This is Part 2 of 3 on this 2005 Massimo MSU 500

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This is Part 2 of 3 on this 2005 Massimo MSU 500

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Limitless Powersports service & repair

2 жыл бұрын

This is Part 2 of 3 on this 2005 Massimo MSU 500. This MSU 500 had a ton of issues. In this 3 part series I take you though all the issues that I find. I show you how to diag the problems & also how to fix what we have found. Here in Part 2 we find major issues with the belt, wet clutch, Wet clutch drum, the oneway bearing & the primary clutch with a sticky surprise inside. Stick around for Part 3 next week as I solve the runability issues. You will be very interested in what I find. Remember if you have any questions you can comment below are send me an
Email@ Limitlesspowersports78@gmail.com
OH did I forget to mention I created a PATREON profile. If you love the content Im putting out & would love to support my channel & future projects. Here is a link to my PATREON. / limitlesspowersports
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NEIKO 01407A Electronic Digital Caliper | 0-6 Inches | Stainless Steel Construction with Large LCD Screen | Quick Change Button for Inch/Fraction/Millimeter Conversions
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Пікірлер: 92

@ccerwin Жыл бұрын

So I am ase 2 year specialized degree from Thaddeus 90’s and your videos are opening a entirely different world 🌎 to me. Great videos easy to follow on 2 times speed and that speaks to the quality of your knolage! Want to be sure that 1 way beating direction with the writing please. I did catch some of your other videos, dry centrifugal clutch vrs grease got me as well lol

@limitlesspowersportsservic3394 Жыл бұрын

Hey C C. I appreciate the kind words. As far as the writing goes it will face the motor when you install it on to the wet clutch.

@shayshelton8601 2 жыл бұрын

Couldn't have done mine without this video🤘😎thanks so much

@user-ft6pd7bb4e Жыл бұрын

Your video was great, walked me thru replacing the wet clutch. In the video you showed the primary clutch and how nasty it was. When I opened my primary clutch it looked just like the one in the video. I bought my Massimo new, so guessing factory is putting all that grease in it.

@limitlesspowersportsservic3394 Жыл бұрын

Yeah it comes from the factory full of grease. The new update has you clean it all out & take the outer ring off & putting it back together. But that's only if you're having an issue with the clutch hanging up.

@tomfairbourn6998 2 жыл бұрын

Great info I have a Kymco 700i and always looking for anything that helps me work on it

@frankpintaro3039 2 жыл бұрын

Great video!

@Michael052. 2 ай бұрын

Great video 👌🏽👌🏽👌🏽

@timsigmond8984 2 жыл бұрын

Great video, lots of good info .

@limitlesspowersportsservic3394 2 жыл бұрын

appreciate the support. if you have any questions at all hit me up here in the comments or shoot me an email.

@FlyingDirty Ай бұрын

Great informative video. Question; I’m changing my one way bearing and as I am taking things apart I found the rollers out of their seat and heard them rattling inside. What makes those rollers come out of their seat? Thanks

@limitlesspowersportsservic3394 Ай бұрын

They are a cheaper bearing & when you are slowing down on the de acceleration the bearings like to chatter in the spring that holds in place are very weak and they will come out. There is a fix for it by changing the spring that holds it in place and shortened it up a little bit so it's tighter

@123keenen 11 ай бұрын

Great video! Mine is doing the exact same thing! Can’t get any mechanic to touch a Massimo in Arkansas.

@limitlesspowersportsservic3394 11 ай бұрын

Well I'm in Southwest Missouri if your close & need anything.

@drew_callaway7164 5 ай бұрын

Is there any way I could contact you for some advice on a madsimo msu 500? Repairing a customers msu and having issues and not too sure what else to inspect or look at. Replaced the wet clutch one way bearing and also the cvt primary clutch. Still having issues going into gear.

@rickypotter5067 2 жыл бұрын

Hey man love the videos ! I have a massimo malitia 1000xs 4 seater. It’s having a random locking up problem. At first I thought I found the problem with the starter clutch bc mine would spin both directions so I replaced the one way starter clutch . Seemed to work fine but it locked up again while test driving . Sometimes it will lock up just letting it idle. You turn the key starter tries to engage but can’t turn the motor . Does this sound like a belt clutch issues or something else?

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Rick thanks for the comment and checking out the videos. My first question would be when the motor is running does it sound okay? It's not knocking or anything like that? The oil is nice and clean? I know these may seem like silly questions but those are definitely some things to make sure first. Now on the 1000 XS the transmission is different than the 500 I show in this video. It does not have a wet clutch. Yours has actual gearbox that bolts up to the motor. It is a good possibility that one of your clutches may be hanging up. easiest way to check that out is by taking the belt off the clutches and trying to start the motor that way. Make sure to check the one-way bearing on the primary clutch by making sure it's been freely. Check the trail blocks in the primary clutch to make sure they are not melted.Also you said you replaced a starter clutch. Are you sure you put the one-way bearing incorrectly on the starter clutch? You can also try taking the spark plugs out and see if it cranks over easier that way. But it does sound like you are possibly having a primary clutch issue of it not letting the belt spin around freely at idle and the belt getting hung up or the clutch locking up. But you also said it locked up while driving so that is a pretty tough one to diagnose without actually having the unit here in front of me. I just hope it's not a motor failing issue. I have a video on a MSU 800 that was hard starting and sometimes would not crank over. after I adjusted the valves and cleaned everything up it ended up being because the number two cylinder was failing and started knocking. Again if you have any more questions please feel free to comment or you can email me at limitlesspowersports78@gmail.com

@brandonpoole9526 7 ай бұрын

The guy that owns this utv sounds like me 😂. Hence why I’m watching this video. I am having to repair my msu 500 currently for same symptoms

@limitlesspowersportsservic3394 7 ай бұрын

Lol. Well let me know if you have any questions. I'm more than happy to help out the best I can.

@rickypotter5067 2 жыл бұрын

Hey man love the videos and glad I came across this massimo project! I have a 1000xs massimo malitia 4 seater. And it is randomly locking up while driving. As in it kills the motor. You go to turn the key and nothing happens. Starter engages but can’t turn the motor. I replaced the starter clutch bc it was bad. Thought I fixed it but same issue is continuing to happen. Do you think it is a belt clutch issue or what’s your thoughts? Thanks in advance

@limitlesspowersportsservic3394 Жыл бұрын

Hey Ricky Im so sorry I missed this comment & Im just now answering you back. Im sure you have the problem fixed by now. So what was the cause of your issue? I have seen then skip time before, issues with primary clutch not free spinning, and just a bad starter clutch. I have installed a new starter clutch before that was already bad lol. have to love cheap parts.

@garyvallejo3491 7 ай бұрын

I have a Coleman 500 UTV and I need a battery for it and I don't know what size or what to put in it

@rockyrockwell1249 2 жыл бұрын

Hi I just purchased a 2014 massimo 500 msu 4×4 utv and I've been having a problem with keeping antifreeze in the radiator I found that the radiator cap was not seating correctly and I ordered a new one also how do you check the radiator cooling fan I've seen a few video however they don't explain things very well. any help would be greatly appreciated. thank you (rocky)

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Rocky. Thanks for checking out my video. There are a few different ways to check the cooling fan. But first off glad you found the bad radiator cap. If your still having any issues with keeping coolant in the radiator you may need to pressure test the system to make sure you don't have a small leak somewhere. I have seen the head gaskets go bad on them before causing them to burn coolant also the water pump seals go bad too but you usually can check your oil to make sure you're not getting coolant in your oil. If you are then the oil will turn kind if a white frothy color. Ok as for as checking the cooling fan. You can let your unit idle intill it reaches around 220° give are take 10° & the cooling fan should kick on. You cN also pull the thermal switch connector off & ground it out that will mKe the fan kick on. Also you can unplug the fan & put power directly to it to make sure it work. I also believe you can do the same by groundi.g the engine temp sensor to make it kick on also. I probably should do a video on how to check all those things.

@user-uu5cb2ui7r 8 ай бұрын

So I have a 2014 Massimo MSU 800. Does it have a one way bearing also? When its running you can shift to a different gear, you need to shut engine off and wiggle the atv and then it shifts easily.

@limitlesspowersportsservic3394 8 ай бұрын

It may have one on the primary clutch but I doesn't have a wet clutch are a oneway bearing. I think I just comment on you're FaceBook post about the same issue. Sounds like your having a primary clutch issue possibly. I wouldn't need to see which clutch is in your unit. They have 2 different styles. The cvtech with plastic trailbloks & the older epi style.

@bradleyhortman3447 Жыл бұрын

What is the compression post to be on motor? I’m having some issue and can’t determine what’s the problem I’m having

@limitlesspowersportsservic3394 Жыл бұрын

Hey Bradley. Your looking for at least 115psi-160psi. 115 is getting pretty low but should start up & run.

@exupakias 2 жыл бұрын

Just a question because my variator is finish.When i ckeck the variator i saw all the aluminium wings from inside was broken, the engine all the time revs and top speed was not more than 35miles working full revs.I bought it second hand and i thought that it had speed limiter via ecu.After i replace the variator new from China market i saw 55 miles, So, now it needs crankshaft as it sound like that, needs full rebuild.My question is how variator had so big damage!!!! What were the reasons that it was destroyed variator? Thanks

@limitlesspowersportsservic3394 Жыл бұрын

Hey Exupakias Sorry Im just mow getting back to you on this. I completely forgot to answer you back. It is a really good possibility that it got so debris sucked inside the cvt & cause that issue. Also I have seen them just fail due to the fact they are made from super cheap metal. I hate to hear that you might need a new crank. Its not hard to rebuild just takes some time to do it.

@codebreakers5896 Жыл бұрын

I have a 2012 massamo msu 500 and I'm having a hard time getting it to start. It acts like its Flooding its self out. If I hold the gas pedal down it actes like a car to stop the flow of gas and I can get it to start and the run. Once warmed up I can turn it off and back on like it should start. Any suggestions.

@limitlesspowersportsservic3394 Жыл бұрын

Hey code breakers. I would start by checking the intake track to make sure it is clean & also the throttle body. The IAC motor controls idle & air flow. Also it controls how easy is starts. If it is dirty then it may not be getting back to the preset steps for start up. You can also try resetting your ECU by starting it up holding the gas all the way to the floor for 3 to 5 seconds then shut the key off while still holding your gas pedal to the floor for another 3 seconds. I k ow it sounds crazy but that's what they say to do in the service manual.

@browner010 10 ай бұрын

I have a 2022 Coleman UT550 that I bought 2nd hand and the guy used it to plow. My wife and I went for a ride and the belt literally exploded. Well I replaced the belt, but my mistake and forgetfulness was not checking the wet clutch and when I took it out for a ride after replacing the belt, it barely made it 1/2 mile. I am assuming it's the clutch as I remember I could smell the clutch just before the belt exploded. My question is, what are the torque specs on the wet clutch cover? I found the specs for the primary and secondary clutches when I replaced the belt but I have watched several videos on the wet clutch replacement with yours going into full detail of the entire process and I found it easy to understand, but the torque specs is one thing nobody talks about for the wet clutch cover. Can you help? Thanks

@limitlesspowersportsservic3394 9 ай бұрын

Hey sorry just saw this comment. The cover bolts are 10nm-12nm

@terrenceshane1752 2 жыл бұрын

What socket fits the wet clutch flange nut?

@limitlesspowersportsservic3394 2 жыл бұрын

Terrence I honestly don't remember off the top of my head. I'm currently out on the road with four horse HSBK New York Ducati Moto America race team for the season. I should be back home this coming Monday and I could double check then and leave you a comment back. but thank you for checking out the channel and I appreciate your comment.

@kierantownend818 11 ай бұрын

I'm getting into the clutch and disassembly of it but cannot get the primary or secondary clutch nuts off. Trying not to go crazy on them but they are really tight! Any advice on getting them off?

@limitlesspowersportsservic3394 11 ай бұрын

Yeah definitely try to use some heat on them & a good air impact. The heat should definitely help. You can also Penetrating lubricant and then let it set and then use heat and then an air impact

@kierantownend818 11 ай бұрын

Thanks! Lots of penetrating oil seemed to help along with the air impact. Got the rest of it opened and the clutch pack is shot and the primary clutch drum badly scored. Like at least 1mm grooves scored into it. Will say I have had to do this with the secondary sheaves on as I could not get them off for the life of me. It's as though the shaft is 1.5 -2mm too long to give me clearance to get it off. Removed as much as I can around it but the drivers side seat frame is in the way and I'm not cutting it!

@chaddickerson2369 2 жыл бұрын

hi hey i have 2 500s hisuns that were running fine then all the sudden while goin down the road sumthing locked up and killed it? thie first time it did it it restarted and drove home? second time it dun it it acts like eng is siezed? primary clutch spins freely counter clockwise like it should but wont turn at all clockwise? can the wet clutch cause this? the oil is clean and it has never had any noise or problems? and i have 2 doing exact thing?

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Chad thanks for checking of my video. The wet clutch bolts directly to your Crankshaft then the drum over the top of that. I really doesn't sound like a wet clutch problem. You say the oil is clean. So no brass are aluminum in it at all? I have seen the timing chain fail & the timing chain tensioner fail causing it to jump time & making the valves hit the piston. I would pull the spark plug & try turning it over by hand with out the belt on the clutches. If it still doesn't turn over I would start by checking the valves then move on to removing the head. But definitely sounds like it jumped time & locked the motor up. They can be a little out if time & still run but then jumps time again & it's a done deal. Just help another subscriber with almost the same type of problem. It ended up having timing chain tensioner fail.

@chaddickerson2369 2 жыл бұрын

@@limitlesspowersportsservic3394 thank u very much for help! And i think ur right, i am going to tear into the first one today. Thanks again

@kierantownend818 11 ай бұрын

Just finished rebuilding my wet clutch and when I installed the one way bearing, I noticed that when the writing was out towards me in the clutch bell, it wouldn't turn counter clockwise but when it was away from me it would turn counter clockwise. Now I've got it finished and started machine for first time and it'll run in reverse no problems but going forward needs a boot full of revs and won't go uphill. Also there's a grinding noise from the clutch and it's bucking into gear. Have I installed the one way bearing the wrong way despite checking it?

@limitlesspowersportsservic3394 11 ай бұрын

Yeah I think you have instate oneway bearing the wrong direction. The writing should be face out from the motor

@kierantownend818 11 ай бұрын

@@limitlesspowersportsservic3394 thanks for the reply. Is that out from the motor when installed on the wet clutch pack or pointing outwards when installed in the clutch housing? Trying to make sense with the manual as well but it tells me to do it a different way...

@limitlesspowersportsservic3394 11 ай бұрын

Every one I have taken apart are installed you can read the writing on it when you install it on to the wet clutch pack. If you install it into the clutch drum you wond be able to read the writing

@kierantownend818 11 ай бұрын

@@limitlesspowersportsservic3394 that's how I installed it but nothing but grinding and bucking when I tried to go forward. Going in reverse it was quick but forward was 3000rpm plus and not hardly moving. Was definitely slipping clutch before and not setting off like it should and the only thing I've done is the clutch replacement.

@arnoldshepherd9508 4 ай бұрын

Do you have a video taking the gas tank out of the massimo 500 2014

@limitlesspowersportsservic3394 4 ай бұрын

No I don't. But it's a simple Job. There are 2 straps that hold it down with a 10mm head on the bolt. Take those 2 completely off & you will have to take some body work off to get the filler neck out but then you just raise the front of it up almost straight up & down & you will have to turn it a little bit it will come out. Take a look at part I think 3 of my Bennche topend rebuild & I talk about how I got it out

@robertguinan2736 2 жыл бұрын

Great video. I was having the same problem with my Massimo 700. I was attempting to remove the clutch cover bolts and they will not loosen. Is there some trick to it?

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Robert. A lot of time what happens is that the rivnut they put in the plastic strips out & just spins inside the plastic housing. You just have to pry out on the housing & hope they come Lose without having destroyed the whole entire CVT housing.

@robertguinan2736 2 жыл бұрын

@@limitlesspowersportsservic3394 thanks for the help. I have another question. I have an 08 Massimo 700, when I took apart the clutch, there wasn't a one way bearing. Do all Massimos have a bearing? Again thank you for your help

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Robert. From what I know all of them have a one way bearing untill you get up to the 750cc & above because the bigger cc units have a separate gear box. When you took it apart was the clutch drum spinning in both directions? I have seen the one way bearing completely com apart & end up inside the motor. also double check the clutch drum & the wet clutch to make sure it didn't stuck on there & that it didn't fall off when you disassembled it.

@robertguinan2736 2 жыл бұрын

@@limitlesspowersportsservic3394 the drum does spin in both directions. I will look for the bearings and or the peices of it. There was a lot of old sludgy oil/ grease everywhere. So I'm cleaning that out too. I bought it used. I have a feeling the past owners didn't take care of it

@robertguinan2736 2 жыл бұрын

Is there a tool to remove the clutch drum seal

@Heather0080 2 жыл бұрын

I have a 2011 mossimo 500 I just bought off someone and when you get going up a hill or it gets distressed while in high it will jump out of gear then you just have to put it back in gear. Also, it has no power hardly whatsoever. Any idea what this could be?

@limitlesspowersportsservic3394 2 жыл бұрын

You may need to possibly adjust your shift linkage. sometimes they're not adjusted perfectly from the factory. You would do that by putting it in neutral and making sure that your shifter is lined up in neutral perfectly along with the shift mechanism on the side of the motor. also not having any power could come from a flat spotted cam. I believe in part 3 of my MSU 500 video I talk about finding a flat spot in the cam and having to replace a cam. also are you sure that the belt is not slipping and is that why you're not making power?

@mnhoss2100 2 жыл бұрын

Unfortunately I think your wet clutch is junk. I just had to replace mine. It's doable if you are mechanical. But it isn't super easy. Check out Kelley motorsports. He has a video for it

@thedothelp2566 11 күн бұрын

I just picked up a Coleman 500 and it is hard shift while running. It’s like it gets stuck in gear but will shift fine when not running. Any ideas?

@limitlesspowersportsservic3394 11 күн бұрын

You definitely have an issue with most likely your clutch. I have multiple videos on how to replace it. I would replace your wet clutch & the oneway bearing. But buy a yamaha grizzly 660 oneway bearing. Then also clean & service your primary clutch. I run across this all the time. Also your idle needs to be no higher than 1,400 rpms.

@thedothelp2566 11 күн бұрын

@@limitlesspowersportsservic3394 of the idle is too high will it keep the transmission engaged and cause this issue?

@limitlesspowersportsservic3394 11 күн бұрын

Yes because if the secondary clutch is spinning then it is putting tension on the transmission & spinning it. The transmission needs to be almost setting still for it to shift in & out if gear properly.

@jordanfletcher2523 3 ай бұрын

I have a 2009 massimo 500. Got it off a guy that said it pops out of high and when it does makes a grinding sound then pops back in. It will go in low fine and not pop out. I adjusted the links to spec. And still pops out of high. What can be the issue. Need help

@limitlesspowersportsservic3394 3 ай бұрын

You could actually be having an internal transmission issue with high gear. Sounds like the dogs are wore off on the internal high gear unfortunately.

@jordanfletcher2523 3 ай бұрын

@@limitlesspowersportsservic3394 is hard to breakdown and change the high gear. I work on a lot of atv just need on one of this.

@limitlesspowersportsservic3394 3 ай бұрын

The hardest part is getting the motor out of the chassis. You have to take the whole rear diff loose so you can get the drive shaft out of the motor. I have a whole video on a 700 rebuild. The bottom end is exactly the same as the 500. Topend if different.

@jordanfletcher2523 3 ай бұрын

@@limitlesspowersportsservic3394 ok thank you all your videos are definitely helpful.

@Vortex5674 Жыл бұрын

I wish you would have shown getting that CVT cover off… I don’t seem to have the clearance to get it off. Any tips?

@limitlesspowersportsservic3394 Жыл бұрын

You have to take the coolant line loose from its mounting point. Then you will have the clearance you need

@Vortex5674 Жыл бұрын

@@limitlesspowersportsservic3394 Okay, thank you! I’m going to drain that and replace it anyway so ill do that tomorrow and see how it goes.

@Vortex5674 Жыл бұрын

That worked, thank you! My belt doesn't have a direction arrow. Is there a rule of thumb as far as the direction of the number printed on it?

@limitlesspowersportsservic3394 Жыл бұрын

Yeah you should have going in the direction of rotation of the motor.

@JM-yx1lm Жыл бұрын

@@limitlesspowersportsservic3394 that makes no sense

@Indeewoods 2 жыл бұрын

Yamaha greases their clutches are these the dry weights?

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Indeewoods thanks for the comment. Yeah there are some models that do use a little bit of grease on there sliders & rollers but not to the extent of packing the clutch completely full. I was actually just doing some research today on the clutch in this unit & the Msu 700. They use the same clutch. I was talking to Massimo & they have started adding a light coat of grease to the rollers & sliders because of heat issues & the rollers getting a flat spot on them.

@Indeewoods 2 жыл бұрын

@@limitlesspowersportsservic3394 Actually they do use a lot of grease if you check out JBS he shows just how much they hold and why they use that much. He specializes in clutching especially the yamaha clutches which these are cloned after. I pulled my Hisun 700 clutch apart and it had lots of grease as well. Check out JBS You Tube videos he shows how it’s done. You’ll be surprised with the amount of grease needed.

@limitlesspowersportsservic3394 2 жыл бұрын

I really appreciate the information. I did check out his channel. They definitely use a lot more grease then what the tech from Massimo told me over the phone. I will definitely follow what JBS performance does. I'm glad you corrected me & put me onto some good information.

@Indeewoods 2 жыл бұрын

@@limitlesspowersportsservic3394 Right on ya to me it seems like to much grease but then he talks about how it holds the dirt/belt dust so it actually made more sense after he explained that. Interesting stuff.

@donaldmacdonald316 2 жыл бұрын

Like the video we just got one I have a few questions it b nice to chat

@limitlesspowersportsservic3394 2 жыл бұрын

Hey Donald. Thanks for checking out my channel & my videos. I'm more than happy to answer any questions you have. I am currently away from the shop for the next few weeks as I am traveling with Warhorse HSBKracing New York Ducati Moto America professional motorcycle road race team. You can email me @ limitlesspowersports78@gmail.com are leave a few questions I the comments & I will be happy to answer.