[Buck]

Hi Folks,
Hoping any 800XC owners can help answer a question I have about the secondary clutch.
In 2022, I purchased a CF Moto 800XC. Recently while doing regular maintenance (cleaning the clutches and replacing my belt), and I came across a situation that pertains to the secondary clutch.
In looking at the exploded diagram for the clutches on the parts diagram as well as the service manual from CF Moto, it seems there should be a small washer or shim on the secondary shaft that the secondary assy pushes up against (in the parts diagram it’s called ‘adjust washer’). I assume this is done to ensure alignment and proper deflection between the primary and secondary clutches. What is odd, is that my secondary clutch shaft had no such washer or shim. I did check inside the secondary clutch (the hole that the secondary shaft slides into), and it was not in there either.
So, the question arises - is this normal? Do some secondary clutch assy’s have it and others don’t? If so, is this done because of MFR’ing tolerances and my particular secondary clutch assy was within acceptable parameters and therefore did not require a shim?
Or, could this have been left out in error by either CV Tech or CF Moto at the time of assembly/production?
I can easily procure the shim and add it if needed, but I don’t want to do so if it shouldn’t have one based on the tolerance considerations at time of manufacturing as mentioned above.

[NMKawierider]

Looking at the diagram, being after the circlip, it must be used for alignment with the primary..if needed. On these it is critical that the belt only ride on the idler bearing and not touch the sheaves of the primary when not moving so the belt has to be able to be aligned both with the secondary and the primary to achieve that. I say assemble it. Then check that you have about the same gap between the belt and the sheaves on the primary If so..good to go. If not, and one side is touching, might want to adjust it with those shims.

[Buck]

Good call NMK!
I took the clutch cover off to inspect. What I found is that the belt was very close (closer), to the inner primary sheave than the outer sheave. This is somewhat normal though, given the outer sheave has the variator components and it moves in to grab the belt once throttle is applied and the RPM’s increase. I started the bike to examine further. Each time I started/stopped the engine, I rotated the secondary to ‘reset’ the belt. In the three times I carried out this process - two times the belt had a very slight twitch back and forth while the engine was running at idle. This suggests the belt is (as you said), riding a little too close to the inner sheave on the idler bearing. I will be picking up the the shim and install it for sure.
It does beg the question though, was the shim deemed not necessary at the factory while undergoing quality testing, or did someone on the line simply forget to add the shim?
I believe it got missed on the assembly line.
Every video I have seen on these clutches shows the shim in place on the secondary shaft…and that goes for any displacement engine, as they all seem to use the CVTech Trailbloc primary/LP3 secondary…

[NMKawierider]

Probably just got missed.

[Ulfthednar]

on this topic, Im planning on going to the DR pulley sliders and doing a routine full inspection here soon.
What special tools do I really need to go all the way into the actuator on the CVT?
I know Ill need a sheave spreader for removing the belt and prefer to not tear things up working on them.

[NMKawierider]

Besides a good torque wrench and that spreader bolt..which many just use a cover bolt, just an adjustable spanner tool to hold both clutches comes to mind. If you will be re-clocking, a compressor of some sort will be necessary.

[Ulfthednar]

Alright . .