[KD1995]

Hey all... I have a question on  21 zforce 800ex. I recently rode a few days at HMT without issue. After getting back  I noticed a slight noise in the clutch area that sounds like lightly grinding brakes when idling. I noticed the bushing on the sliding sheave is toasted. I do not see this in any parts diagrams online. Is this bushing available or does the whole sheave need to be replaced? I also bought the cover bearing. Has anyone changed the bearing and seal in the cover without the specialty tools?

[NMKawierider]

I have never seen or heard of that bushing wearing out. I would think there must be a reason like it's spinning on the hub when it shouldn't be...something. Inspect the splines on the cam plate as they may be stripped. As for the cover bearing my 15's was bone dry and I was going to replace it but without a puller I couldn't get it out even with heating the cover in that area so with the seal pulled I was able to clean it up with spray braklean and pack grease from the back side to the front through the center, then reinstalled the seal. I now grease it whenever I have the cover off and it's holding up fine. I don't think that primary bushing is replaceable through CFM but may be through CVTeck. Don't hold your breath though.   

[KD1995]

Thanks for the insight! I'm hoping to solve this issue without going into the wet clutch. I saw a video online that attributed the wear to the harmonic balance being off and vibrating on the shaft. I found the inner sheave for $99 and the outer for $119. I may just replace both and start new. A new cam is about $30. Hopefully, that and a fresh belt solves the issue.

[NMKawierider]

The key is to trace any "effect" back to the "cause" and restrain from just tossing parts at a problem. I do know that with either of the two bearing on that shaft loose can cause all kinds of problems including wet clutch and one-way clutch alignment problems...and if the case bearing is loose enough it will effect the primary's functioning and destroy the inner bearing so.. take a close look at it...and those splines...on both the cam plate and the shaft.   

[KD1995]

I finally got to take the cover off and look at the clutch. There is a hellacious amount of dust that I assume is from the belt slipping. The light grinding noise is from the cover bearing retainer it appears that the retainer is bent out on the end opposite the screw with grind marks. I need to check the bearing it looks like it could be damaged. I did'nt notice any shaft play, the one way works and it turns quietly.
I still have to remove the secondary. Do you by chance know if the secondary nut is left or right threaded?

[NMKawierider]

The only times I have seen something like that was when the bearing wasn't installed straight or all the way in from the factory and the retainer was not laying flat or all the way....or...that bearing is shot and when under load it pulls to one side and makes the primary rub the retainer. Mine was OK but...it came from the factory near bone dry and if I hadn't pulled it and greased it at 300 miles, it would have been toast by 500. Most people don't realize that that clutch shaft after the wet clutch is fully engaged, spins the same speed as the crank. Most ball and roller bearings can't take sustained RPMs of 3000-7500 for long. Every time I have mine open I grease that bearing...and boy does it need it. Mine only has 2500 miles on it and that cover bearing has been greased-packed 4 times now. But...it's still tight.

[KD1995]

The cover bearing is toasted. I pulled it out today. Luckilly, I bought a bearing and oil seal a while ago and have them on hand. 

[NMKawierider]

Yeah that's F'ed. Pack the new one with the best high heat & RPM grease you can get. In the future you can just pull the retainer and seal, then put grease through the hole and with your finger pack it back through to the front side all the way around, then put it back together.