Hey fella's,

I've exhausted all avenues on my own so figure I'd post the question on the forum and see if others have found a work-around.

I recently picked up a 97 sportsman 400L - W97AC38C
It was not running and missing several parts, so I got it really cheap. I've got it running like a top at the moment, so now on to finding/replacing all the missing pieces and other misc repairs.

Here's where my question come in: I absolutely cannot find the clutch air intake down tube (the one with the coolant overflow catch built on it). The Part # is 5432442. I have searched all parts sources I know both locally and online. Even eBay which had ZERO results. the part is obsolete on all sites. Here's just one link to show what I am talking about: http://parts.polarisparts123.com/oem...sportsman-400l

I also have a 1990 Trail Boss 350L which is nearly identical to the 97 400L. So I looked into the down tube on that one. While sites did not list them as interchangeable, they looked identical on the parts breakdowns, so I picked one up (needed a new one for the 1990 Trail Boss 350L anyhow). Not to my surprise it does not fit after all. I've tried using some PVC and other tubing to try and make it work, but nothing good enough so far.

Does anyone know where this part may be procured? It was also installed on the following Polaris rigs:
1997 BIG BOSS 6X6 400L (N97AE38D) - Clutch Cover Big Boss 6X6 400L W97ae38a
1997 BIG BOSS 6X6 400L (W97AE38A) - Clutch Cover Big Boss 6X6 400L
1997 SPORTSMAN 400L (W97AC38C) - Clutch Cover Sportsman 400L

 

This inlet duct tube/coolant tank has been discontinued for quite a while now. What I advised most people on was just to get a used 500 reservoir coolant bottle on ebay to bypass the coolant bottle on these as they all crack. http://www.ebay.com/itm/2006-Polaris-Sportsman-500-EFI-Coolant-Reservoir-Overflow-Bottle-/111597169533?pt=Motors_ATV_Parts_Accessories&hash=item19fbb5ab7d&vxp=mtr A new one's about 38 bucks, which is a little steep.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Cover still should be available,as it's been updated for some time now.http://www.cyclepartswarehouse.com/f...1997&fveh=5424 All used the same covers.

 

Hey OPT, yeah I figured this part has been obsolete for a while. funny that it is NLA, but I can still buy the same item for a 1990 Trail Boss. I should add more details I didn't think of. I did have an extra overflow bottle that I already installed, but my issue was more about getting cooling air to the clutch without issues of water intrusion without having to jerry-rig it up. All other parts are there for the air intake/output for the clutch. I'm thinking of just getting some 2' ID tubing (cut up a radiator hose or something if need be) and making it work.

Gonna hit up Lowe's and some other type stores tomorrow and see what I may find.

 

Sounds like your best bet on this one.Actually old cut up inner tubes make good pipe connections,as that's what the oem actually feel like.Little more flexible so you can wiggle things around rather than a stiff radiator hose.

 

That's a good idea as well. Just need to find one with a 2" I.D. I went to my shop to have a look around because I new I had a couple bicycle tube NIB, but they were too small I.D.

That sounds like my best route.

Thanks

 

Well, took a piece of the rubber tube connection to TSC today and matched up the diameter to a lawn mower tire inner tube. I was able to cut to length to make the older down tube Pt# 5432336 I originally ordered work. I did have to cut off the tab which went around the fuel valve shutoff as it did not line up, but that was no big deal. Now onto replacing the water pump/case seals (I have water leaking from the weep hole and water getting into the counter balance oil). I've seen a few threads on here or the other Polaris forum on how to do all that....Next on the to-do list and this one will be 100% ready to roll.

Thanks again for the advice OPT.

 

I'd still get the 400 manual as it has a good step by step on the w/p seals and bearing relacement.W/p housing hole must not be covered by a seal or the bearing. Plus it can help on the 350 also.DOWNLOAD 1985-1995 Polaris ATV Repair Manual ALL MODELS - Download ...

 

I'll check when I get back home, but I believe I have that manual in pdf. I'll give it a look over.