Have a 1998 sportsman 500 and need a new clutch cover..it was rubbing and the P.O. cut it at the top to stop it from banging. Will part number 5433540 work? The cover on it now says 5431961.

 

The bigger bulbous cover(5433540) would work,but you have to make an adaption for your smaller exhaust duct and sleeve as the cover was designed for a larger duct. The updated replacement cover for your model that was built stronger,but still had the same smaller shape and fit the existing duct is #5433542. This cover is expensive on ebay as well as the 5433540. I'd keep an eye out for a good used one in either part #if you don't want to spring for a new one.

 

Sounds good, thanks! I will keep an eye out. I had found the 5433540 both inner and outer cover for a decent price used but wanted to confirm it would work. May look for the 5433542.
Here is a pic of the new ride along with some info.
1998 Sportsman 500
Purchase price: $500
Needed when I got it:
Clutch work, clutch cover, air box, front gear box/differential, front axles and prop shaft.
Ordered all the parts except clutch cover and air box which I am still on the hunt for.

 

Another question for you. Is there another air box that will fit this model with modifications?
I'm having a hard time finding an air box for the 96-98 Sportsman 500 as I'm looking for used parts to keep my cost low.

 

I hated the early wing nut air box lids as the studs would always crack off. 99 models went to the better clamp style air boxes. You might keep a check on these on ebay.1999 through 2005 or 2006 has the basic same box. You might have to change the carb to box tube also,but not sure.

 

Thanks - I'll do a little digging. I just wasn't sure if a 99 box would fit on the 98 but I would think with modification it would. I'll order one and try it out. If all else fails I'll just sell it on ebay if it doesn't fit.