Because the new primary cover is wider than the stock unit, the clutch rack must be spaced outward. We used internal snap-ring pliers to remove the clutch rack assembly. The threads in the rack engage the pinion shaft arm-gear teeth that operate the clutch mechanism. | 
The threaded clutch rack and bearing were pressed into the longer S&S rack insert. The assembly was slid back into the pressure plate and secured with the snap ring. | 
Before proceeding, we had to remove the stator from the stock cast Victory primary cover. |
A 5mm Allen wrench was used to remove the stator and the wire bracket from the stock cover. | 
Using the stock hardware, the stator was bolted into the S&S cover. | 
Bearings for the shifter shaft and pinion shaft arm were lubricated with motor oil before... |
...putting the primary gasket in place. A few drill bits were used to hold the gasket in place. This prevents pinching the gasket and makes assembly easier. | 
The S&S primary cover was slid into place; the drill bits helped locate the cover into its proper position. | 
After snugging up the new cover, the pinion shaft arm was slid into the primary cavity. For proper clutch actuation, the top of the arm must be oriented approximately 15 degrees out from the centerline of the bike. |
A longer pinion shaft retaining bolt was tightened down and all the cover screws torqued to 85 lb-in. | 
A new billet derby cover, with Viton O-ring, rounds out the new primary cover. To keep the O-ring in place, a dab of grease was spread around the groove in the back of the derby cover... | 
...followed by tightening the new chromed button-head Allens. Finally, the clutch cable was reinstalled, stator plugged back in, shifter linkage reinstalled, and the battery reconnected. |
SourcesPolaris West(281) 391-8800www.polariswest.comS&S Cycle (608) 627-1497www.sscycle.com