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My clutch cover is sort of sagging and has a paper thin spot above the front clutch. I looked at new ones and they seem sort of pricey. I found an OPT response in a Sportsmans 400 post that said:
Originally Posted by old polaris tech
Common problem on pre 97 model clutch covers warping/melting and hitting the front clutch. Later model covers can be found on ebay and solve this problem. Any cover from a later model 250 ,325,400,etc would work. Later model bulbous 500 covers would also,but you have to use an adapter sleeve to use your vent.
and I wondered if my 300 might fall into this category?
I found a lot of listings on ebay for different models and they look very similar but have more bolt holes than mine and a drain plug. If one of these might work would the inner clutch cover that goes with the outer clutch cover be compatible as well?
5533542 is the replacement cover for a lot of machines and will fit yours. Updated from the covers that would melt. If you go to the latest model bulbous covers you have to adapt your exhaust by rigging a bigger sleeve that would fit over it and the larger opening of this cover.I'd stay with the one that's updated for the 300. Not cheap,around 142 bucks on ebay for new ones,but you can check around for good used ones also.
This is just some of the models it fits. Usage : 5433542
You are a wealth of knowledge. That must have taken some time to compile that listing and it is very much appreciated. I'll now have some confidence when rooting through all those different models I see listed.
Just wanted to thank OPT again for all his help, never would have attempted this without his guidance.
This turned out to be a lower priority project than originally thought but finally got to it. Being retired I have more time than money so waited for some good deals on eBay.
Upgraded Outer Clutch Cover from 1994 Polaris 300 4×4 to 2012 Polaris Sportsman 500. ($43)
Upgraded Inner Clutch Cover from 1994 Polaris 300 4×4 to 1997 Polaris Xpress 400. (Had to shorten tranny mount standoffs.) ($12)
Outer Clutch Cover Air Outlet Boot made with Versimold. ($19)
And still have plenty of the Versimold left to make a good battery strap.
Thanks again OPT. This has been a fun bike to work and learn on, and fun to ride and enjoy.
Glad you got it to work. Didn't think about using Versimold for transitioning from the larger duct outlet to the smaller one on the 300. Good idea.. Most of the guys I've seen that have converted to larger covers just used old inner tubes for sleeves..
11-11-2014, 08:59 AM
1994 Polaris 300 4x4 warped clutch cover
and I wondered if my 300 might fall into this category?
