[Killer Kilgore]

Trouble again.

Wife and I were heading to fishing hole.
Been on road about 10ish miles. Blacktop. In 2 wheel drive.
Everything was going fine until it wasn't.

Moto engine sounded as if it was way way bogged down. Then the rear wheels locked up. Went skidding about 20ft and went off side of road. Landed on driver side.

No serious injuries. Got a little road rash on shoulder, left arm. No seat belt. Wife a few bruises from seat belt. Knot on shin.

Tell you one thing the good Lord was watching over us yesterday. Could have ended a LOT worse than it did.

Shut off moto with key, wife and I climbed out. Shook the poop out my britches leg and before I could get Cell phone out of pocket to take pictures. Guy came along in truck and flipped back over on the wheels.

Gave it about 5 minutes and started back up.
Started just fine. Put in gear and wouldn't budge. Engine sounded as if it was bogged down. No forward no reverse no moving machine won't move. Can't push in gear with or without engine running. Can push by hand in neutral. Even in neutral the engine sounds bogged down. If I remember correctly.

We loaded on trailer in neutral has no trouble rolling. Off load at home and parked it.

Since it will roll in neutral the differential isn't locked.

Don't even know where to start looking to see what's wrong.

Any advice?

Thinking about starting again. Listen to engine. Remove cvt belt. Then listen to engine. Compare the difference.. See if can move the trans side of cvt to see if it will spin with cvt belt off. Then go from there.

Anything I should look for?

[NMKawierider]

Belts coming apart and getting wound-up in the clutches is the #1 cause for this so...step #1, get the cover off and give it a full inspection. Glad you two are OK. Like you said, it could have been far worse.

[Killer Kilgore]

NMK,

Dude, do you ever get tired of being right?

I just hope nothing inside is broken.

This is (was) a 2ish year old Gates belt from Amazon.

[Killer Kilgore]

I don't think anything is broken in trans.

[NMKawierider]

Trany looks OK. Those clutches need a good clean-up though.

[Killer Kilgore]

Well got back together.

After a good cleaning.
Had old belt check with caliber was width of 35mm manual I got from somebody, (thanks again), says to replace at 33.5mm . Only reason  I replaced the 1st time. Is I THOUGHT it was bad. Turned out to be wet clutch.

Well wet clutch is bad again. I remember how to check for a bad wet clutch. So got to order another clutch and going to get a new belt before I take apart again.

BUT was able to travel about 500 ft. 😆

NMK thanks for the help.

[NMKawierider]

Welcome.

[Killer Kilgore]

Well jumped the gun.

Checked to see if wet clutch was slipping. And it made an awful racket, so I "KNEW" the wet clutch was gone.

Drained oil (nope didn't check to see if low).
Pulled CVT housing off to expose the wet clutch. So I could clean everything up and get ready to install new wet clutch when it gets here.

As you can see from the pics wet clutch looks good.

Then I drained oil from catch pan and even though there was a little oil that came out then I removed the CVT housing. It wasn't enough to account for what was missing.

So I think I'm just going to get some gasket material and make new gaskets. And reinstall the old clutch.

When the new wet clutch gets here just keep it for incase of.

There was just a little ware on the clutch drum but it isn't that bad. Can't catch my fingernail.

The new belt arrived Thursday so I'll install that and see what happens.

Getting kinda late. Got to pick up tools..
So just going to soak the clutch overnight before reinstalling. Have to get some gasket paper anyway.

Just one question. When I took the CVT housing off. The one-way bearing fell out. I'm not 100% sure how it goes back in to work correctly. Any tips or secrets?

[NMKawierider]

One-Way- Think of it like this: with the unit not moving and in gear, the engine must be able to idle without engaging the one way and looking at the primary straight-on the engine would be rotating clockwise. That's the same as the shaft being able to rotate counter-clockwise when the engine isn't running. So, if looking straight-on at it and it rotates counter-clockwise freely.. and engages when you turn it clockwise, it's correct.
Check for any play or movement on the shaft bearings-both the one on the shaft and the one in the cover. Any play will cause an alignment problem between the wet clutch and the bell/shaft and that can make some bad noises. Look for odd angled marks where the one-way makes contact on either side. That's a sign of at least the cover bearing bad.

[Killer Kilgore]

No play in bearings.
But the seal in the CVT housing was weeping moist around the clutch drum.
The bearing in the CVT cover was shot.

Since I already had parts on the way. Went ahead and ordered the bearing and both seals.

Got seal out of the cover with no issue. The bearing was a different story. Kinda put a hole in the CVT cover. See pic
Think I'm going to get some 2 part putty like JB Weld, and rough up the outside and apply the putty.

But I put the new clutch, one-way bearing, clutch drum, belt, the 2 seals and new bearing in.

Need to do something about the case. Even if it is just duct tape over the hole in CVT case. Before I can put fuel tank and rest back together.

A new CVT cover is out of the question. To be honest. I've sunk enough money in this pit. Wife is kinda leary of it now. So after I get it back together. I'm going to put it up for sale. It should be right and have an extra good wet clutch to go with it.

I think the issue with it slipping before. Was when I cleaned the sheaves. I used purple power and soap. Maybe not enough soap. Then took 1500 Grit sand paper to sheaves. And didn't wash the within specs belt. Guess between the sanding and not wash belt. It just wouldn't grape.
But either way there's a new wet clutch, one-way bearing, clutch drum, clutch drum bearing replaced last time, seal, CVT cover bearing and seal, new belt, oil filter and oil in it now.

Just need to do something about this hole.

[Killer Kilgore]

And thanks for the one-way bearing info.
That is what I was thinking but not 100% sure.

[NMKawierider]

Maybe just cut a round piece of aluminum, bevel the edges and JB Weld it to the cover over the hole. Shoot a little paint over it.

[Killer Kilgore]

Thanks for the suggestion. But went a slightly different route.

Since I'm selling it. I just took back apart,
Used existing bearing. Cut out a piece of cardboard. Took clear tape. And taped the cardboard over hole and reassemble.
The gas tank is going to hide that side anyway. And by the time the new owner has any trouble. He will have forgotten where I live.

Was in such a rush I only got one pic. I didn't even trim the clear tape around the cardboard

[Killer Kilgore]

No just joking. I wouldn't do anything like that.
I did cut out cardboard and taped over the bottom of hole from inside.

Then I flipped over and filled the hole with JB Weld. Once the JB weld has cured.
I'll remove tape and cardboard.
Sand the outside and paint

Brother did the same thing when he laid his bike over and put his kickstarter thru his. He didn't have the bearing to contend with. But same process.

[NMKawierider]

Lol..had me go'n for a bit...