8 pages of clutch info on the search but could not find any recommendations on when to rebuild a clutch. How many miles would you Kawi riders recommend? I have 2500 miles on mine and I've never even had the cover off. I have not had any problems at all and I have rode in deep mud, very steep, rough and rocky trails.
Any info would be appreciated.

 

You will most likely have to tune it soon after 2500 miles. Reshim it probably wouldn't hurt to take off the cover have a look see.

 

The question is "WHEN" to rebuild...
There is no numerical answer for this because every rider has different riding style on different terrain. It could be as short as 100 miles or 1000 miles or as high as 5000 miles. Here is something to check:

> Measure the belt deflection and it should in the range of 22-27 mm. If too tight, the quad may creep when idling in gear - it should not. If too loose, it may slip and/or squeal when trying to take off and may experience reduced top speed.
> Inspect the belt width and cogs for any damage or wear.
> Inspect the converter sheaves for any damage or wear.
> Inspect converter bushings, weights, buttons, etc. for wear.

When to rebuild the CVT clutch should be determined by inspecting the components, not by counting miles or hours on the quad... that's what I do.

 

Thanks for the replies. I will just have pull the cover off and check all the things you mentioned. I know on my snowmobile the dealer told me to rebuild every 800 to 1000 miles rather it looks like it needs it or not because the 900 is hard on clutches, he was right.

 

Yes, there is a number that you can use ONLY as a guideline to check CVT clutch on your V-twin Kawi quads (& 360). It is when the BELT LIGHT coming "STEADY ON" every 100 engine run hours. That's like the "CHECK" engine light coming on every freaking 30,000 miles on early Japanese cars and can't pass the state smog check with the light on even though there is nothing wrong. As far as the CVT life goes, it all depends how you ride and maintain it.

 

I replaced the outer cover on the primary at 1200 miles and also the bushing on the inner sheave.Mine was knocking more than I cared for at the time,especially in cold weather.The bushings were just at the max of the range ,the shoes were still in spec. After I did this the knocking definitiely was quieted down but now at 2200 miles and cool weather here I am noticing it getting a tad louder again.I am not sure of the magic mileage but thats my story.
02 650 camo

 

A cheap & simple fix to worn buttons is to take them off and put a piece of shim stock behind them when reassembling.
If everything else is ok and not badly worn this will take the knock out of the clutch as well.