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Old 04-16-2009, 11:05 AM
stray stray is offline
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remove the cvt cover with a T-30 torx bit or 10mm socket (some remove the left side floorboard, but it isn't necessary - just makes it a lil easier, you can carefully manipulate the cover around the secondary clutch). now, your primary and secondary clutches are exposed, as well as your belt. since i'm in there, i like to clean everything up and inspect. use a M8 x 1.25 bolt that's at least 3 1/2 - 4 inches long, to thread into the single threaded hole in the secondary clutch - this will spread the sheaves and allow the belt to be removed. i carry this bolt when i ride, along with the tools to remove the cvt cover (haven't forked over the $140 for a spare belt yet, but will soon) just in case i need to do some maintenance on the trails. ok, so the cover is off and belt is removed. now you need to remove the primary clutch by removing the bolt that runs through it's center into the crankshaft (i believe it's 17 or 19mm). to stop the clutch from turning, i wedge a 3/8" extension between one of the "fins" and the footpeg bracket. press in on the clutch housing when it's close to coming off so that it doesn't fly off and get damaged. behind it is the primary spring, a spring retainer cup and friction washer. the shiny thing left on the crank is the one-way. don't pull it off just yet! there are two holes in the crank that keep two spring-loaded pins in them. slowly slide the one way out, a little at a time, until you locate these. use your fingers to keep the 2 pins/springs from flying across the room and remove everything. inside the one-way are the two bearings. one side has a circular wire clip, remove that and both can be carefully tapped out with a drift. carefully press the new bearings into place and replace the wire clip. clean everything really well and apply isoflex to the springs/pins, inside the one-way where they slide and the friction washer. once you do this, it's much easier than my directions make it sound. in fact, here's a series of videos to give you a better understanding of the clutch components. btw, john cannon is a legend, but i don't agree with using an impact on some of the areas that he does. just my 2 cents...


this part 1 of 3

when you put the belt back on, give the secondary clutch a few spins and it closes the sheaves and puts the tension back on the belt. also, be 100% sure to get the gasket back in correctly when re-installing the cvt cover. use your fingers to go around the bottom and check (this is why some people remove the floorboards, also). don't overtighten the bolts securing the housing.


Last edited by stray; 04-16-2009 at 11:10 AM.
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