Now I know my 425 mag is getting some years on it and it has been ridden hard and put up wet but has been well maintained and I would love to replace it but would like to get another hunting season or 2 out of it.

My question is belt cover has a loud noise in it when the motor is idiling. when I pick up on the throttle the belt noise goes away. I am told it is in the cover. If I purchase a new belt drive cover will this solve the problem?? I just hate to spend $125 if it is not going to help this noise. Other than that it runs great and the belt does not slip at all however this noise is kinda of a pain in the rear.

Thanks for any help

 

I have a 99 scrambler 500 and it is also making noise from the belt cover. I think it is because it does not disperse the heat from the cover so it heats up and melts the cover. I took my dermal and was able to sand down the milted spots and make it work a little longer till I have to buy a new cover…

 

Thanks for the input I may try that

 

Had the exact same thing happen to my 1995 Sportsman 400. Didn't think much of it for awhile but then looked at it and discovered that the clutch had eaten through the cover. We just replaced the cover and strapped it down to the bottom of the frame.

 

The clutch cover will distort over time so a new cover will help.

 

Hey you might try Ebay. They have them all the time for a lot less than a 125 bucks. They probably aren't brand new but are in useable shape.

Hey I just happened to look and they have one brand new for 69 bucks. Check it out.New Clutch Cover

 

As I have read, the 2004 covers have larger air vents to assist in removing this hot air. Also a drain plug for those times of water in the clutch.

Now for my bike, '96 400. I understand the TrailBlazer is the matchup. Of course the air in/out vents and backing plate would have to be upgraded at the same time. Lots cheaper going with what came with ur bike. But for a 425 Mag. I bet a Sportsman500 parts are the same? This should resolve high heat issues within the clutch.

Go to ur favorite Polaris dealer and see if they have some of these parts on the shelf and match up what is on ur ATV.

When of if my clutch cover melts, this is what I am planning on checking out.

 

I have found them on ebay so I may go ahead and order one and see if that solves the problem

 

The clutch was rubbing on the outer cover at idle on my Scrammy. Replaced the outer PVT cover and it's good as new.