825i CVT locking up? Help!

[doc527uk]

Just purchased 825i - first 6 hrs - great..... now CVT very hard to shift. Impossible to shift unless engine is off. Anyone with any ideas? Do I need to take back to dealer for warranty work? Any help appreciated.

[purplewg]

I assume you mean to put it into gear or shift from fwd to reverse? First thing I would look for is to make sure the linkage isn't binding on something. Lift the bed and make sure nothing is dragging on the linkage/cable. Are you in high range or low range. Low range can be a bit of a problem but high range should not be.

[doc527uk]

thanks will do.... literally now when engine running - difficult to shift into high or reverse from neutral....then impossible to shift out of high or reverse without turning engine off... then with engine off - shifter becomes normal again.....???? I will look at linkage....

[purplewg]

That don't sound like anything is binding in the linkage. I'm thinking I would have the dealer look at it.

[GATORDONE]

Sounds like the engine rpm's are too high at idle making it difficult to engage gears because the cvt is turning too fast.

[doc527uk]

Talked to dealer - He thought RPM's too high - idling too fast to allow shifting to occur.... I backed out the idle adjustment screw at small amount - no change in RPM... My 825i is idling at 2200 rpms to start and then over 1 min will slowly creep up to 2500 to 2800 rpms..... What rpms is the 825i supposed to idle at? I do think this is the problem.... any ideas?

[purplewg]

Mines idles at around 900 within a minute or two of starting. Yeah, 2000 is way too high. I think I saw in the manual where it said not to shift into gear over 1300 I think it was. I haven't looked at this engine much but typically on a Fuel Injected engine there is little if any idle adjustment. It is handled by the throttle position sensor. I woud say something is wrong with yours. I wold have them come get it....

[GatorMover]

I have seen the idle so high and guys force the shifter, it will go directly from fwd to rev not stopping at Neutral. I am not impressed with the shifter quadrant and linkage. There should be a neutral gate lock out or something there. To be able to go F to R without stopping at N is a sign of bad things possible.

[JDMasterTech]

I just had one come into the dealership that the clutch wouldn't release causing the hard shifting. I removed and diasembled the clutch and there was fine dust in the bushing. I installed a new clutch and now am in the process of building a different belt intake that goes behing the drivers seat that is not in the direct path of dust.

[jdman]

let us know how u built that diff. belt intake lots of pic. please i ride in fine dust all the time its like flour

[JDMasterTech]

529It was easy. I used the 3" Planter vacuum manifold hose and cut the stock intake and put the hose inside and clamped it down. Then i routed it behind the seat and secured it with a couple zip ties. I reused the original filter. I also turned the golg clamp over and redrilled the hole for the bolt. Here are a couple pictures528527

[825joe]

Great Idea. nice job! I'll be doing that to mine soon as well. Now we need to find out how to make a drain plug for the cvt. Im surprised it doesn't have one.

[JDMasterTech]

I use a valve stem out of a wheel. Drill the hole so the valve stem seats in and remove the valve core. Install the cap and there is your drain.

[825joe]

wow! Good idea. You got any pics of the location and install??

[JDMasterTech]

No I don't I haven't done it to a gator yet but I have done it to a couple Polaris Atv's. You would have to put it in a low spot just make sure the belt is clear of it and also it needs to be protected something doesn't hit it

[ThomasM]

I think that all would be needed is to replace the curr
ent filter with a more denser foam filter that would be washable

[JDMasterTech]

That would restrict air flow and cause the belt to get too hot.. Also a denser foam piece will get sucked into the belt housing when it gets plugged up. Been there, done that.

[825joe]

They have filters like that for the rhino's but im not sure how the gators belt would react temp wise.

[jdman]

jdmasterT. what planter did u get the hose from?

[BarnDoor]

That hose is on a few planters. Most deere dealers have it in stock, just ask them to measure what they have.

[jdman]

great i will check with my local dealer. any thoughts on moving the air filter to help with fine dirt like JDMasterT
did with the belt intake?

[MossyGator]

Is there a way to wash it out via intake or submerging the cluch in water? I just took my gator in Monday to JD and they are still scratching their heads about it. They replaced a cable and are about it get into the cluch they said.

[JDMasterTech]

If it is still under warranty have them replace the clutch. Tell them there is a DTAC case on hard shifting. Make sure the idle is slowed down to around 950 or so. As far as cleaning them I havent tried it yet. Make sure they relocate the clutch intake to stop further issues with the dust. The customer called me the other day and said his has never been easier to shift and it is smooth on acceleration after I installed the new clutch and put in the new intake. He has used it for another 12 hours and the inside of the belt housing is spotless. He removed the hose where it comes into the housing and said there is no sign of dust at all.

[number3shot]

529It was easy. I used the 3" Planter vacuum manifold hose and cut the stock intake and put the hose inside and clamped it down. Then i routed it behind the seat and secured it with a couple zip ties. I reused the original filter. I also turned the golg clamp over and redrilled the hole for the bolt. Here are a couple pictures528527

So where is the filter now? Still in the stock intake or in the 3 in. manifold?
Thanks.

[JDMasterTech]

I put it in the end of the 3" extended intake.

[Zephyr74]

529It was easy. I used the 3" Planter vacuum manifold hose and cut the stock intake and put the hose inside and clamped it down. Then i routed it behind the seat and secured it with a couple zip ties. I reused the original filter. I also turned the golg clamp over and redrilled the hole for the bolt. Here are a couple pictures528527

JDMasterTech-- Great pictures. Do you think this is an absolute necessary thing to to do? I ride all over dusty logging roads in N. California. Will this in anyway void the warranty?

Thanks!