[impact]

Isn't there is tapped hole in the secondary, M6. Take a long bolt and thread it in there to open it up to take tension off the belt.

Yes, that is done. I'm fighting the main spring and possibly belt to get the front primary sheave back on.
Can't compress enough by hand to line things up and install the washer and retaining nut.

I'm going to try removing the belt again tomorrow. Re-installing the primary sheave and see if I can slip the new belt onto the open secondary......what a painful setup!

[NMKawierider]

I guess when they sent to a non-wet clutch they also went to a spring primary set up. Interesting that by removing the retainer that it would release the spring as well. Most aren't made that way.

[impact]

Got up this morning after a good night’s sleep and tackled the belt install. Finally figured out that removing the new belt allowed me to re-assemble the sheave on the primary clutch and was able to shoe horn it back on and into place. Took it for a test drive and all is well except for a small hesitation on take-off from idle which is probably due to the new belt settling in.

Observations:

No way this belt change can be done out in the field. Too many tools required. The CVT belt cover was a challenge having to use a universal on my socket to reach a couple of fasteners blocked by the frame.
The driver seat had to be removed and a storage box underneath as well.
Driver side roll cage member also was removed for convenience sake.
Not having a proper special clutch tool I had to make do with a crowbar and a torque wrench set at 40 N-M.

Surprise: No drain plug on the CVT cover and not that it would matter anyway as it is not accessible without removing a storage box or skid plate.

Conclusion:

If you blow a belt or flood the CVT with water you are being towed out to a repair shop.
Homer Simpson moment to myself: Ensure that the bolt separating the secondary sheaves is removed before complete re-assembly of the UTV…Doh!

[Etchluke90]

Strange I can't fathom why they wouldn't put a drain plug I would consider making your own with a oil drain plug kit all auto parts stores sell them.

[Cosmosdan]

I have forgotten the bolt in there too. Feel pretty stupid after that move.

[impact]

Question for you guys:

Is the skinny little bearing in the primary that the belt rests on at idle suppose to be one way?
Mine is not. I still get a wee bit of hesitation / jerkiness forward or reverse from idle even with a new belt and cleaning the sheaves. I don't recall it doing so before smoking the belt. Once the UTV gets rolling everything is fine. Please see picture of bearing up above.

[NMKawierider]

No, it shouldn't be a one-way bearing. Stall is what we call the time from idle RPMs to where the belt is engaged by the clutch making contact with it. There are several things that add to the stall...ie increases the RPMs before engagement. Binding flyweights or movable sheave parts and/or stronger springs are always possible. Another things that is possible is the distance the clutch has to close to make contact with the belt has changed. Usually warn belts..ie skinner increases the gap but also warn sheaves from slipping at startup is very common especially when low range should have been used where high range was instead. It's like slipping the clutch on a car all the time..wears the clutch, yes, but also wears the pressure plate and flywheel. You can resurface those but CVT sheaves are tougher to do...and if too much, they have to be replaced. Here's an example of another type of primary that has this warn section of sheaves. This clutch is shot and will have to be replaced.

http://images48.fotosik.pl/471/f0ad2f0a81451eedmed.jpg

[impact]

OK, so why this small idle bearing in the cvtech clutch setup on the 500 HO?
Everything I have googled to date shows the belt resting on a large one way bearing.
It appears out of character in regards to everything else out there.

[NMKawierider]

OK, so why this small idle bearing in the cvtech clutch setup on the 500 HO?
Everything I have googled to date shows the belt resting on a large one way bearing.
It appears out of character in regards to everything else out there.

No clue. Most just ride on the spindle with no bearing like in the pic I posted of a Kawasaki primary. The bearing in though seems like a good idea..until you look at the possibility if it wearing out or slinging grease out onto the belt. No need for it to be a one-way, it's purpose is just to keep the bottom of the bely from glazing on the spindle anyway.

[Cosmosdan]

I can speak to can am. I have worked on these. They do have a one way bearing at the bottom of the primary. You use a little bit of special synthetic grease in them. They also have thin seals on the ends. They do need service now and then. When the bearing starts to drag, the belt will keep moving and make shifting difficult. You should be able to run the cvtech without the cover on. For more info on your primary look up the trailbloc clutch.

[impact]

I can speak to can am. I have worked on these. They do have a one way bearing at the bottom of the primary. You use a little bit of special synthetic grease in them. They also have thin seals on the ends. They do need service now and then. When the bearing starts to drag, the belt will keep moving and make shifting difficult. You should be able to run the cvtech without the cover on. For more info on your primary look up the trailbloc clutch.

There must be various flavors of the trailbloc because mine has an additional idler belt support skinny bearing. (see my first post picture) unlike this one on a tear down hence why I'm asking questions.

[NMKawierider]

You know...it's possible that CFM put it's own version of someone else's clutch in their machine...ie how do we know what in yours is a CVtech clutch? Does it say it on it somewhere? I know like my 800 has a CVTech secondary but a CFM primary.

[Cosmosdan]

You might just have to take it apart and look closely at it. If it is a bearing it should move smoothly.

[impact]

You know...it's possible that CFM put it's own version of someone else's clutch in their machine...ie how do we know what in yours is a CVtech clutch? Does it say it on it somewhere? I know like my 800 has a CVTech secondary but a CFM primary.

Nah, its got cvtech written all over the primary and secondary.
ps: ignore the bolt in the secondary. It was there for thread sizing purposes only. I inserted a fully threaded one afterwards to separate the sheaves.

[NMKawierider]

You know...it's possible that CFM put it's own version of someone else's clutch in their machine...ie how do we know what in yours is a CVtech clutch? Does it say it on it somewhere? I know like my 800 has a CVTech secondary but a CFM primary.

Nah, its got cvtech written all over the primary and secondary.
ps: ignore the bolt in the secondary. It was there for thread sizing purposes only. I inserted a fully threaded one afterwards to separate the sheaves.

Well, sure does. Maybe its special made just for CFM..