I have a 425 Magnum 1998. The ATV only has 600 orginal miles mainly use it around the farm. The COVER-CLUTCH,FRONT that covers the drive belt is rubbing on the inside. I have tried reposition the cover many times and had no luck at keeping it from rubbing. It is going to eventuall wear a hole and i want to try and prevent this. At higher RPMs the belt or pulley that is under the cover does not rub the cover.
I'm wondering if anyone else has ever had this problem and if so were you able to fix it?

I case you ae wondering eactly what part I'm talking about I have included a link to an exploded view and the cover is item 9.
http://houseofmotorcycles.bike...4-w968144-1996/o/m5438

 

Buy a new cover. The old ones actually shrank when they got older due to heat and age. The replacement is molded with a little more room in there and it is also a different composition which helps too. It doesn't have the styrene content that the old one does. Should run about $110 to 120 dollars from the dealer.

 

That's the fix, my 97 did the same thing.

 

Check the amount of movement in your engine mounts. If they are getting some movement that also would cause the rub. Doc

 

Replace it!!! and be done

 

<div class="FTQUOTE"><begin quote>Originally posted by: CaptainQuint

Buy a new cover. The old ones actually shrank when they got older due to heat and age. The replacement is molded with a little more room in there and it is also a different composition which helps too. It doesn't have the styrene content that the old one does. Should run about $110 to 120 dollars from the dealer.</end quote></div>

$87 from these guys http://www.cheapcycleparts.com...brands/14/default.aspx

 

my 2000 trail boss soes this ,buy a new one

 

I have the same problem, but were just going to let it chew a hole through

 

If any water at all splashes in you might wish you didn't do that.

 

More then likely your gasket is over tightened around cover put permatex behind foam gasket and just barely put cover back on to seat evenly then later tighten up but not too tight otherwise it's your motor mounts and motor is flexing to make it rub .otherw oth have fun paying +$200 for covers .