I have a 94 Sportsman 400L 4x4 that I am bringing back to life. The clutch cover is melted and pretty much dead. Parts for this old bike are rare and expensive. I am told that newer covers dont warp but researching newer covers that may fit is maddening.

My existing cover is pn# 5430771
Does anyone know what part numbers or years will fit my 94?

 

Just get a later model cover, 97 or later on ebay for any 250,300,or 400. Built sturdier and won't collapse like your model has. If you get the BIG bulbous type covers for later model 500s and up, you will have to make accommodations for the larger air exhaust outlet on the cover to fit your smaller duct. 5433542 is the later part number you need.

 

So any of the newer covers will bolt up to my inner cover and all I need to adapt is the tube?
Like this one or is it not new enough?

04 Polaris 500 Sportsman 4x4 Outer Clutch Cover Free Shipping 016 | eBay

This one is newer.
http://www.ebay.com/itm/2006-06-POLA...RVwQWY&vxp=mtr

 

Those are the big bulbous type that you'd either have to fit a larger exhaust duct or have a rubber sleeve that would fit over the cover and adapt to your existing duct. Easier if you can just find a #5433542 that is the exact replacement for yours. No alteration needed. Just have to keep an eye out for a used one. Here's a new one but pricey. Belt Cover Clutch Left Side Polaris 5433542 | eBay
Cycle Parts Warehouse has the updated one for 108 bucks also. Item#8.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

I think I will get the big one and adapt, shouldn't be to difficult.
THANK YOU for the tech. I have literally spent 6-8 hours trying to make sense of the part numbers and which part fits what...you answered it 20 minutes after I posted the question. I wish I could just download your brain... :-)

 

Better keep the one you have.. Ain't much left of this one.. My wife will tell you that..

 

I have a 1993 350l 4x4 model W938139. Babbitt's shows the part number for the outer clutch cover is 5430771. I ordered a 5433542 outer cover from Pure Polaris on Amazon as a replacement. The new cover does not fit the same as the original 5430771. The part number for the 1994 original cover is 5431961 not 5430771. The 5433542 is very close but doesn't fit the same as the 5430771.