[RealMeanGolfCart]

Hey guys, I recently bought a 2021 Zforce 800 trail (CF800US-A) (Really mean-looking golf cart edition) second-hand with 207 miles on it. Got another 100 or so miles on it (313 now) when I heard the engine get just a bit louder (no angry sounds or anything of the sort) then just sort of lose all power and stop. It did run after that but very poorly and with a serious lack of power (because running on one cylinder).

Got it pulled home and after taking the cylinder 1 valve cover off found that the bolt at the end of the cam shaft had backed out causing enough play for the dowel pin to ream out the hole, the sprocket keyway, and break off the shoulder the sprocket rides on. The dowel pin then dropped into the wet clutch side of the engine.
Where could the dowel pin find itself having dropped into the wet clutch side of the engine? The best I've found on a teardown of this engine(2v91w) was some Russian rebuild videos and they show a hole through the side of the case toward the rear (Does this one go into the sump?) and only maybe a hole through toward the front, both behind the driveshaft at the bottom of the case. I've had my borescope down through the timing chain opening down to the bottom but couldn't really see much.
Does anyone have any clue where these go? Where that pin could end up?
if it got into the sump in how safe of a position would this pin be?

I've got a dealer that says they would try and do the warranty process for me even though its about 6 months out of its period yet only has 313 miles. But tells me if we end up out of luck that I would get a disassembled vehicle back. And there's the time and money it costs for them to do that (170 for diag plus gas). where I could have the parts cheaper and have them to me faster than they would be able to work on it in their shop and not roll the dice with cfmoto. I'm leaning towards having it apart myself and just ordering parts. How would you go about this?

For some reason, I faintly recall reading that people have had the wet clutch side of this engine off with the engine still in the vehicle. The left side mount is even bolt-on instead of welded on. Is this possible?

How hard is it to get this engine out of the machine totally?
Does anyone know about how much it might weigh?

Has anyone been able to get the cvt clutches off without a special holding tool? how so?

Will probably have plenty more questions as time passes. But any knowledge or advice on the matter would be greatly appreciated!

[NMKawierider]

Hey guys, I recently bought a 2021 Zforce 800 trail (CF800US-A) (Really mean-looking golf cart edition) second-hand with 207 miles on it. Got another 100 or so miles on it (313 now) when I heard the engine get just a bit louder (no angry sounds or anything of the sort) then just sort of lose all power and stop. It did run after that but very poorly and with a serious lack of power (because running on one cylinder).

Got it pulled home and after taking the cylinder 1 valve cover off found that the bolt at the end of the cam shaft had backed out causing enough play for the dowel pin to ream out the hole, the sprocket keyway, and break off the shoulder the sprocket rides on. The dowel pin then dropped into the wet clutch side of the engine.
Where could the dowel pin find itself having dropped into the wet clutch side of the engine? The best I've found on a teardown of this engine(2v91w) was some Russian rebuild videos and they show a hole through the side of the case toward the rear (Does this one go into the sump?) and only maybe a hole through toward the front, both behind the driveshaft at the bottom of the case. I've had my borescope down through the timing chain opening down to the bottom but couldn't really see much.
Does anyone have any clue where these go? Where that pin could end up?
if it got into the sump in how safe of a position would this pin be?

I've got a dealer that says they would try and do the warranty process for me even though its about 6 months out of its period yet only has 313 miles. But tells me if we end up out of luck that I would get a disassembled vehicle back. And there's the time and money it costs for them to do that (170 for diag plus gas). where I could have the parts cheaper and have them to me faster than they would be able to work on it in their shop and not roll the dice with cfmoto. I'm leaning towards having it apart myself and just ordering parts. How would you go about this?

For some reason, I faintly recall reading that people have had the wet clutch side of this engine off with the engine still in the vehicle. The left side mount is even bolt-on instead of welded on. Is this possible?

How hard is it to get this engine out of the machine totally?
Does anyone know about how much it might weigh?

Has anyone been able to get the cvt clutches off without a special holding tool? how so?

Will probably have plenty more questions as time passes. But any knowledge or advice on the matter would be greatly appreciated!

Those things don't usually go too far so the first thing I would do is go fishing...with a small but strong telescoping magnet down the same track the pin would have taken. Check for any lands and other places it could have stopped on it way like the tension bar or tensioner...but end up in the oil n the bottom and check all around. YES, you can pull the wet clutch side cover off in-frame and that will give you access to the main sump for your magnet. Remember to replace everything is is even a little damaged and my rule-of-thumb on CFM torque specs- spec plus 5 minimum..weather that be inlbs or ftlbs..or Nm. And use some blue loc-tite on that SOB. Others have had this happen too.

Although you may be able to use and impact to remove the retainer nuts...and a stress "may" on the clutches, torquing back to 84ftlbs without some kind of spanner will be near impossible. Many of us have made our own but a 6" adjustable spanner with side pins isn't that expensive.

[RealMeanGolfCart]

Hey guys, I recently bought a 2021 Zforce 800 trail (CF800US-A) (Really mean-looking golf cart edition) second-hand with 207 miles on it. Got another 100 or so miles on it (313 now) when I heard the engine get just a bit louder (no angry sounds or anything of the sort) then just sort of lose all power and stop. It did run after that but very poorly and with a serious lack of power (because running on one cylinder).

Got it pulled home and after taking the cylinder 1 valve cover off found that the bolt at the end of the cam shaft had backed out causing enough play for the dowel pin to ream out the hole, the sprocket keyway, and break off the shoulder the sprocket rides on. The dowel pin then dropped into the wet clutch side of the engine.
Where could the dowel pin find itself having dropped into the wet clutch side of the engine? The best I've found on a teardown of this engine(2v91w) was some Russian rebuild videos and they show a hole through the side of the case toward the rear (Does this one go into the sump?) and only maybe a hole through toward the front, both behind the driveshaft at the bottom of the case. I've had my borescope down through the timing chain opening down to the bottom but couldn't really see much.
Does anyone have any clue where these go? Where that pin could end up?
if it got into the sump in how safe of a position would this pin be?

I've got a dealer that says they would try and do the warranty process for me even though its about 6 months out of its period yet only has 313 miles. But tells me if we end up out of luck that I would get a disassembled vehicle back. And there's the time and money it costs for them to do that (170 for diag plus gas). where I could have the parts cheaper and have them to me faster than they would be able to work on it in their shop and not roll the dice with cfmoto. I'm leaning towards having it apart myself and just ordering parts. How would you go about this?

For some reason, I faintly recall reading that people have had the wet clutch side of this engine off with the engine still in the vehicle. The left side mount is even bolt-on instead of welded on. Is this possible?

How hard is it to get this engine out of the machine totally?
Does anyone know about how much it might weigh?

Has anyone been able to get the cvt clutches off without a special holding tool? how so?

Will probably have plenty more questions as time passes. But any knowledge or advice on the matter would be greatly appreciated!

Those things don't usually go too far so the first thing I would do is go fishing...with a small but strong telescoping magnet down the same track the pin would have taken. Check for any lands and other places it could have stopped on it way like the tension bar or tensioner...but end up in the oil n the bottom and check all around. YES, you can pull the wet clutch side cover off in-frame and that will give you access to the main sump for your magnet. Remember to replace everything is is even a little damaged and my rule-of-thumb on CFM torque specs- spec plus 5 minimum..weather that be inlbs or ftlbs..or Nm. And use some blue loc-tite on that SOB. Others have had this happen too.

Although you may be able to use and impact to remove the retainer nuts...and a stress "may" on the clutches, torquing back to 84ftlbs without some kind of spanner will be near impossible. Many of us have made our own but a 6" adjustable spanner with side pins isn't that expensive.

Thanks for your guidance on this NMK! I've had it apart now in the machine and it hadn't made it too far! Couldn't find anywhere near to get a pin spanner but made a tool that's at least good enough so far to get it off. Time to hurry up and wait for parts.

Side note. Does the air outlet for the cvt case get piped right into the cylinder 2 exhaust on your machine?

[NMKawierider]

Yeah. It blows right at it.