[cpwebb]

We have a 2016 800 EFI UForce that shifts into all gears fine when the engine is turned off, but is extremely hard to shift while the engine is running. We have taken off the cover to the CVT and the belt is turning while in Park or Neutral and will stop turning when put into a drive gear - not sure if this is normal or not. We can put the UForce into the gear before starting and it will run fine but is almost impossible to shift while the engine is still turning. Checked the idle and it is running at 1300 rpm, which the manual states is proper. Not sure if we have a linkage problem or a clutch problem or something else entirely. Any ideas on what to look for next or what could be causing this? I have video of the open CVT showing how it is working if that will help.

[NMKawierider]

We have a 2016 800 EFI UForce that shifts into all gears fine when the engine is turned off, but is extremely hard to shift while the engine is running. We have taken off the cover to the CVT and the belt is turning while in Park or Neutral and will stop turning when put into a drive gear - not sure if this is normal or not. We can put the UForce into the gear before starting and it will run fine but is almost impossible to shift while the engine is still turning. Checked the idle and it is running at 1300 rpm, which the manual states is proper. Not sure if we have a linkage problem or a clutch problem or something else entirely. Any ideas on what to look for next or what could be causing this? I have video of the open CVT showing how it is working if that will help.

It would appear the wet clutch is dragging for some reason. The three main reasons for this are: 1-one of the springs on the shoes has stretched or broken..and that's not uncommon. 2-one of the two primary shaft support bearing is or has failed and caused an alignment with the wet clutch shoes. Usually the one on the CVT belt cover as it needs greased often. 3- the idle is high enough that it's causing the wet clutch shoes to make contact with the bell. But 1300 is normal. Still, with a spring loss it will drag. How's the oneway clutch acting? They have been known to come apart and cause issues. People have also been known to install them backwards when replacing the wet clutch shoes. 

[cpwebb]

Thanks for the quick response! The one way seems to be fine but we haven't removed it from the machine and not sure I can get a real test with it still inside. We have only taken the Belt cover off to watch it function - while inspecting the cover support bearing we noticed what appears to be belt rub marks inside the cover. The belt seems to run fine with no wobble or shaking with the cover off so not sure why there would be rub marks on it. I don't have the special tools that the manual calls for to remove the wet clutch - how critical are they? I'm guessing if I have to take out the wet clutch it would be worth my effort to go ahead and replace the support bearings as well.

[NMKawierider]

Thanks for the quick response! The one way seems to be fine but we haven't removed it from the machine and not sure I can get a real test with it still inside. We have only taken the Belt cover off to watch it function - while inspecting the cover support bearing we noticed what appears to be belt rub marks inside the cover. The belt seems to run fine with no wobble or shaking with the cover off so not sure why there would be rub marks on it. I don't have the special tools that the manual calls for to remove the wet clutch - how critical are they? I'm guessing if I have to take out the wet clutch it would be worth my effort to go ahead and replace the support bearings as well.

If it has a problem, it needs fixed. Give it a full inspection and if you do need to open it up to get to the wet clutch, I think you can do it with mostly standard tools.

[cpwebb]

I agree that it needs to be fixed, and thanks again for the quick response and the words of encouragement! I think we'll order the parts for the clutch and support bearings and tackle taking it down further when we have them in hand. I'll follow up when we get to that point.

[NMKawierider]

I agree that it needs to be fixed, and thanks again for the quick response and the words of encouragement! I think we'll order the parts for the clutch and support bearings and tackle taking it down further when we have them in hand. I'll follow up when we get to that point.

I wouldn't order anything until you know what you need. Bearings may be fine. Pull it down first.

[cpwebb]

I'll have to wait until later in the week to finish tearing into it. I'll update when I get it apart.

[cpwebb]

Is there a trick to removing the Drive Pulley Nut and the Driven Pulley Nut? I had some time this afternoon that I didn't think I'd have so I thought I'd start removing parts, I put everything I had into the Drive Pulley Nut and couldn't get it to budge. The manual says it only torques to 115 N.m so that shouldn't be a problem. I don't have the special tool required, but it appears to only be there to keep the pulley from turning while loosening the bolt. I didn't try a reverse thread, but the manual doesn't state that it is and has been fairly good at pointing that out as far as I can tell.

[NMKawierider]

Is there a trick to removing the Drive Pulley Nut and the Driven Pulley Nut? I had some time this afternoon that I didn't think I'd have so I thought I'd start removing parts, I put everything I had into the Drive Pulley Nut and couldn't get it to budge. The manual says it only torques to 115 N.m so that shouldn't be a problem. I don't have the special tool required, but it appears to only be there to keep the pulley from turning while loosening the bolt. I didn't try a reverse thread, but the manual doesn't state that it is and has been fairly good at pointing that out as far as I can tell.

All with wet clutches are the same-Right-hand threaded to from 12:00 to 11:00 to loosen. And both are right at 84ftlbs (115Nm.) torque. We have vids in the how to section. You will need to hold it with something like a spanner. I built my own. These:

For the Primary.




For the secondary.

[cpwebb]

Thanks again, I'll check out the videos and try to build something when I can get back to it.

[cpwebb]

I finally got both the drive pulley nut and the driven pulley nut off, thanks for pointing me to the videos and showing the tools you built. That helped clear it up for me. I am now trying to pull off the drive pulley fixed sheave but it is being stubborn. I don't see where there is anything holding it on and it should just pull straight out but I can only get it to wiggle back and forth about 1/8th of an inch but won't budge off the shaft. I re-watched all of the videos to make sure I wasn't missing something but none show it being taken off. The manual just says to remove it and the diagram doesn't show any other bolts or screws in it.

[NMKawierider]

I finally got both the drive pulley nut and the driven pulley nut off, thanks for pointing me to the videos and showing the tools you built. That helped clear it up for me. I am now trying to pull off the drive pulley fixed sheave but it is being stubborn. I don't see where there is anything holding it on and it should just pull straight out but I can only get it to wiggle back and forth about 1/8th of an inch but won't budge off the shaft. I re-watched all of the videos to make sure I wasn't missing something but none show it being taken off. The manual just says to remove it and the diagram doesn't show any other bolts or screws in it.

The drive clutch shaft comes out by taking off that next cover off the case. It has a fixed bearing and seal that only comes out toward the wet clutch...now you are about to embark on some real mechanicals. Hope you are up to it. Do you have an actual shop manual? You will need it. This is kinda what you are looking at:



 

[NMKawierider]

This guy is modifying the cover but it does show him taking it off

On this one you can see the wet clutch shoes on the crank.

[cpwebb]

Hopefully I can get to that point, I can't believe he just pulled the fixed sheave out. I pulled and rocked and pried and couldn't get it to budge. Maybe tomorrow will be better.

[cpwebb]

By the way, the item I'm struggling with is number 8 in the picture I posted above.