Turbotec Drive Sprocket Pulley Installation for Victory Motorcycles

Victory motorcycles with 5-speed transmissions have slightly short gears. The first gear is almost unusable and the high gear is not high enough. This larger two tooth pulley makes your bike easier to use.

The Victory 32 tooth overdrive pulley. Fits all 03-05 Victor and 99-01 Victory motorcycles with upgraded transmission. This pulley will drop RPM by 7% and uses all factory parts. I decided to install this pulley on my 2004 Victory Kingpin and wrote step by step installation instructions along with photos of the installation. Below are my working notes for doing the installation.

I was doing other maintenance and decided to put the bike on a jack.
It is not necessary to remove the wheel. In fact, you want to leave it on to help remove the sprocket.
First I removed the slider part of the exhaust to lighten the exhaust.
Remove the belt guard.
Remove the floor board from the right side transmission so you can get the exhaust out.

Before removing the exhaust.
Note the condition of the exhaust flange nuts.
The exhaust flange bolts may be rusted. Spray with WD-40 and let it sit overnight to loosen them up.
After removing these flange nuts, remove the exhaust.

Here is the Kingpin with everything removed.
Exhaust, belt cover, driver’s right side floorboard.
It is not necessary to disassemble the wheel. In fact, it must be installed to help in the removal of the sprocket.

Exhaust removed. The slippery boats are around here somewhere.

With the exhaust off, remove the sprocket pulley cover.

With the sprocket cover removed, you will now see the sprocket.
Here I have the loose belt. You want it snug and the wheel on as this will be used as your resistance when removing the nut from the sprocket.

Another shot of the right side of the completely stripped Kingpin.

Remove the sprocket lock plate bolts and the lock plate.

Remove the sprocket lock plate.

The sprocket nut has a 48mm socket.
The nut has been located at the factory.
You can use an impact wrench to remove. Heat it to loosen the Loctite.
Here I am using my heat gun. It took me about 10-15 minutes until I was able to just hold the rear brake pedal and remove the nut.
Let the sprocket cool down.
It will slide right off.
Next, clean any Loctite dirt from the sprocket rod threads.

After removing the nut, you will need to loosen the belt to remove it and install the new pulley.
The sprocket will slip immediately after loosening the belt.

Here’s the lone driveshaft just waiting for its new drive sprocket.
Stay tuned for more as this is as far as I’ve gotten. Now I need to order the new sprocket.

The bike must be completely disassembled on the right hand side, bags removed, passenger floorboard, driver floorboard and controls, pulley side cover, belt covers (upper and lower ) and the leash. The worst part of the job was the exhaust system, watch out for them. Here is a photo of the motorcycle ready to start assembling it. Now clean everything you have removed and clean the engine and all the areas that are exposed.

Grind the Tab that holds the Speed ​​Sensor. Grind 3/8 to 1/4″ from the bottom of the tab, but not to the side of the engine block.

Continue testing the OD pulley until it is fully advanced without touching the tab. The side pulley cover will also need to be resurfaced to allow clearance for the drive belt. It will rub the sleeves of the bolts.

Now install the speed sensor using washers that are about 3/8 to 1/4″ thick, place them over the screw hole, then place the speed sensor on top of the washers, insert the bolt and tighten.

Check wheel alignment and belt tension. With the bike raised on a hoist, rotate the rear wheel until you find a tight spot on the belt, halfway between the front and rear pulleys. You should have about 9mm of flex with 10lbs of force on the bottom. The markings on the swingarm are useless. After adjusting the tension, rotate the wheel and check the belt alignment by observing the path of the belt on the front and rear pulleys. The drive belt should not rub against the sides of the rear sprocket.

Finally reinstall the exhaust system. Be careful not to scratch the pipes as you put them into position.

Please note that the Victory Overdrive Pulley manufacturer does not include installation instructions with their product. We hope these instructions help you during the installation. I have found some very good help on the Kingpin Cruisers site at http://www.KingpinCruisers.net. This installation requires some good wrench skills, but if a service technician can do it, they will surely be able to do it and do a much better job.