Eventually in our riding adventures we do wear out certain components on our ATVs. Having staged our "One Bad Mudda" (September '08 issue) in some of the south's deepest bogs, we noticed more and more slipping in the transmission at lower rpm on our Can-Am Outlander 800. This began to get worse until finally the quad couldn't pull its own weight. Stress on the CVT is undeniably huge as this is where the rubber really meets the road before the tires ever turn. Getting the belt in our CVT wet did nothing to help our situation either. With smoke billowing from the awesome Gorilla snorkel kit, we knew it was time to address the problem. Our hope is that this little how-to might help get your machine out of the garage and back on dirt. So here is the short course on changing the CVT belt.
Tools Required
Clean shop, nut/bolt tray, common metric wrench set, flat-head screwdriver, Torx bit assortment, OEM service manual (not necessary but helpful), driven pulley expander tool (available through your dealer), new CVT belt (we used an EPI heavy-duty replacement)
Summary
Getting our "One Bad Mudda" Can-Am lifted and into the air brought on many challenges--which were not for the mechanic only. Putting massive amounts of additional weight on the machine meant the CVT belt and transmission would have to disperse the weight and work twice as hard for the same results in performance. Keeping your belt healthy is a key to many fun days and nights of trail riding. If you notice the transmission slipping, be sure to address this issue immediately. It's not a difficult task, and with the help of your service manual and our basic instructions you can save the major repair dough for more bling!
Tip
As on most of today's ATVs, there are many types of fasteners. Our Can-Am Outlander 800 had both a nut/bolt combo and plastic pushpins, which were used to hold on the plastics.
Tip
Be sure to wash your machine thoroughly to prevent any mud or dirt from not only getting into the CVT enclosure, but also to keep it out of your eyes while working.
Tip
Make sure the ATV is in neutral as it makes turning the drive and driven pulleys easier.
Tip
Adding anti-seize lubricant to the CVT bolts will ensure that you'll have less trouble should you need to remove the cover again.
Tip
Most belts come with a directional indicator on the belt. Be sure the arrow is in the correct direction of travel before moving on and securing the belt.
As we have stated in past...
As we have stated in past technical articles, you really need a clutter-free environment to work efficiently. So clear out a spot in the garage and leave plenty of room in case you drop something on the floor. It's easier to find nuts or bolts on a clean shop floor.
Locate the CVT cover and sections...
Locate the CVT cover and sections of plastic that may need to be removed to get a clean and clear handle on the CVT cover. This is where the service manual comes in handy!
Remove each of the pushpins...
Remove each of the pushpins by gently inserting the flat edge of a flat-head screwdriver under the top portion of the pin and prying it out of the stationary piece.
Starting with your tools,...
Starting with your tools, lay out everything you might need to complete the job. This will ensure a quick and easy change-out.
Then you will need to remove...
Then you will need to remove the nut and bolt combos from the fenders that hold the floorboards in on your machine. Our Can-Am has Torx-head bolts, so this is where that specific tool comes into play.
Look closely at the fasteners...
Look closely at the fasteners that hold on the cover and proceed to remove with the correct socket and wrench combo. Our CVT cover had bolts with an 8mm head. Be sure to inspect the cover closely as some of the bolts can be well hidden.
Screwing this driven pulley...
Screwing this driven pulley expander bolt into the pulley will allow the belt to become loose, and once the bolt is at its limit you will be able to remove the belt.
After all the bolts and pushpins...
After all the bolts and pushpins have been removed, then you'll need to pull the complete floorboard section off of the ATV. This should expose your CVT cover where the belt is hiding.
Once the cover is removed...
Once the cover is removed you'll notice two pulleys; the larger of the two is going to be the driven pulley. This is where you'll need to work. Locate the small holes on the driven pulley near the retaining nut and find the one that is threaded. This is where you will insert the driven pulley expander bolt. See the service manual for the proper tool to fit your specific ATV.
Starting with the bottom of...
Starting with the bottom of the belt placed at the deepest point inside the driven pulley, gently coax the belt over the driven pulley's topside. Rolling the pulley clockwise should release the belt into your hands.
Now it's time to inspect the...
Now it's time to inspect the inside of the pulleys for cracks and abnormal wear as specified in your owner's manual.
Placing the new belt on the...
Placing the new belt on the drive pulley and into the bottom of the driven pulley just in reverse to the way the old belt came off is our next step. Rolling the driven pulley counterclockwise should let the belt seat itself on the pulleys.
Removing the driven pulley...
Removing the driven pulley expander slowly while rolling the driven pulley in either direction will allow the belt to seat itself. The belt should be at the top outside edge of the pulley when the pulley expander tool is removed.
Reinstall the plastics and...
Reinstall the plastics and take your beast out for a test run. Be sure to inspect all nuts and bolts as well as pushpins before the first full ride to make sure that nothing was left loose.
Reinstalling the CVT cover...
Reinstalling the CVT cover can be tricky so be patient. Start with the topmost bolts and be sure to not pinch the rubber gasket. These bolts require very little torque.