Modifying CVT belt cover

[toomanytoys2]

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

[OLDKID]

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 .

[toomanytoys2]

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.

[ckau]

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.

[SYCARMS]

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

[scjeep4.7HO]

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.

[fan4chevy]

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.