I have a 2000 Sportsman 500 it has over 1500 miles now 700 since last belt replacement. I was riding up a hill in low gear and clicking sound started in the Clutch cover. I figured it was a drive belt issue and nursed it 8 long miles back to the trailer. Got it home and pulled the cover to discover the belt is ok but the front clutch started rubbing on the cover. I am sure this has been posted before but after two hours of reading I am still stumped. Help and guidance would be appreciated.

 

You can try to adjust the small "L" bracket at the bottom of clutch backing plate to see if helps move the cover out a little. If this doesn't help it could be the cover has gotten hot and warped allowing the clutch to rub the cover. This was a common problem from the early days up until about 2008 when they went to the over size covers.http://forums.atvconnection.com/pola...ml#post3208811