took my cover off and as expected the deflection was WAAAAY off. over 30mm....... i tore it all apart (what a pain in the neck) and put it back minus one shim. When i put the belt back on it was more loose than before i took out the shim?!?!?!? I was running out of daylight so i put the cover back and fired it up. There was a distinct thumping noise coming out of the CVT area.........kinda like the belt flopping around. Pulled out and everything seems normal. It pulls better and no abnormal noises while moving.

So when you put the belt back does it settle in when you ride a bit? I'm puzzled. I didn't have any light left to tear the cover back to check deflection so i'm assuming it's tight again

thanks again for the help fellas

l8r
cart

 

There is a shim in both the front and rear clutch, what was the location of the shim that you removed ???

 

You should have pulled off shims from the driven (rear ) pulley. Probably all shims.

If you did this, you also have to rotate the driven pulley by hand until the belt is all the way out before you measure. If you did this and the belt is looser, you may not have put the driven pulley back together right, or I guess maybe the bushing is bad it your driven pulley.

The shoes in the CVT make a little thumping noise normally (very rhythmic) only at idle.

 

the shim cam out of the rear pulley. left one in so that aluminium wasnt' riding on aluminum. The thump was only at idle and seemed to clear up after a short ride. When i get time i'll pull the cover and check again.

thanks for the help guys

l8r
cart