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Old 07-02-2020, 10:23 AM   #1
strantor
Not Yet Wild
 
Join Date: Jun 2020
Posts: 15
Default Seeking knowledge of Dana/Schafer diff & CVtech CVT

Hello all, new member, first post.

I recently purchased a used American Sportworks Bulldog 300 UTV with Kohler 9.5HP/277cc engine and the following 2wd drivetrain:
  • Dana/Schafer 265 transaxle (Dana P/N 012AJ420-1) (ASW P/N 2-20869)
  • CVTech Series 06 CVT

The cart had a recall about the engine; throttle sticking wide open, causing the operator to lose control. Judging by the damage to the front end I assumed that had already happened and been fixed. It hadn't. Happened to me once and that was all the justification I needed to pull that Kohler edger motor out and drop in a Predator 670cc V-Twin.

After engine swap it had gobs of torque but was still slow. Max speed with the Kohler was 17mph. With the Predator it went up to 20mph. I resolved that the issue was in the CVT. The drive pulley was not fully closing and the driven pulley was not fully opening.

I took apart both pulleys, gave a thorough cleaning and inspection, all seemed well, put back together, no improvement. I found that the drive pulley did not have enough travel to fully close. This is due to the way it was machined. The step on the shaft which limits travel was too far out. I don't know why. According to pictures on the internet it should not be this way. Perhaps ASW custom ordered them this way because it is not a rally racer and they didn't want it capable of 50mph. But I do.





I put the shaft in my lathe and moved that step back about 1/4" (the distance still left between pulleys when fully closed) and now it fully closes.







New top speed is 32mph. I know it can go even faster. The driven pulley is still not fully opening.

I suspect my problem now is too much belt slack. I can make the belt tighter but then I run into another (2-part) problem. (Part 1) This CVT does not have any freewheeling bearing on the shaft, so the belt rides against the spinning shaft at idle. Too much tension and the friction between shaft and belt alone is enough to spin the driven pulley. (Part 2) If the driven pulley (transaxle input shaft) is spinning with even a little bit of torque applied, it will not shift into neutral, instead stubbornly staying stuck in fwd or rev. So if coming to a stop with the belt tight, I must shift into neutral while coasting, then come to a stop. If I come to a stop with it in gear, the belt will squeal and I'll have to kill the engine to get back into neutral.

Now you have the background and I'll ask my questions:

1. Is the transaxle supposed to behave this way (Staying stuck in fwd or rev if torque is still applied)? If so, can it be modified to behave the way I need it to? If not, what might be wrong with it?

2. Is there some other reason maybe that the driven pulley isn't fully opening?

3. Does anyone here have service manuals for this transaxle and/ or this CVT? Information available for both seems to be scarce on the internet.
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