First of all hello to all you guys using these machines ! I'm litterally green as they come with a utv .love my cars classic and modern rode moto x for 20 years but needed something to keep me busy while not doing my latest sport of stage rally..(keeps the daughter happy she loves mud lol)

Anyway I got the zforce after reading up bought a 2018 with 1700 Miles and clean with some spares parts included .

First trip awesome day road I trail (I live in UK devon and the lanes and moors are amazing but as I need to use a few roads it's half road half track trips to do routes and tracks.
.
all of a sudden on a road section accelerating hard to keep up with flow of 50mph traffic the belt snapped I heard it felt it instantly knew the belt had snapped!.

Roadside 3 hour repair later with little tools!(high 5 cf moto for easy of tool selection required and tool kit Pro idea plus my basic bag of kit and the spare parts previous owner supplied I managed to watch a view videos on you tube and easy remove the required casings plastics ect access the cvt I saw the remains of the belt in pieces with the rope inside wrapped around both clutches tightly wound up.
I removed as much as I could roadside  cutting twisting pulling unwinding but there was still remains in the secondary clutch.hammering with rain I popped on the belt as daughter was stressed now only 11 years been out 8 hours muddy wet and stranded..belt went on put vase on and crawled home thefinal 4 Mike's of trail to home  no issues .


Day 2.took it out for a clean at local power wash ..instantly realised on the roads as I need to speed up that it was only doing 30mph..day before 65 with easy ...rpm was hitting 7500 and doing 30 mph.
Running pulling like a horse but no speed.
Went home decided strip the cvt again and clutch...found the worn sliders !! All 6 meted with rough edges and 3 broken nylon guides on clutch..luckily I had some so replaced all the sliders and sleeve all fine..then i trued to separate the secondary clutch h to get the old last bits of rope out and still couldn't get it out ...so tried to remove the 2ndary clutch for closer inspection tion as you guys k ow not much room in there ..I can not seem to get it all the way off and joined nothing but few cuts and bruses so again got a few more bits of rope out tiny stands buy must be more in there .my thoughts are it's spread the secondary causing the slack belt and lack of drive at high speed ..I'm new to ctv barely understand how it works to be honest!

Any tips to remove secondary clutch ? And is this the issues with rpm or am I  chasing nothing..I rebuilt it again and one again won't exxed about 28 mph drives and pulls better but now won't reverse as his limiter before clutch engages....

Ps my local service centre is 80 miles away and I don't have a way to transport it there ...I have tools I'm no mechanic but have knowledge to service maintained and carry out basis repoars and rebuilds of 2 stroke engines ..
I'm considering buying a new secondary clutch to make it simple if it's the issue but if I can't fit it illbe at desk end stuck.

Sorry long post but figured read all the story at once .

Thanks for any info

[2015 Z Force 800 53/Trail EPS]

Well, there is no way around taking off both clutches completely and doing a full service and inspection on both. Move or remove what you must to get that secondary off and build or buy a compression tool to get it apart..but it must be done. And if by chance the belt had been slipping, it will be glazed and damaged beyond repair by now so a new one is in your future. Slipping belts damage sheaves  so inspect them closely and if you see any flat areas, you will be replacing the clutch. Those CFM flyweights are known to melt, so two things- one don't replace hem with CFM's plastics, use the Dr Pulley's as they are made for higher temps and two- road travel at high RPMs makes more heat then any trail riding so install a belt temp gauge..either the air temp or the IR type and if you see it reaching 200F, slow down or give it a break running in neutral. Better yet, install a CVT booster fan that you can flip on and get those temps down fast.

Hi thanks for infor I today have stripped both clutches full cleaned removed last pieces of old rope from secondary ..all looks clean and flat .cleaned both replaced the sliders and weights new belt ..after3 hours work rebuilt and its lotsbettrrclut h engagement but I'm still topping out at 34 mph aghhhhh please something me into the next direction

Just a thought? Would it make a difference if the belt was wrong way around ect? I fitted it with arrow facing forwards ..now realised the drive goes backwards?? Iv swapped belt around and still the same ..have a worn it out by running wrong way around .  I'm litterally at a dead end now ..so pissed off was due for a Bank Holiday weekend away with it this weekend

[2015 Z Force 800 53/Trail EPS]

Direction doesn't matter for operation, only that it needs to put back on turning in the same direction as it was during break-in. The arrows are to be on top pointing towards the primary as it pulls from the top and that's the easiest way to remember.
Are you sure you are in High range? 35 is about the peak speed in low range. Maybe jack the back end off the ground with the clutch cover off and rap it up to see if the clutches fully shift out. The belt should come near the top of the primary sheaves. Double-check the direction of the flyweights too. If backwards that effects shift-out....and while there make sure it is assembled correctly. One piece out of place can do this as well.

Juat checked as you said the belt seems to stay at the bottom of primary??? So frustrating but learning

[2015 Z Force 800 53/Trail EPS]

Juat checked as you said the belt seems to stay at the bottom of primary??? So frustrating but learning

Then the primary is seized or locked for some reason. Take it back apart and check everything.

What am I checking for ??weights position sliders function ect?? I'm 100 % new to cover and any sort of atv utv machine this my first few hours of manual work on one

[2015 Z Force 800 53/Trail EPS]

What am I checking for ??weights position sliders function ect?? I'm 100 % new to cover and any sort of atv utv machine this my first few hours of manual work on one

Any reason why the movable part of the clutch can't move. Do you need a service manual?

One other thought is- that if the helix can't slide on the ramps, it can't open in response to the pressure sent by the primary. From the top of the belt push down real hard. That pressure should force the belt down in the secondary moving the sheaves apart. If it does, then the problem is in the Primary. If it doesn't, the problem is in the secondary. Pull it and post some side-shots of the helix and ramps.

I havea manual that's how I did the works but did exactly what is said is there a way to manually check the movement of primary clutch? Sorry to be a pain this my 1st machine and had probs since day 1 only a week ago..

[2015 Z Force 800 53/Trail EPS]

I havea manual that's how I did the works but did exactly what is said is there a way to manually check the movement of primary clutch? Sorry to be a pain this my 1st machine and had probs since day 1 only a week ago..

See above on the secondary. If you pull the cam plate and open the secondary, you should be able to slide the movable sheaves in and out...in you will be pushing against the spring and it won't move far by hand.

I just though .May havebeen stupid as I did the mark the clutches primary or secondary when removed and replaced ?? I did mark the primary back when I replaced the weights though....I can't help think iv done something silly

[2015 Z Force 800 53/Trail EPS]

I just though .May havebeen stupid as I did the mark the clutches primary or secondary when removed and replaced ?? I did mark the primary back when I replaced the weights though....I can't help think iv done something silly

It's likely, these CVTech clutches are pretty much bullet-proof..if assembled properly.   One of the things that happens more often then any other is people put the weights in backwards.

Mmmm well I put them in the same way I'm sure of it do you have a pic of the correct way?

[2015 Z Force 800 53/Trail EPS]

Mmmm well I put them in the same way I'm sure of it do you have a pic of the correct way?

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