Ok, I have a, 88 Trail Boss 250 and It sounds like the belt in the PVT is rubbing during acceleration a bit against the outer cover. I just got off the phone with the dealer, I called to check the price of a belt. I thought it may have stretched or worn. He said it's common and it's not usually the belt, but the outer cover that is warped due to heat. Now he said THEY usually let them go, cause the inner and outer cases are quite expensive(like $250 for both) and its no big deal, it won't effect performance. He also said that if I remove the cover, it will NOT be obvious and apparent that the cover is warped...That is what confuses me. I've had the cover off before and it looked fine. I'm gonna take it off and check were it is making contact, but wouldn't warping due to heat be apparent??
I also have a Haynes Manual for this quad and it says something about tightening the belt by adjusting Shims somewhere around the driven clutch. I cannot see what shims they are talking about. Unless it is under the inner cover.
Its just the noise buggin me and I'd like to tighten things up a bit. The belt actually looks fine, I just thought it may be original and was worn thin or stretched.

 

I know what that my old 96 sport would rub the cover, and it was one of the clutches doing it not the belt. Sometimes would accidentally step on it and would punt the cover into the clutches. Just make a bunch of rubbing noise till booted the side back.

Clutch cover is 150 on bikebandit.com. Check other sites if want to get a new one. The inner is 90. HATE dealers that give high prices just to avoid work or whatever there reason is.

 

I know shims on my 500pop are in between secondary plates(I forget what they call the pully the belt rides on) and from the factory there are two, There has to be at least one in there. Go on you tube and search mudinmyblood, there's a like ten minute video on changing clutch springs and they talk about the shims being removed. It's called "Brute force secondary spring change"

 

the dealer is right by saying its most likely a warped cover that is rubbing on the clutch. the have a newer style that people have used to fix this issue. adjusting shims wont fix this issue unfortunitly.

 

thanks for the replies. I hear a noise and it bugs me until i fix it, even if it's no big deal.

 

The old covers were made of a plastic which tended to shrink with time and heat. The new ones are a made of different plastic which is more "soft" while the old ones appeared to have a much higher styrene content which made them more brittle and "hard".

Mine actually wore holes through the cover before I replaced it.