After looking at my new Dr Pulley sliders and new carbon fiber belt that sat neglected on my bench for an obscene length of time, I finally dug into it. Going to re-clock the clutch to C-1 and put in the new stuff.
I found I didn't have to take the cab plastic off nor the driver seat out, I could reach the two forward belt box bolts with this 8 MM offset box end wrench.
With the compression tool made and the secondary ready to compress, the first sign of trouble was the half inch allthread rod seemed about to strip out and the cup had not moved at all.
That didn't seem right. I replaced the 1/2" allthread rod with 3/4" and with great pressure the cup finally compressed enough to get the snap ring off but then when I released the pressure the compression tool came completely loose and the secondary just sat there like a loaded gun! (or bomb). Prying up on the cup did nothing. This really had be second guessing myself
At length I decided to loosed the compression tool by half a full turn of thread (so if it let go it would only slam up a little) and with the generous use of a ball peen hammer, tapped the hell out of the cup. After a minute or so of the spring pushing and me tapping it snugged up, and I backed the nut off another half turn and repeated the tapping. 10 or 15 minutes of this and the cup came loose enough to use the wrench to complete the removal. Then I saw the problem. steel swarf and debris was in between the cup's aluminum bore and the steel secondary shaft. Someone had used a press and hadn't cleaned metal fragments off, they just shoved it together.
Since these parts do not move relative to one another once assembled, this means the clutch was carelessly assembled in a dirty work station six years ago! (It's a '17) It would have gone undiscovered if I hadn't gone in there to re-clock. Note the score marks in the cup that doesn't move relative to the shaft unless disassembled. This is not the first example of sloppy assembly I have found in CF Moto.
A little emery cloth work and it became a good slip fit. It was pretty straight forward after that.
I took a belt sander to one of the case bolt ends and made it a smooth convex to spread the sheaves. As NMK pointed out one time, the bolt feels like it is digging into the aluminum of the sheave, not anymore, it feels good.
A clamp keeps the belt from being pinched in the primary till it starts to snug up.
Homemade clutch holder tool. Hey, it worked.
Today we'll see how it works.