I had the same problems on my high hp sport I used to have.......the high hp tends to have high heat temps.......and then causes the covers to warp.......and sometimes they do cut into the covers......

I ended up getting a new style one(maybe not for the sport, don't remember if they are different or not)...but this one was bigger than the old style......also, you need to watch how you tighten it back up, sometimes just loosening some of those screws will let it stop rubbing.......

 

Mine was warping around the secondary like yours was. The first one I had it cut a hole in the back of it. Now the new one I got like last week is warping around the secondary but isn't rubbing. I will try and get a newer one. Thanks

 

im having this problem too, it doesnt look like its melted but i think the cover shifted, the bottom of the primary is rubbing and i toke a chunk of rubber and stuck it inbetween the clutch cover and the airfilter so it pushes the clutch cover down and its all good now.

 

Have you checked your tranmission mounts? Are they soft or broken. I have an 02 400 and I have the old style cover and run a 700 belt and have no problems. If you overtorque the cover bolts too it will warp. If your belt is overheating the cover then you need to check for slippage to raise that much heat. I know sportsmans with over 20000 miles that still have their original covers.

 

alright i havent checked my transmission mounts, i dont think thats it. the top of hte cover looks a little warped anyways it doesnt quiet fit in the seal just perfect, ill look into getting a new cover, it works fine for now though.

 

at dunefest i saw a very nice scrambler that had a very nice aluminum clutch cover, Bing did have pics of this bike up on his photo page.

 

Can you post a link?

 

AZBADBOYZ has this race chassis with an aluminum Clutch Cover. Pretty sweet. If you contact Dennis he may be able to point you to who makes them.


Here is a link to the picture.....

--Dave


Clutch Cover

 

that might not be aluminum...i no jx2 made me an offer to chrome my plastics and it would look like that