i went on a hard ride this weekend a lot of rocks and steep climbs towards the end of the ride i noticed my clutch cover rubbing could i have warped my clutch

 

My 99 500 rubs also. I have tried to shim it move it kick it you name it and sometimes it rubs and sometimes not. If it is warped you will see where the plastic was exposed to excessive heat. On the front lower part of the cover is a frame attachment point that positions the rear or back part of the cover. You can try shimming that as it seems to do the most good on mine. If you find a solution please post it as I would like to fix mine once and for all.

Steve Lubecki

 

Shiming it is just a temporary fix. You will ahve to bite the bulllet and get a new outer clutch cover. I would recomend getting a clutch cover off a newer style bike. ie get one for a 2003 scrambler it will work just fine, but their is an extra bolt hole o nthe newer style instead of a clip, this is the only differance

 

I had same problem with my clutch cover on an xplorer. the previous owner had children who when they rode would put their feet on cluch cover because they could not reach floorboards.

 

Your clutch cover is warped. You cant warp the clutch itself. You can either get a new outer cover and gasket or spend more money on the new style clutch housing. The new style is thicker, has a bigger intake and also has a drain in the bottom. These are much better but the older ones will do. A new outer clutch cover is around $80. The new style clutch cover complete will run around $250. You can also look on ebay to asee if you can find a newer cover.