You hit the gas on your Can-Am Defender, but instead of that crisp, responsive snap you love, you get a sluggish hesitation, a weird grinding noise, or maybe a slipping belt. Sound familiar? It’s a frustrating feeling that can ruin a day on the trail or a hard day’s work on the farm.
You’ve come to the right place. That annoying performance issue is often caused by a small but critical part: the secondary clutch rollers. The good news is that you don’t need to rush to the dealer and hand over a pile of cash.
This guide promises to walk you through the entire can am defender secondary clutch roller replacement process, step-by-step. We’ll cover how to spot the problem, what tools you’ll need, and exactly how to get your machine running like new again. Let’s get those hands dirty.
Why Bother with a Secondary Clutch Roller Replacement? (The Big Benefits)
It’s easy to overlook these small parts, but replacing worn-out rollers is one of the most effective maintenance jobs you can do. The benefits of can am defender secondary clutch roller replacement go far beyond just fixing a noise.
Restore Smooth Acceleration
The rollers are what allow your secondary clutch to open and close smoothly, shifting gears seamlessly. When they develop flat spots or wear out, the clutch action becomes jerky and inconsistent.
New rollers bring back that buttery-smooth power delivery you expect from your Defender, whether you’re crawling over rocks or hitting a straightaway.
Prevent Costly Belt Damage
Worn rollers cause the clutch to bind and operate incorrectly, which puts a ton of stress on your CVT drive belt. This can lead to glazing, slipping, and eventually, a shredded belt on the trail.
Replacing the rollers is cheap insurance against a much more expensive and inconvenient belt failure. Protect your belt, protect your ride.
Regain Lost Power and Torque
A clutch that isn’t shifting properly is a clutch that’s robbing you of power. Your engine might be running perfectly, but if the clutch can’t transfer that power to the wheels efficiently, you’ll feel it.
A proper can am defender secondary clutch roller replacement ensures your machine is putting all its power to the ground, restoring that “like-new” feeling.
Telltale Signs: How to Know Your Defender’s Rollers are Shot
Your Defender is pretty good at telling you when something is wrong, you just have to know what to listen and feel for. Here are the most common problems with can am defender secondary clutch rollers that signal it’s time for a replacement.
Unusual Noises
This is often the first sign. Listen for a rattling, grinding, or clunking sound coming from the clutch (passenger) side of the machine, especially at idle or low speeds. This is the sound of worn rollers flopping around inside the helix.
Poor Engagement and Hesitation
Does your machine jerk or hesitate when you first take off? Worn rollers with flat spots can cause the clutch to engage erratically, leading to a rough start instead of a smooth one.
Noticeable Performance Drop
If your Defender feels sluggish, struggles to hit top speed, or doesn’t climb hills like it used to, your clutch is a prime suspect. Worn rollers prevent the clutch from shifting into the proper “gear ratio,” effectively capping your performance.
Excessive Belt Wear or Slippage
If you keep burning through belts or notice black rubber dust inside your CVT cover, it’s a major red flag. A malfunctioning secondary clutch is one of the leading causes of premature belt failure.
Gearing Up: Tools and Parts You’ll Need for the Job
Having the right gear on hand before you start makes all the difference. This isn’t a job you can do with just a screwdriver and a pair of pliers. Here’s a breakdown of what you’ll need.
Essential Tools List
- Socket set (metric) and ratchet
- Torque wrench
- Impact wrench (highly recommended for the clutch bolts)
- Can-Am Secondary Clutch Compression Tool (this is non-negotiable for safely disassembling the clutch)
- Snap ring pliers or a small flathead screwdriver/pick for the clips
- Brake cleaner or a degreaser
- Clean rags or shop towels
- Safety glasses and gloves
The Right Replacement Rollers
You have two main choices: OEM or aftermarket. OEM rollers are a direct replacement and a safe bet. However, many aftermarket companies like GBoost, KWI, or EPI offer heavy-duty rollers made from superior materials that can last longer, especially on modified or hard-ridden machines. Do your research and pick what’s best for your budget and riding style.
The Complete Can Am Defender Secondary Clutch Roller Replacement Guide
Alright, it’s time to get to work. This can am defender secondary clutch roller replacement guide will walk you through every step. Take your time, stay organized, and remember that safety comes first.
Step 1: Safety First & Prep Your Workspace
Park your Defender on a level surface and ensure it’s in Park with the engine off and cool. Chock the wheels for extra safety. Put on your safety glasses. This is one of the most important can am defender secondary clutch roller replacement best practices.
Step 2: Remove the CVT Cover and Drive Belt
Use your socket set to remove the numerous bolts holding the black plastic CVT cover on. Once it’s off, you’ll see the primary (front) and secondary (rear) clutches. Use the Can-Am belt removal tool (it should be in your factory toolkit) or spread the secondary clutch sheaves apart by hand to create slack and slip the belt off.
Step 3: Remove the Secondary Clutch
Using an impact wrench or a breaker bar, remove the single large bolt holding the secondary clutch to the transmission input shaft. The clutch should slide right off the splined shaft. It might be a little snug, but a gentle wiggle should free it.
Step 4: Disassemble the Secondary Clutch (The Tricky Part)
This is where your clutch compression tool is essential. Mount the clutch in the tool according to the tool’s instructions. Carefully compress the spring just enough to take the tension off the snap ring or C-clip holding the helix in place. DO NOT ATTEMPT THIS WITHOUT A PROPER COMPRESSION TOOL. The spring is under extreme pressure and can cause serious injury.
Once the tension is off, use snap ring pliers or a pick to remove the clip. Slowly back off the compression tool, allowing the spring and helix to come apart.
Step 5: Inspect and Replace the Rollers
With the helix removed, you’ll see the rollers sitting in their channels. They are held in by small cotter pins or clips. Carefully remove the pins/clips and slide the old rollers out. You’ll likely see significant flat spots on them. Slide your new rollers in and secure them with the new pins/clips that came with your kit. Never reuse old cotter pins.
Step 6: Clean and Reassemble the Clutch
Before reassembly, use brake cleaner and a rag to clean the clutch sheaves, the helix, and the spring. Any dirt or old belt dust can hinder performance. Reassemble the clutch in the reverse order of disassembly, using your compression tool to safely reinstall the helix and snap ring.
Step 7: Reinstall and Test
Slide the reassembled clutch back onto the transmission shaft. Apply a dab of blue Loctite to the bolt threads and torque it to the factory specification (typically around 40-50 ft-lbs, but always check your service manual). Reinstall the belt and the CVT cover. Start the machine in neutral and let it idle for a minute to seat the belt before taking it for a gentle test drive.
Pro Tips & Best Practices for a Flawless Job
Want to do the job like a seasoned pro? Here are a few can am defender secondary clutch roller replacement tips that we’ve learned over the years at FatBoysOffroad.
Don’t Skip the Cleaning
It’s tempting to just swap the parts and close it all up, but taking 10 minutes to thoroughly clean the inside of your CVT housing and both clutch faces with brake cleaner makes a huge difference. A clean clutch is a happy clutch.
Inspect Everything While You’re In There
You have the whole system apart, so take a moment to inspect other components. Check the primary clutch rollers, look for cracks in the clutch sheaves, and inspect your drive belt for any signs of glazing, cracking, or missing cogs.
Torque Specs are Your Best Friend
Don’t just “guess” how tight the clutch bolt should be. Over-tightening can damage the shaft, and under-tightening can lead to catastrophic failure. Look up the correct torque spec in your service manual and use a torque wrench.
Thinking Green: Sustainable and Eco-Friendly Replacement Practices
Being an off-roader means respecting the environment we love to play in. A little mindfulness during your maintenance can go a long way. This is how you can approach a sustainable can am defender secondary clutch roller replacement.
Proper Disposal of Old Parts
Don’t just toss old metal parts in the trash. Collect them and take them to a local metal recycling facility. Used rags soaked in brake cleaner should be disposed of according to your local hazardous waste regulations.
Choosing Long-Lasting, High-Quality Components
An eco-friendly can am defender secondary clutch roller replacement starts with buying better parts. Investing in high-quality, heavy-duty rollers might cost a few dollars more upfront, but they last longer. This means you’re consuming fewer resources and creating less waste over the life of your machine.
Frequently Asked Questions About Can Am Defender Secondary Clutch Roller Replacement
How often should I check my secondary clutch rollers?
A good rule of thumb is to visually inspect your rollers every time you change your drive belt or at least once a year (around every 1000-1500 miles). If you ride in harsh conditions like deep mud or water, check them more frequently.
Can I reuse the old cotter pins or clips?
Absolutely not. The small pins or e-clips that hold the rollers in place are single-use items. They are designed to be replaced. Every quality roller kit will come with new hardware. Using the old ones risks them failing, which would cause major damage inside your clutch.
What’s the difference between OEM and aftermarket rollers?
OEM (Original Equipment Manufacturer) rollers are identical to what your Defender came with from the factory. Aftermarket rollers are often designed to be more durable, using materials like Delrin or other high-performance composites to better withstand heat and wear, making them a popular upgrade.
My clutch is still acting up after replacing the rollers. What now?
If new rollers didn’t solve your issue, the problem may lie elsewhere in the clutch system. Check the primary clutch for worn parts, inspect the clutch springs (they can weaken over time), or check for proper clutch alignment. If you’re unsure, it might be time to consult a professional mechanic.
Tackling your own can am defender secondary clutch roller replacement is an incredibly rewarding job. You not only save money, but you also gain a deeper understanding of how your machine works. By following this guide and taking your time, you can restore your Defender’s performance and get back to what matters most: hitting the trail with confidence.
Now, grab your tools, put on some tunes, and give your Defender the TLC it deserves. Ride safe out there!
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