Modifying CVT belt cover
 

Yesterday my son and his buddy took the HH to a nearby field and stretched its legs. I was sitting in my Baja on a nearby hill to keep an eye on them. All of a sudden, they stopped, got out and looked at the engine. So I drove down to them to investigate. Turns out they didn't have any drive in forward or reverse. I always carry a tow rope, so I towed them home. 1st thought was CVT belt, so I grabbed a flashlight and looked in a vent hole - sure enough, belt cords. I drive this buggy fairly long distances in the SoCal desert, so I looked at what would be the minimum tools needed to swap the belt in the field. I decided that it would be a royal pain in the rear.

So I came up with an Idea, What if I pull the cover off, and use a metal bandsaw to cut the cover into two pieces. Where I would cut it would be vertically through the hole that was originally for the kick starter. Then I would have a front and rear halves, and wouldn't have to worry about pulling the exhaust off . We never go through water, and there would only be a small slit between the two pieces. Does anyone see a problem with this?

Thanks

I only ever had the cover off of my first one a few years ago and can't remember how much meat it had , heavy , or flimsy . My concern would be how much reinforcement does it add to the rear arm of the case itself ? Couldn't you do an exhaust mod. to accomplish the same thing , two piece header pipe , slip joint , springs , etc. Like a bike exhaust . :swordfight:

My exhaust is already like that. However, for support the muffler has a strap that goes to the kick start shaft. In the field, don't really want to wait for the exhaust to cool down, before I can work. Especially if the ride is right before dark.

I have consider doing this. one of those "round to it" projects. for the same reason as yourself , making access easier. I know a scooter builder who does some pretty radical stuff. he removes the cover completely, uses a polished aluminum plate held off with spacers to act as a guard. there seems to be no effects as far as bracing or strength to the motor case. Basically the cover simply serves as protection from the elements and a guard to keep fingers and toes out. IMo there's no problem making a two piece unit.

The only problem I see with cutting it is it wouls not have a tight enough seal for air o circulate cooling the cvt.

You could get a thin piece of rubber to fill the cut line, trim it and glue it to the side that would be staying bolted on most of the time.

Maybe for the center area you can get a T gasket of some sort. T rubber. Maybe a modified seal from a door bottom seal. Just a thought.