Hi, I have a 1987 Polaris TRAILBOSS 250. I got the bike back from having someone work on it and something was hitting behind the clutch cover whenever I pulled the chord. The clutch cover will not come off because one of the threaded inserts in the cover spins in the plastic so I can't see what is hitting, does anyone have any suggestions as to what might be hitting the cover?

 

The clutch itself is probably hitting the cover at an idle as most of the pre 96 models did from getting hot and warping. Spun inserts weren't any fun as usually you just had to cut the screw to remove the cover. Almost all parts have updated to a newer backing plate,screws and cover. Here's the breakdown on updated backing plate kit. Item#1. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Kit is a little cheaper on ebay,but look for a good used 96 or later cover,plus you might be able to find the complete set up.http://www.ebay.com/itm/Polaris-Inner-Clutch-Cover-Kit-2200803-1985-1992-Trail-Boss-Blazer-Scrambler-/311172571620?pt=Boat_Parts_Accessories_Gear&hash=item487354a1e4&vxp=mtr Plus you'd need the new engine seal for the different cover. http://www.ebay.com/itm/Inner-cover-to-engine-seal-Polaris-94-99-5410749-/271058796352?pt=Motors_ATV_Parts_Accessories&hash=item3f1c5cff40&vxp=mtr

 

[QUOTE=old polaris tech;3281732 . Thanks that sounds like a great idea. I forgot to mention one weird thing though, it only hits on one stroke. Whenever I pull it over its quiet for one and on compression, whatever it is that's hitting scrubbs.

 

Check the motor mounts also for any separation,but it's still probably the cover. Replaced a bunch of these on almost all the early models.Later model covers were designed larger and stronger around the drive clutch area so heat wouldn't distort them and collapse down and touch the clutch.

 

Ok sounds good, I appreciate the help