Overdrive pulley

A modification offered for many of the 5-speed Victorys is an overdrive pulley. It lowers rpms by 7%. After having the Victory for awhile I could see the merit in it. What would be even better was a 6-speed but I have to settle for the pulley. I had the bike tore apart to install a Big sucker intake and Lloydz VFC-III so I decided to install the pulley as well.


What little installation information I could find online all showed the removal of the exhaust and related items. I was able to use a wrench and 5mm bit to get the pulley coverplate off without removing the exhaust. I thought I was going to save myself a bunch of work but it was not to be. The exhaust is still in the way of the socket needed and doesn't give enough space for the pulley to come off. Curses!


To remove the exhaust you also have to remove the right floorboard and lay it out of the way.


I didn't have to completely remove the entire exhaust system...just the mufflers. Once the front and rear cylinders head connections were loose the exhaust had enough movement to clear the socket. The tension has to be taken off of the belt.


The retaining ring is removed.

All the instructions I've seen said to heat the locktite to allow the nut to come off. I was able to get it off with an air wrench and the required 48mm socket.


I might have been able to get the pulley off by heating the locktite but I used a puller instead.


Success!


Stock vs Overdrive pulley pictures.


The overdrive pulley is nicely machined and slightly wider.


It would nice if it was time to reassemble everything but there is still work to do. Because the pulley is wider the speed sensor boss has to be clearanced by about 1/8".

Tip: When using a burr on aluminum go very slow and allow the burr to eat the aluminum away. If you go fast the aluminum will get hot and glob up your burr bit.


Here is the clearanced boss. I didn't pay attention to how far back the stock pulley was so I clearanced the boss back farther than I needed to. It didn't hurt anything other than wasting some time.

I drilled the threads out of a 1/4" nut and used it to space the speed sensor back. I like to use one item as a spacer instead of a stack of washers.


The new overdrive pulley installed.


When I got ready to install everything I touched the exhaust and it literally fell off the bike. Ha! I used an inspection mirror to make sure the pulley and belt had clearance with the pulley cover installed.

The pulley is expensive and a pain to install but I like the results. Driving to work on the country roads 4th gear revved more than I liked and 5th gear was a little too tall. I needed a 4.5 gear. Now 4th gear is just right. First gear doesn't seem like a tractor gear and the lower rpms on the highway are much nicer, too.

I took my time reassembling the exhaust and when I fired up the bike I was surprised to find it was much quieter. Apparently I had had an exhaust leak or two before.


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