I have a 1998 Polaris Sportsman 500 ATV. Recently, a clicking noise has developed in the area of the primary clutch. When the engine is idling, sounds like the clutch is hitting the cover. After removing and inspecting the cover, it is definitely hitting the cover. I can see wear on the cover and on the outer edge of the clutch. The clutch seems to have a little play in it. I can push it in about 1/4 inch very easily. I am new the to ATV world and am not real sure what I am doing. I believe I can pull the clutch, purchase, and install a new primary clutch. I just want to feel confident that will fix the issue.

 

Older model clutch covers were molded too close to he shape of the drive clutch and heat from the clutches could cause the covers to get soft and collapse. Just get a later model cover or you can sometimes move the L bracket on the backing plate out enough to keep the clutch from touching the cover.Item#25.

 

Thanks for the insight. I have ordered a new cover and hoping that will fix the problem. The clutch is quiet and smooth with the cover removed. I will update after installing the new cover.

 

If you ordered an oem replacement cover,these were strengthened also so you shouldn't have that problem again. Polaris had plenty of complaints on the first clutch covers.

 

I had a '97 Sportsman 500 that had the old style cover and when I hit bumps hard I would hear the clutch grinding into it but the rest of the time it was okay after a slight adjustment to the bracket. Until it got hot that is, then it made a hole all the way through and I slapped a patch on it. I can't remember what I used for it. I never had any problem with my '01 500 H.O. that had a better cover.

 

I replaced the front clutch cover and I still have a slight rubbing. I think the back cover is also out of shape. I was able to use a small chunk of rubber to wedge in as a shim to slightly hold the back cover out. Works perfectly. Thanks for all the insight.

 

Check you drive belt closely. I had one fail on a Sportsman, took out the whole cover.

 

A warped rear cover can cause problems but don't forget you can move the L bracket a little also. Good luck with the new cover.