINDSHIELD ADJUSTMENTp. 27
TURN SIGNAL SWITCHp. 27
TURN SIGNAL MONMENTARY FEATUREp. 27
CLUTCH LEVERp. 27
STARTER INTERLOCKp. 27
RIGHT HANDLEBAR CONTROLSp. 28
ENGINE STOP SWITCHp. 28
ENGINE STARTER BUTTONp. 28
MIRRORSp. 28
LINKED BRAKE SYSTEMp. 28
FRONT BRAKE LEVER REACH ADJUSTMENTp. 29
FOOT CONTROL ADJUSTMENTp. 29
FUEL DOORp. 30
FUEL CAPp. 30
GLOVE COMPARTMENTp. 30
SADDLEBAGSp. 31
TRUNK OPERATIONp. 31
+RADIO / AUDIO SYSTEMp. 32
RADIO / AUDIO SYSTEMS OPERATIONp. 32
RADIO FREQUENCIESp. 32
MAIN USER INTERFACEp. 32
Lower Left-Hand Controlp. 33
Upper Left-Hand Control*p. 33
Rear Passenger Controlp. 33
System Powerp. 33
Volume Controlp. 34
Audio Mutep. 34
Audio Volumep. 34
Passenger Volumep. 34
Selecting Audio Sourcesp. 35
FM source active:p. 35
AM source active:p. 35
WB (Weather) source active:p. 35
AUX source active:p. 35
iPod source active:p. 35
XM Radio source active*:p. 35
CD Changer source active*:p. 35
MW (Medium Wave) source:p. 35
LW (Long Wave) source:p. 35
Audio Tuningp. 36
Memory Presetsp. 36
AUDIO SUB-MENU ACCESSp. 36
Bass Settingp. 36
Treble Settingp. 37
Fader Setting*p. 37
External Speakersp. 37
Automatic Volume Control (AVC)p. 37
CB Headset ENT Mode*p. 38
ICOM Volume*p. 38
CB Volume*p. 38
Tuning (Seek / Scan Modes)p. 38
CB LO/DX*p. 38
XM Display*p. 38
NOAA Weather Band (WB)p. 39
+CB Radio / ICOM Systemp. 39
Getting Startedp. 39
Adjusting Channelsp. 40
Push-to-Talk (PTT)p. 40
Squelchp. 41
CB Radio Volume Setting (Driver)*p. 41
CB Radio Volume Setting (Passenger)*p. 41
CB LO/DX*p. 42
CB Frequenciesp. 42
ICOM Systemp. 43
VOX Break Settingp. 43
ICOM Volume Setting (Driver)*p. 43
ICOM Volume Setting (Passenger)p. 43
Headset Receptaclesp. 44
+AUX / iPodp. 44
Getting Startedp. 44
AUX Input Cablep. 45
iPod Input Cablep. 45
Input Cable Setupp. 45
iPod Play-Listsp. 45
iPod Tuningp. 45
+XM SATELLITE RADIOp. 46
XM Satellite Radio*p. 46
Getting Startedp. 46
Activating XM Radio Servicep. 46
+CD CHANGERp. 47
Getting Startedp. 47
CD Player Cartridgep. 47
Selecting CDsp. 47
CD Track Selectionp. 48
+MAINTENANCEp. 49
+SERVICE SPECIFICATIONSp. 50
TUNE UPp. 50
OIL CHANGEp. 50
+FASTENER TORQUE SPECIFICATIONSp. 51
+SPECIAL TOOLSp. 51
+MAINTENANCE PRODUCTSp. 52
LUBRICANTS / CHEMICALSp. 52
+PERIODIC MAINTENANCEp. 53
Periodic Maintenance Interval Tablep. 53
Air Filterp. 54
AIR BOX DRAIN HOSEp. 54
ENGINE OIL LEVELp. 54
ENGINE OIL AND FILTER CHANGEp. 55
TIRESp. 56
CABLE INSPECTION / LUBRICATIONp. 57
THROTTLE CABLE FREE PLAYp. 57
CRUISE CONTROL CABLEp. 58
FRONT BRAKE LEVERp. 58
FRONT BRAKE LEVER REACHp. 58
CLUTCH LEVERp. 59
REAR BRAKE PEDALp. 59
SHIFT PEDALp. 59
CLUTCH FLUIDp. 59
FRONT BRAKE FLUID LEVELp. 60
REAR BRAKE FLUIDp. 60
FRONT BRAKE PAD INSPECTIONp. 61
REAR BRAKE PAD INSPECTIONp. 61
CRANKCASE VENTILATION SYSTEMp. 62
EVAPORATIVE EMISSION CONTROL SYSTEM (California Models)p. 62
FUEL FILTERp. 62
FUEL SYSTEM INSPECTIONp. 62
FUEL TANK VENT INSPECTION (49 State)p. 63
SPARK PLUG REMOVAL & INSPECTIONp. 63
SPARK PLUG INSTALLATIONp. 63
BATTERYp. 64
BATTERY CHARGINGp. 64
BATTERY STORAGEp. 64
BATTERY INSPECTIONp. 64
BATTERY REMOVALp. 65
BATTERY INSTALLATIONp. 65
ENGINE COMPRESSION TESTp. 66
ENGINE COMPRESSION TEST (WET)p. 66
SPROCKET INSPECTIONp. 66
DRIVE BELT WEAR ANALYSISp. 67
DRIVE BELT CONDITIONp. 67
DRIVE BELT TENSION GAUGEp. 67
DRIVE BELT TENSION – INSPECTIONp. 68
DRIVE BELT ADJUSTMENT / ALIGNMENTp. 69
HEADLAMP AIM INSPECTIONp. 70
HEADLAMP AIM ADJUSTMENTp. 70
SIDESTAND INSPECTIONp. 71
SIDESTAND PAD INSPECTIONp. 71
SIDESTAND & SPRING REMOVALp. 71
SIDESTAND PAD REPLACEMENTp. 72
REAR SUSPENSION / SWINGARM INSPECTIONp. 73
REAR SUSPENSION ADJUSTMENTp. 74
FRONT SUSPENSION INSPECTIONp. 75
STEERING HEAD / FRONT WHEEL INSPECTIONp. 75
FUSE REPLACEMENTp. 76
FASTENERSp. 76
CLEANINGp. 76
WAXING, POLISHING, APPLYING PROTECTANTSp. 77
STORAGEp. 78
+FRAME-BODY-EXHAUSTp. 81
+SAFETYp. 82
+GENERAL INFORMATIONp. 83
BODY FASTENER TYPESp. 83
SPECIAL TOOLSp. 83
HOW TO USE THIS CHAPTERp. 83
+ASSEMBLY VIEWS – FRONT BODYp. 84
WINDSHIELD / WINDSHIELD MOTORp. 84
BELLY PANp. 85
CONSOLE / CONSOLE ATTACHMENTSp. 86
CONSOLE / RADIOp. 87
FRONT SUPPORT / SPEAKER / SPEAKER VOLUMEp. 88
VISOR / FRONT SPEAKER GRILLp. 89
FUEL TANK COVERp. 90
LEG FAIRINGp. 91
LEG FAIRING SUPPORTp. 92
FRONT TURN SIGNAL HEADLAMP / FAIRINGp. 93
LOWER FRONT FRAMEp. 94
BATTERY BOXp. 95
+REMOVAL / INSTALLATION PROCEDURES – FRONT BODYp. 96
FRONT FENDERp. 96
CONSOLE COVERp. 97
AIR DEFLECTORSp. 97
IGNITION SWITCH / IAC COVER REMOVAL / INSTALLATIONp. 98
WINDSHIELD ACCESS PANELp. 98
INSTRUMENT BEZELp. 99
MIRRORSp. 99
VISORp. 100
CONSOLEp. 101
SPEAKER GRILLp. 102
FUEL TANK COVERSp. 102
BELLY PANp. 103
LEG FAIRINGp. 103
GRILLp. 104
FRONT FAIRING & TURN SIGNAL LENSp. 104
+ASSEMBLY VIEWS – REAR BODYp. 105
TAIL TRIMp. 105
TRUNK MOUNT AND ATTACHMENTSp. 106
TRUNK BASEp. 107
TRUNK LIDp. 108
SADDLEBAG INNERp. 109
TAIL LIGHT / TAIL LIGHT HOUSINGp. 110
FLOORBOARD / FOOT CONTROL MOUNTINGp. 111
PASSENGER FLOORBOARD MOUNTINGp. 112
LOWER ACCESS PANEL / PASSENGER HAND GRIP / SIDE COVERp. 113
+REMOVAL / INSTALLATION PROCEDURES – REAR BODYp. 114
SEATp. 114
SIDE COVERp. 114
LOWER ACCESS PANELS (SADDLEBAG LOWER PANEL)p. 115
STREET TRIM PANEL REMOVALp. 116
STREET TRIM PANEL INSTALLATIONp. 116
TRUNK REMOVALp. 117
TRUNK INSTALLATIONp. 117
TAIL LIGHT TRIM (“M”) PANELp. 118
REAR BUMPER COVERp. 118
TAIL LIGHTp. 119
TAIL LIGHT HOUSINGp. 119
SADDLEBAG DOORp. 120
SADDLEBAG (INNER BAG)p. 120
SADDLEBAG SUPPORT PLATE (PASSENGER HAND GRIP AND TRIM)p. 121
+EXHAUSTp. 122
ASSEMBLY VIEW – EXHAUST SYSTEMp. 122
ASSEMBLY VIEW – MUFFLER & HEAD PIPE SHIELDSp. 123
EXHAUST MUFFLER REMOVALp. 124
HEAD PIPE REMOVALp. 125
+LUBRICATION & COOLINGp. 127
+OILING SYSTEMp. 128
OPERATIONp. 128
TROUBLESHOOTINGp. 128
SPECIAL TOOLSp. 128
+OILING SYSTEM DATAp. 129
SPECIFICATIONS – LUBRICATIONp. 129
+OIL FLOWp. 130
+OIL COOLERp. 131
ASSEMBLY VIEW – OIL COOLER AND LINESp. 131
OIL COOLER INSPECTION / CLEANINGp. 132
OIL COOLER REMOVALp. 132
OIL COOLER / LINE INSTALLATIONp. 133
+OIL PRESSURE INSPECTIONp. 134
LUBRICATION OIL PRESSUREp. 134
COOLING OIL FLOW INSPECTIONp. 134
+OIL PUMPp. 135
OIL PUMP REMOVALp. 135
OIL PRESSURE RELIEF VALVESp. 136
OIL PUMP INSPECTIONp. 137
OIL PUMP DISASSEMBLYp. 138
OIL PUMP ASSEMBLYp. 139
OIL PUMP INSTALLATIONp. 141
+FUEL SYSTEM / FUEL INJECTIONp. 143
+SAFETY PRECAUTIONSp. 145
+SPECIFICATIONSp. 146
FUEL SYSTEM SPECIFICATIONSp. 146
+SPECIAL TOOLSp. 146
FUEL SYSTEM SERVICE TOOLSp. 146
+TROUBLESHOOTINGp. 146
BASICS TROUBLESHOOTINGp. 146
THROTTLE BODY FLOWp. 146
IDLE STOP SCREWp. 146
+SERVICE PRECAUTIONSp. 147
EFI SYSTEM PRECAUTIONSp. 147
+FUEL SYSTEM ASSEMBLY VIEWSp. 148
FUEL TANK HOSE CONNECTION – 49 STATE MODELSp. 148
FUEL TANK HOSE CONNECTION – CALIFORNIA MODELSp. 149
FUEL LEVEL SENSOR / FUEL PUMP ASSEMBLY VIEWp. 150
IDLE AIR CONTROL ASSEMBLY VIEWp. 151
AIR INTAKE / BOX FRAME ASSEMBLY VIEWp. 152
+FUEL SYSTEM SERVICEp. 153
FUEL SYSTEM DEPRESSURIZATIONp. 153
PRIMING THE FUEL SYSTEMp. 153
FUEL TANK VENT INSPECTIONp. 153
FUEL PUMP REMOVALp. 153
FUEL PUMP INSTALLATIONp. 154
FUEL TANK REMOVALp. 156
FUEL TANK INSTALLATIONp. 157
FUEL PUMP CIRCUIT DIAGRAMp. 158
FUEL LEVEL SENSOR RESISTANCE TESTp. 159
FUEL PUMP ELECTRICAL DIAGNOSTICSp. 160
FUEL PUMP SUPPLY VOLTAGE TESTp. 160
BATTERY VOLTAGE NOT REACHING FUEL PUMPp. 160
FUEL PUMP CURRENT DRAW TESTp. 161
FUEL PUMP PRESSURE INSPECTIONp. 162
IDLE AIR CONTROL REMOVALp. 163
+EFI SYSTEM COMPONENTSp. 164
FUEL INJECTION COMPONENT LOCATIONSp. 164
FUEL RAIL / FUEL INJECTOR REMOVALp. 165
FUEL RAIL INSTALLATIONp. 165
+FUEL INJECTION SYSTEM TESTING AND DIAGNOSTICSp. 166
FUEL INJECTION SYSTEM – OVERVIEW OF OPERATIONp. 166
IDLE AIR CONTROL (IAC) – OVERVIEW OF OPERATIONp. 166
SELF-DIAGNOSTIC FEATUREp. 166
PCM CONNECTOR MAPp. 167
VIEWING AND CLEARING FAULT CODESp. 168
SENSOR DIAGNOSTICS – IMPORTANT INFORMATION TO UNDERSTAND BEFORE YOU BEGINp. 168
FAULT CODESp. 169
PCM HARNESS CONNECTOR TEST PRECAUTIONSp. 170
PCM CONNECTOR REMOVALp. 170
PCM REMOVALp. 170
+SENSOR TESTSp. 171
THROTTLE POSITION SENSOR (TPS) DIAGNOSTICSp. 171
TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) DIAGNOSTICSp. 172
AIR TEMPERATURE SENSOR (ATS) DIAGNOSTICSp. 173
CYLINDER HEAD TEMPERATURE SENSOR (CHT) DIAGNOSTICSp. 174
VEHICLE SPEED SENSOR TESTp. 175
GEAR POSITION SWITCH TESTp. 175
MEMORY CHECK SUM ERRORp. 175
CRANKSHAFT POSITION SENSOR DIAGNOSTICSp. 176
BATTERY VOLTAGE AT PCM DIAGNOSTICSp. 176
+DIGITAL WRENCHp. 177
USING DIGITAL WRENCH™ DIAGNOSTIC SOFTWAREp. 177
TOOLSp. 177
DIAGNOSTIC SOFTWARE VERSIONp. 177
TPS CALIBRATION NOT REQUIREDp. 177
DIGITAL WRENCH‘ FEATURESp. 178
DIGITAL WRENCH‘ FEATURE MAPp. 179
DIGITAL WRENCH SCREEN EXAMPLESp. 180
DIGITAL WRENCH SCREEN EXAMPLESp. 181
DIGITAL WRENCH SCREEN EXAMPLESp. 182
REPROGRAMMING THE POWERTRAIN CONTROL MODULE (PCM) PROCESS OVERVIEWp. 183
REPROGRAMMING TIPSp. 183
REPROGRAMMING PROCESSp. 185
+TROUBLESHOOTINGp. 186
FUEL SYSTEM TROUBLESHOOTINGp. 186
FUEL SYSTEM TROUBLESHOOTING (cont.)p. 187
FUEL SYSTEM TROUBLESHOOTING (cont.)p. 188
FUEL SYSTEM TROUBLESHOOTING (cont.)p. 189
+ENGINE REMOVAL & INSTALLATIONp. 191
+OVERVIEW – ENGINE REMOVALp. 192
GENERALp. 192
SPECIFICATIONSp. 192
SPECIAL TOOLSp. 193
+TORQUE VALUESp. 194
ENGINE MOUNTING – AIRBOX / MAIN FRAME ASSEMBLYp. 194
ENGINE MOUNTING – REAR SUB FRAME ASSEMBLYp. 195
+ENGINE REMOVALp. 196
PREPARATION FOR REMOVALp. 196
PRECAUTIONSp. 196
REMOVAL PROCEDUREp. 196
INJECTOR REMOVALp. 200
+ENGINE INSTALLATIONp. 201
PREPARATION FOR INSTALLATIONp. 201
INSTALLATION PROCEDUREp. 201
+CYLINDER HEAD & VALVE TRAINp. 203
+GENERAL INFORMATIONp. 204
IMPORTANT NOTESp. 204
SPECIAL TOOLSp. 204
+DATA – CYLINDER HEADp. 205
+TORQUE VALUES AND ASSEMBLY VIEWSp. 206
CAM DRIVE & VALVE COVERp. 206
CAMSHAFT CARRIER / ROCKER ARMp. 207
CYLINDER HEADp. 208
CAMSHAFT TIMING QUICK REFERENCEp. 209
+CYLINDER HEAD SERVICEp. 210
CAMSHAFT DRIVE COVERp. 210
VALVE COVER REMOVALp. 210
VALVE COVER INSTALLATIONp. 210
CAM CHAIN TENSIONER REMOVALp. 210
CAM CHAIN TENSIONER INSPECTIONp. 211
CAM CHAIN TENSIONER INSTALLATIONp. 211
CAMSHAFT CHAIN & SPROCKET REMOVALp. 212
ROCKER ARM REMOVALp. 213
ROCKER ARM & SHAFT INSPECTIONp. 213
CAMSHAFT INSPECTIONp. 214
CYLINDER HEAD REMOVALp. 214
CYLINDER HEAD DISASSEMBLYp. 215
CYLINDER HEAD INSPECTIONp. 216
VALVE SPRING FREE LENGTH INSPECTIONp. 216
VALVE INSPECTIMONp. 216
VALVE INSPECTIONp. 218
VALVE GUIDE REMOVAL / INSTALLATIONp. 219
VALVE SEAT INSPECTIONp. 220
VALVE SEAT RECONDITIONINGp. 220
CYLINDER HEAD ASSEMBLYp. 221
CYLINDER HEAD ASSEMBLYp. 222
CYLINDER HEAD INSTALLATIONp. 223
CAMSHAFT & ROCKER ARM INSTALLATIONp. 225
CAMSHAFT TIMING – REAR CYLINDERp. 226
CAMSHAFT CHAIN GUIDE INSTALLATIONp. 226
CAMSHAFT TIMING – FRONT CYLINDERp. 227
TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAINp. 230
+CYLINDER & PISTONp. 233
+CYLINDER & PISTONp. 234
GENERALp. 234
BASE GASKET SEALING & CYLINDER STUD TORQUEp. 234
PISTON RING PROFILE AND ORIENTATIONp. 234
SPECIFICATIONSp. 235
SPECIAL TOOLSp. 235
CYLINDER REMOVALp. 236
CYLINDER INSPECTIONp. 236
CYLINDER BORE MEASUREMENTp. 236
PISTON TO CYLINDER CLEARANCE WORKSHEETp. 237
CYLINDER WARPAGE MEASUREMENTp. 238
PISTON & PISTON RING REMOVALp. 238
PISTON & PISTON RING INSPECTIONp. 238
PISTON PIN / PIN BORE INSPECTIONp. 239
CYLINDER STUD REPLACEMENTp. 240
PISTON RING INSTALLATIONp. 240
PISTON INSTALLATIONp. 241
CYLINDER INSTALLATIONp. 242
TROUBLESHOOTING, CYLINDER & PISTONp. 243
TROUBLESHOOTING (Cont.)p. 244
+CLUTCH, PRIMARY, & SHIFT LINKAGEp. 245
+GENERALp. 246
SERVICE INFORMATIONp. 246
+SPECIFICATIONSp. 246
GENERALp. 246
SERVICE / MAINTENANCEp. 246
+SPECIAL TOOLSp. 246
PRIMARY DRIVE SPECIAL TOOLSp. 246
+ASSEMBLY VIEWS & TORQUE VALUESp. 247
HYDRAULIC CLUTCH HOSE ROUTINGp. 247
CLUTCH (HYDRAULIC) SYSTEM COMPONENTSp. 248
SHIFT LINKAGE / FOOTREST – FASTENER TORQUEp. 249
PRIMARY COVERp. 250
SHIFT MECHANISMp. 251
+SERVICE PROCEDURESp. 252
CAP PLATE & CAP PLATE SEAL REMOVALp. 252
CAP PLATE & CAP PLATE SEAL INSTALLATIONp. 252
CLUTCH PINION SHAFT REMOVALp. 252
CLUTCH PINION SHAFT BEARING INSPECTIONp. 252
CLUTCH PINION SHAFT SEAL REMOVAL & INSTALLATIONp. 253
CLUTCH PINION SHAFT INSTALLATIONp. 253
PRIMARY COVER REMOVALp. 254
SHIFT RATCHET REMOVAL & INSPECTIONp. 255
SHIFT RATCHET INSTALLATIONp. 256
SHIFT SHAFT BEARING & SEAL REPLACEMENTp. 256
PRIMARY COVER INSTALLATIONp. 257
LOCKING THE CRANKSHAFTp. 257
+CLUTCH SERVICEp. 258
CLUTCH ASSEMBLY VIEW & TORQUEp. 258
CLUTCH REMOVALp. 259
CLUTCH DISASSEMBLYp. 259
CLUTCH INSPECTIONp. 261
CLUTCH ASSEMBLYp. 263
CLUTCH INSTALLATIONp. 264
PRIMARY DRIVE ASSEMBLY VIEW & TORQUEp. 265
TORQUE COMPENSATOR REMOVALp. 266
TORQUE COMPENSATOR INSPECTIONp. 266
TORQUE COMPENSATOR INSTALLATIONp. 267
ROTOR (FLYWHEEL) REMOVALp. 268
ROTOR (FLYWHEEL) INSTALLATIONp. 269
SPLIT GEAR REMOVALp. 269
SPLIT GEAR INSPECTIONp. 269
SPLIT GEAR INSTALLATIONp. 270
+STARTER DRIVEp. 271
STARTER DRIVE REMOVALp. 271
STARTER GEAR INSPECTIONp. 271
STARTER CLUTCH REMOVAL / INSPECTIONp. 271
+PRIMARY DRIVE GEARp. 272
PRIMARY DRIVE GEAR REMOVAL / INSPECTIONp. 272
STARTER TORQUE LIMIT CLUTCH INSPECTIONp. 272
PRIMARY DRIVE GEAR INSTALLATIONp. 273
STARTER GEAR / STARTER CLUTCH INSTALLATIONp. 274
+TROUBLESHOOTINGp. 275
+TRANSMISSION & CRANKSHAFTp. 277
+GENERALp. 278
SERVICE INFORMATIONp. 278
+SPECIAL TOOLSp. 278
CRANKCASE / CRANKSHAFT / CONNECTING ROD SPECIAL TOOLSp. 278
+SPECIFICATIONSp. 278
DRIVE TRAINp. 278
CONNECTING ROD AND CRANKSHAFT SPECIFICATIONSp. 279
+ASSEMBLY VIEWS & TORQUE VALUESp. 280
CRANKCASE COMPONENTSp. 280
CRANKSHAFT / CONNECTING ROD / CRANKCASE TORQUE PATTERNp. 281
CRANKCASE BOLT LENGTH AND TORQUE PATTERNp. 281
+SERVICE PROCEDURESp. 282
CRANKCASE SEPARATIONp. 282
TRANSMISSION ASSEMBLY VIEWp. 284
MAINSHAFT / CLUTCH SHAFT ASSEMBLY VIEWp. 285
COUNTERSHAFT ASSEMBLY VIEWp. 286
SHIFT DRUM AND SHIFT FORK ASSEMBLY VIEWp. 287
POWER DELIVERYp. 288
TRANSMISSION REMOVALp. 289
CLUTCH SHAFT INSPECTION / REMOVALp. 289
TRANSMISSION INSPECTIONp. 290
CRANKSHAFT REMOVALp. 291
CONNECTING ROD SIDE CLEARANCE INSPECTIONp. 292
CONNECTING ROD REMOVAL / IDENTIFICATIONp. 292
CONNECTING ROD INSPECTION (Big end)p. 293
CONNECTING ROD BEARING INSPECTIONp. 293
CONNECTING ROD BEARING CLEARANCE INSPECTION (Typical)p. 294
CONNECTING ROD BEARING SELECTIONp. 294
CRANKSHAFT INSPECTIONp. 295
CONNECTING ROD INSTALLATIONp. 295
CRANKSHAFT CLEANINGp. 296
MAIN BEARING INSPECTIONp. 296
MAIN BEARING OIL CLEARANCE INSPECTIONp. 296
LEFT CRANKCASE ASSEMBLYp. 297
RIGHT CRANKCASE ASSEMBLYp. 298
CRANKCASE REED VALVE ASSEMBLY REMOVAL & INSPECTIONp. 298
CRANKSHAFT INSTALLATIONp. 298
TRANSMISSION INSTALLATIONp. 299
+BALANCE SHAFTp. 300
BALANCE SHAFT REMOVAL & INSPECTIONp. 300
BALANCE SHAFT INSTALLATIONp. 300
+CRANKCASEp. 301
CRANKCASE ASSEMBLY & SEALINGp. 301
+TROUBLESHOOTINGp. 304
+DRIVE LINEp. 307
+SPECIAL TOOLSp. 308
DRIVE LINE SPECIAL TOOLSp. 308
+ASSEMBLY VIEWS & TORQUE VALUESp. 308
REAR WHEEL FASTENER TORQUESp. 308
DRIVE SPROCKET FASTENER TORQUESp. 309
BELT GUARD / FASTENER TORQUEp. 310
+DRIVE BELTp. 311
BELT INSPECTIONp. 311
BELT REMOVALp. 311
BELT INSTALLATIONp. 311
+DRIVE SPROCKETp. 311
DRIVE SPROCKET AND SEAL REMOVALp. 311
DRIVE SPROCKET INSPECTIONp. 312
DRIVE SPROCKET AND SEAL INSTALLATIONp. 312
+REAR SPROCKETp. 314
REAR SPROCKET REMOVALp. 314
REAR SPROCKET INSPECTIONp. 314
REAR SPROCKET INSTALLATIONp. 314
+TROUBLESHOOTINGp. 315
+FRONT WHEEL / SUSPENSIONp. 317
+GENERALp. 318
IMPORTANT INFORMATIONp. 318
+SPECIAL TOOLSp. 318
+MAINTENANCE PRODUCTSp. 318
MAINTENANCE PRODUCTSp. 318
+TORQUE SPECIFICATIONSp. 318
FASTENER TORQUE SPECIFICATIONSp. 318
SPECIFICATIONSp. 319
+ASSEMBLY VIEWS & TORQUE VALUESp. 319
ASSEMBLY VIEW, FRONT FENDER ATTACHMENTp. 319
ASSEMBLY VIEW, TRIPLE CLAMP & FRONT AXLEp. 320
ASSEMBLY VIEW, FRONT FORKp. 321
ASSEMBLY VIEW, FRONT WHEELSp. 322
ASSEMBLY VIEW, FRONT WHEEL / HUB CUT-AWAYp. 323
+SERVICE PROCEDURESp. 324
ASSEMBLY VIEW, HANDLEBARp. 324
HANDLEBAR REMOVALp. 325
HANDLEBAR INSTALLATIONp. 325
FRONT WHEEL REMOVALp. 326
FRONT AXLE INSPECTIONp. 327
FRONT WHEEL INSPECTIONp. 327
BRAKE DISC REMOVALp. 328
BRAKE DISC INSTALLATIONp. 328
FRONT WHEEL BEARING INSPECTIONp. 328
FRONT WHEEL BEARING REMOVALp. 329
FRONT WHEEL BEARING INSTALLATIONp. 329
FRONT WHEEL INSTALLATIONp. 330
FRONT FORK REMOVALp. 331
FRONT FORK DISASSEMBLYp. 332
FRONT FORK INSPECTIONp. 334
FRONT FORK ASSEMBLYp. 335
FRONT FORK INSTALLATIONp. 338
ASSEMBLY VIEW, STEERING STEM / TRIPLE CLAMPSp. 339
TRIPLE CLAMP REMOVALp. 340
TRIPLE CLAMP INSTALLATION / BEARING LOCK NUT ADJUSTMENTp. 340
STEERING STEM BEARING REMOVAL (TYPICAL EXAMPLE)p. 341
STEERING STEM BEARING INSTALLATION (TYPICAL EXAMPLE)p. 342
AIRBOX / FRAME ASSEMBLY BEARING RACE REMOVALp. 343
AIRBOX / FRAME ASSEMBLY BEARING RACE INSTALLATIONp. 343
+TROUBLESHOOTINGp. 344
TROUBLESHOOTINGp. 344
TROUBLESHOOTING (cont.)p. 345
+REAR WHEEL & SUSPENSIONp. 347
+GENERAL INFORMATIONp. 348
WARNINGS AND PRECAUTIONSp. 348
+TIRE PRESSUREp. 348
TIRE PRESSURE TABLEp. 348
+SPECIAL TOOLSp. 348
+SPECIFICATIONSp. 349
SPECIFICATIONS – REAR WHEEL AND SUSPENSIONp. 349
+ASSEMBLY VIEWS & TORQUEp. 350
ASSEMBLY VIEW – REAR AXLE & ADJUSTERSp. 350
ASSEMBLY VIEW – SWINGARM & SUSPENSIONp. 351
REAR WHEEL – CASTp. 352
REAR WHEEL – BILLETp. 353
+REAR WHEEL SERVICEp. 354
REAR WHEEL REMOVALp. 354
REAR AXLE INSPECTIONp. 355
REAR WHEEL INSPECTIONp. 356
REAR WHEEL BEARING INSPECTIONp. 356
WHEEL BEARING REMOVAL (Typical)p. 356
WHEEL BEARING INSTALLATIONp. 358
BRAKE DISC REMOVALp. 360
BRAKE DISC INSTALLATIONp. 360
REAR SPROCKET REMOVALp. 360
REAR SPROCKET INSTALLATIONp. 360
REAR WHEEL INSTALLATIONp. 361
+REAR SHOCKp. 363
REAR SHOCK SERVICE DATAp. 363
REAR SHOCK REMOVALp. 364
REAR SHOCK AND PIVOT INSPECTIONp. 365
SHOCK ABSORBER INSTALLATIONp. 366
+SWINGARM SERVICEp. 367
SWING ARM REMOVALp. 367
SWING ARM BUSHINGS / BEARING REPLACEMENTp. 368
SWING ARM INSTALLATIONp. 369
+TROUBLESHOOTINGp. 370
+TIRES / WHEELSp. 371
+GENERAL / SAFETYp. 372
WARNINGS / PRECAUTIONSp. 372
+TIRE DATAp. 373
Tire Pressure / LOADINGp. 373
+WHEEL DATAp. 373
Wheel Specificationsp. 373
+SPECIAL TOOLSp. 373
+TIRE INSPECTIONp. 374
TIRE WEAR PATTERNS & GENERAL CAUSESp. 374
OZONE CRACKINGp. 374
FRONT TIRE CUPPINGp. 374
+TIRE CHANGINGp. 375
+TIRE REMOVALp. 376
TIRE REMOVAL (TYPICAL)p. 376
+WHEEL INSPECTIONp. 377
VISUAL INSPECTION & RUNOUTp. 377
TIRE REPAIR PRECAUTIONSp. 378
+VALVE STEMp. 378
TIRE VALVE INSPECTIONp. 378
TIRE VALVE INSTALLATIONp. 378
+TIRE INSTALLATIONp. 379
+TIRE BALANCINGp. 381
+TROUBLESHOOTINGp. 383
+BRAKESp. 385
+BRAKE SYSTEM SAFETYp. 386
+SPECIAL TOOLSp. 386
BRAKE SERVICE SPECIAL TOOLSp. 386
+SPECIFICATIONSp. 387
GENERAL SPECIFICATIONSp. 387
+TORQUE SPECIFICATIONSp. 387
BRAKE SYSTEM TORQUE SPECIFICATIONSp. 387
+ASSEMBLY VIEWS & ROUTINGp. 388
FRONT BRAKE SYSTEM, ASSEMBLY VIEWp. 388
FRONT BRAKE SYSTEM, EXPLODED VIEWp. 389
REAR BRAKE SYSTEM, ASSEMBLY VIEWp. 390
REAR BRAKE SYSTEM, EXPLODED VIEWp. 391
+MASTER CYLINDERSp. 392
FRONT BRAKE / CLUTCH MASTER CYLINDERp. 392
REAR BRAKE MASTER CYLINDERp. 393
+CALIPERSp. 394
FRONT BRAKE CALIPERp. 394
REAR BRAKE CALIPERp. 395
+BRAKE SYSTEM OPERATIONp. 396
MASTER CYLINDERS / BRAKE CALIPERS / DELAY VALVE / PROPORTIONING VALVEp. 396
+BRAKE SYSTEM SERVICEp. 396
BRAKE FLUID REPLACEMENT & BLEEDING PRECAUTIONSp. 397
BRAKE BLEEDING / FLUID CHANGEp. 398
FRONT BRAKE PAD REPLACEMENTp. 401
REAR BRAKE PAD REPLACEMENTp. 402
BRAKE DISC INSPECTIONp. 404
FRONT BRAKE MASTER CYLINDER / CLUTCH MASTER CYLINDER SERVICEp. 404
FRONT MASTER CYLINDER INSTALLATIONp. 407
FRONT CALIPER REMOVALp. 407
FRONT CALIPER SERVICEp. 408
FRONT CALIPER INSTALLATIONp. 411
REAR MASTER CYLINDER REMOVALp. 412
REAR MASTER CYLINDER INSTALLATIONp. 412
REAR CALIPER SERVICEp. 413
REAR CALIPER INSTALLATIONp. 415
TROUBLESHOOTINGp. 416
+BATTERY CHARGING SYSTEMp. 419
+IMPORTANT INFORMATIONp. 420
GENERALp. 420
BATTERY SAFETYp. 420
SPECIAL TOOLSp. 421
+SPECIFICATIONSp. 422
GENERALp. 422
CHARGING SYSTEM & ALTERNATORp. 422
FASTENER TORQUEp. 422
+BATTERYp. 423
BATTERY REMOVALp. 423
BATTERY CHARGING – NEW BATTERYp. 423
BATTERY CHARGING – GENERALp. 423
BATTERY INSPECTIONp. 424
+DIAGNOSTICSp. 425
TROUBLESHOOTINGp. 425
BATTERY LOAD TESTp. 426
CURRENT DRAW INSPECTION (KEY OFF)p. 426
REGULATED VOLTAGE / AMPERAGE OUTPUT INSPECTIONp. 427
STATOR NO-LOAD AC VOLTAGE OUTPUT INSPECTIONp. 428
STATOR RESISTANCE INSPECTIONp. 429
STATOR WINDINGS TO GROUND INSPECTIONp. 429
VOLTAGE DROP: RECTIFIER / REGULATOR TO BATTERY(+)p. 430
RECTIFIER / REGULATOR CONNECTOR INSPECTIONp. 430
DIODE LEAKAGE TESTp. 431
REGULATOR / RECTIFIER TESTp. 432
RECTIFIER / REGULATOR REPLACEMENTp. 433
STATOR REMOVALp. 434
STATOR INSTALLATIONp. 434
FLYWHEEL REMOVALp. 434
+IGNITIONp. 435
+GENERAL INFORMATIONp. 436
SAFETY INFORMATIONp. 436
IGNITION SYSTEM SPECIFICATIONSp. 436
TORQUE SPECIFICATIONSp. 437
SPECIAL TOOLSp. 437
+TROUBLESHOOTINGp. 437
BASICSp. 437
TEST LEAD ADAPTER KITp. 438
PCM CONNECTOR MAPp. 438
IGNITION SYSTEM TEST FLOWCHARTp. 439
BATTERY VOLTAGE INSPECTION – Test 1p. 440
SPARK INSPECTION – TEST 2p. 440
COIL HIGH TENSION LEADS – Test 3p. 441
IGNITION COIL SIGNAL – Test 4p. 441
IGNITION COIL RESISTANCE – Test 5p. 442
CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION – Test 6p. 443
CRANK POSITION SENSOR CIRCUIT and SIGNAL Test 6Ap. 444
CRANK POSITION SENSOR CIRCUIT CONTINUITY Test 6Bp. 444
GROUND CIRCUIT INSPECTION – Test 7p. 444
+IGNITION COILp. 445
IGNITION COIL REMOVALp. 445
IGNITION COIL INSTALLATIONp. 445
IGNITION SWITCH REMOVALp. 446
+ELECTRIC STARTERp. 447
+GENERALp. 448
+SPECIFICATIONSp. 448
STARTER SPECIFICATIONSp. 448
FASTENER TORQUE SPECIFICATIONSp. 448
+SPECIAL TOOLSp. 449
STARTER SYSTEM SPECIAL TOOLSp. 449
+DIAGNOSTICSp. 449
TROUBLESHOOTING FLOW CHART MENUp. 449
STARTER CIRCUIT DIAGRAMp. 450
TROUBLESHOOTING FLOW CHART 1p. 451
TROUBLESHOOTING FLOW CHART 2p. 452
TROUBLESHOOTING CHART 3p. 452
BATTERY INSPECTION & CHARGING PROCEDURESp. 453
BATTERY LOAD TESTp. 453
+CIRCUIT & SWITCH TESTINGp. 453
STARTER RELAY GROUND BYPASS CIRCUIT TESTp. 453
NEUTRAL SWITCH BYPASS TESTp. 454
CLUTCH SWITCH / CIRCUIT TESTp. 455
CLUTCH SWITCH REMOVALp. 456
CLUTCH SWITCH INSTALLATIONp. 456
STARTER RELAY TO STARTER MOTOR POSITIVE CABLE BYPASS TESTp. 456
STARTER RELAY POSITIVE CIRCUIT TESTp. 457
STARTER RELAY BYPASS TESTp. 457
STARTER RELAY TO STARTER MOTOR POSITIVE CABLE BYPASS TESTp. 458
POSITIVE SIDE VOLTAGE DROP TESTp. 459
NEGATIVE CABLE BYPASS TESTp. 461
NEGATIVE SIDE VOLTAGE DROP TESTp. 462
STARTER CURRENT DRAW TESTp. 464
STARTER MOTOR REMOVALp. 465
STARTER MOTOR INSTALLATIONp. 465
STARTER CLUTCH REMOVALp. 465
+WIRING / LIGHTING SYSTEMSp. 467
+FUSESp. 468
Fuse Panel Locationp. 468
Fuse Replacementp. 468
+PRIMARY HEADLAMPSp. 469
ASSEMBLY VIEWp. 469
HEADLAMP CIRCUIT – LOW BEAMp. 470
HEADLAMP CIRCUIT – HIGH BEAMp. 471
+SECONDARY LIGHTING SYSTEMp. 472
FRONT MARKER LAMP ASSEMBLY VIEWp. 472
FRONT MARKER LAMPS CIRCUITp. 473
REAR MARKER / LICENSE LAMP ASSEMBLY VIEWp. 474
REAR MARKER / LICENSE LAMPSp. 475
BRAKE LAMP CIRCUITp. 476
+TURN SIGNAL SYSTEMp. 477
SYSTEM DIAGRAMp. 477
AUTO CANCEL MODULE – OVERVIEWp. 478
AUTO CANCEL TURN SIGNAL SYSTEM SELF-DIAGNOSTICSp. 479
BLINK CODESp. 480
+SPEEDOMETERp. 481
SPEEDOMETER TROUBLESHOOTINGp. 481
SPEED SENSOR TESTp. 481
+SWITCH TESTINGp. 482
REAR BRAKE LIGHT SWITCH TESTp. 482
FRONT BRAKE LIGHT SWITCH TESTp. 482
CLUTCH SWITCH TESTINGp. 483
GEAR POSITION SWITCH TESTINGp. 483
GEAR POSITION SWITCH REMOVALp. 484
+CRUISE CONTROLp. 485
OPERATION OVERVIEW – SETTING SPEEDp. 485
OPERATION OVERVIEW – RESUME / ACCELERATEp. 485
Operation – Decelerate / Cancelp. 485
CRUISE CONTROL DIAGNOSTIC FLASH CODES (OVERVIEW)p. 486
CRUISE CONTROL DISENGAGE CODESp. 486
CRUISE CONTROL SWITCH DIAGNOSTICSp. 487
CRUISE CONTROL CABLE REPLACEMENTp. 488
CRUISE CONTROL CABLE “LASH LEARN” PROCEDUREp. 488
+HORN RELAY CIRCUITSp. 489
+WINDSHIELD / TRUNK LAMP CIRCUITSp. 490
+INSTRUMENT PANELp. 491
+AUDIO SYSTEMp. 492
+HEATED SEATp. 493
RADIO ON-BOARD DIAGNOSTICSp. 494
INDEXp. 495
WIRE DIAGRAMSp. 509
- Chapter 11 – Drive Line
- Drive-belt inspection, removal and installation
- Drive sprocket, output-shaft seal and rear sprocket service
- Chapter 12 – Front Wheel / Suspension
- Front wheel, axle, bearings and brake-disc service
- Front-fork removal, disassembly, inspection, assembly and installation
- Steering stem, triple clamps and bearing service
- Chapter 13 – Rear Wheel & Suspension
- Rear wheel, axle, bearings, brake disc and sprocket service
- Rear shock service data, removal and pivot inspection
- Swingarm removal, bushing / bearing replacement and installation
- Chapter 14 – Tires / Wheels
- Tire data, pressure / loading, wheel data and inspection
- Tire removal, repair precautions, installation and balancing
- Chapter 15 – Brakes
- Brake-system specifications, routing and front / rear exploded views
- Master cylinders, calipers, brake-fluid replacement and bleeding
- Brake-pad replacement, disc inspection and brake-system troubleshooting
- Chapter 16 – Battery Charging System
- Battery inspection / charging and charging-system specifications
- Battery load, current draw, regulated voltage and stator tests
- Regulator / rectifier testing and stator / flywheel service
- Chapter 17 – Ignition
- Ignition-system specifications, PCM connector map and troubleshooting flowchart
- Spark, ignition-coil and crankshaft-position-sensor tests
- Ignition coil and ignition-switch service
- Chapter 18 – Electric Starter
- Starter specifications, circuit diagram and troubleshooting flow charts
- Battery, neutral / clutch switch, relay, bypass and voltage-drop tests
- Starter current-draw test and starter-motor service
- Chapter 19 – Wiring / Lighting Systems
- Fuses, primary / secondary lighting and headlamp circuits
- Turn-signal self-diagnostics, speedometer and switch testing
- Cruise control diagnostics, horn, windshield, instrument-panel, audio and heated-seat circuits
Taken together, these chapters give a technician a connected view of the motorcycle rather than isolated repair notes. Specifications and service limits sit beside inspection methods; assembly drawings support removal and installation; troubleshooting charts lead into electrical or mechanical tests; and torque values appear throughout the procedures where correct assembly matters.
Service Data, Diagrams and Diagnostic Support
The manual contains detailed machine data for both Victory Vision Street and Victory Vision Tour. General specification pages cover capacities, dimensions, weights, engine configuration, brakes, transmission, suspension, wheels, tires, lighting, alternator and battery data. Service chapters add component-specific limits, clearances, pressures and torque values used during inspection and reassembly.
Illustrated assembly views are a major part of the manual. Bodywork and exhaust sections show how panels, brackets, trunk and saddlebag components fit together. Internal-engine chapters provide views for cam-drive parts, cylinder-head components, clutch and primary drive, transmission shafts, crankcase components and the balance shaft. Chassis chapters show front and rear wheel, fork, steering, shock and swingarm assemblies. Brake chapters include front and rear system assembly and exploded views, while Chapter 19 provides circuit diagrams for lighting and other electrical functions.
For diagnostic work, the fuel-injection section addresses fuel-pump current draw and pressure, electrical checks, self-diagnostics, fault codes and individual sensors. The charging chapter covers battery condition, key-off current draw, alternator output, stator resistance and regulator / rectifier tests. Ignition and starter chapters then build on that electrical foundation with spark testing, coil and CPS checks, starter-relay testing, circuit bypass checks and voltage-drop procedures. The wiring chapter supports system-level troubleshooting of lamps, turn signals, cruise control, switches and other electrical equipment.
Maintenance and Major Repair in One Reference
For regular service, the periodic maintenance table and Chapter 2 procedures provide the recurring inspection and replacement work needed to keep the motorcycle within the manual’s specifications. Procedures cover engine oil, filters, tire condition and pressure, throttle-cable free play, brake and clutch controls, fluids, brake pads, fuel-system inspection, spark plugs, battery condition, drive-belt wear and tension, suspension checks, headlamp aim and storage preparation.
When the job goes deeper, the same manual continues into complete component work. Engine removal is followed by dedicated chapters for the cylinder heads and valve train, cylinders and pistons, clutch and primary drive, transmission, crankshaft and connecting rods. That continuity is valuable when one repair exposes another inspection point or when measured wear must be compared with the applicable service limit before deciding whether a component can be reused.
Repair With the Right 2008 Victory Vision Procedures
The 2008 Victory Vision Street & Tour Service Manual PN 9921254 PDF supports everything from scheduled maintenance and adjustment to engine teardown, fuel-injection diagnosis, driveline repair, suspension work, brake servicing and electrical fault tracing. Using the procedures, diagrams, specifications, service limits and torque values written for the 2008 Vision Street and Tour helps reduce guesswork when inspecting parts, diagnosing faults and putting assemblies back together correctly.
After payment, the manual is delivered instantly as a PDF with no shipping delay. Open it on a compatible computer, tablet or phone for workshop reference, or print the pages you need for the job.
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