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.
Skill Level
Moderate
[3/5]
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)
Time
1.5 hours
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.