I'm going to buy a new Xplorer 250 4x4. I read where someone had a warped clutch cover on a 00 trailboss. Is this a common problem? What impact does this have on clutch performance? Are all the cover on the different models the same?

 

I'm not sure if the clutch covers are the same but i have met many Polaris owners that have had a rubbing cover. Eventualy it will wear a hole in the cover. Mine used to come and go until i stuffed some plastic shims behind the rear cover. Move the cover until the rubbing stops and then figure out how to keep it in that position.

Chris Picciotto
99 Scrambler 500

 

Like Steve said, make sure it's not rubbing anywhere. They usually won't rub unless you took them apart and put them together wrong. I forgot one of the spacers in mine, but I stopped the rubbing before a hole was put in it. It can also happen from people using it to rest their foot on (the sticker says: NOT A STEP). Or not using low range, and too much heat is generated, making the cover soft.

 

Take care of those covers! The heat from my pipe caused one of the front nubs (where you put the bolt thorugh to secure it) closest to the front to crack, to the point I could'nt use it anymore. I ordered a new one, nearly $100!!!!.

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Jerry Goodman '99 400L, '98 TBlazer

 

for those who care,i will say it one more time. rubbing covers are no problem.polaris covers have been rubbing since they started building atvs.even a person who has never had the cover off of his atv can fix one in 30min. take the cover off. find where it is rubbing. use a heat gun to heat the spot (carefully) then take something blunt (screwdriver handle) and push the spot out. reinstall cover.

 

I have had a 1993 Trail Boss 250 for five years and have never had a rubbing problem. I ride the quad VERY hard. The Trail Boss has held up exceptionally well. 4-Wheel ATV Action magazine wrote an article saying the new 4x4 Trail Boss was an outstanding trail machine with a nice powerband.

 

I had a guy tell me his cover melted down from the heat off the clutch. He also broke 3 belts on a new Scrambler. I've got a five year old Sport 400L and haven't had this or any belt problem. If I had constant trouble like this fellow had I think I would try to fab one from aluminum and let it breathe. I would also try to adapt a sled belt to the atv clutch as I believe they are better at handling extreme conditions. His trouble was water though and I'm not sure what would happen from constant splashing and dunking, but at least the cover wouldn't fill up and make the clutch work submerged in water. He gave up on the Polaris machines for his type of riding and Polaris was of no help in resolving his problem, especially while in warranty.

 

I'm the guy with the 00 Trailboss...

I was told they overheat because of no low gear, you should be OK if you use the low gear when riding slow. Polaris will cover the part, but it's been a big hassle to make them own up to the warranty.

Mark

 

try a ranger belt polaris p.n. 3211072 it has a top cog design that runs cooler its helped us!