Does everyones clutch cover from below the year 2000 (whatever year they stopped making that design) rub when at idle?
Mines been rubbing for 2 years now and we finally got tired of it. Damn thing is a complete rip off though.. 150$ for the cover.
Anyways while it fixed the problem of the original heat warped cover... I still noticed that the top left section of the cover has no support at all and could easily be moved around so the clutch could hit it from inside.

I made a bracket of 1/4" steel (by 1") going from the top left bolt hole of the bracket to the two bolt holes on the frame on top that normally attach the air breather for the clutch cover onto it.
It's really solid now and we shouldn't have a problem with it for a long time now.
Just wanted to mention it to those that'll need to get their covers replaced.

 

it would be really nice if a company would design an inner and outter cover made of billet aluminum...alot of people would buy them

 

maybe not billet, but cast-- check out the hawkeye. The big bore machines won't typically have a solid inner & outer cover because of how difficult it is to move vibration out of the system.

 

Even cast might be way more expensive than the stock plastic ones. Our polaris xplorer 400 is a 1996.. so that's like a clutch cover for every 10 years. 150$ every ten years isn't so bad when you think about it... only when the time comes to buy it lol.

The old cover was so messed up.. last year I tried putting a heat gun to it and pushing the plastic towards the outside so the clutch wouldn't hit. It didn't last very long and a little while after it was hitting all over the place again.
I hope it'll last even longer with the new bracket added. Although I'm not sure we'll still have it in 10 years... but it's highly possible since I'd probably buy it off my dad. (Sort of sentimental value)

 

Luda,

Do you have any PICS?

R'

 

I think you can up grade to the newer style but you have to replace the inner and outer covers.The newer ones are a better design.

 

What difference do the newer ones have? More plastic support I'm guessing?
I will get a pic soon.. I'm gonna have some more fun with it today and replace a couple things (tie rods ends, front hub oil change, tranny oil change, engine oil change, replace front 4x4 electrical wires with larger wires)
Why did they use those tiny 4x4 wires anyways... it was running on 3 wheels last winter because one of the wire came loose.. and one time they ripped out completely.

 

Well I got some pics.


It's a 1/4" by 1" steel flat bar. I painted it afterwards so it doesn't rust anytime soon.
And here's the atv..

So far I've done:
-Emergency brake tensioned, throttle cable end fix (atv landed on my dad while he tried to cross a ditch a year ago), tie rod ends (needs alignment), clutch cover with bracket, new air filters, shifter adjusted (low, high & reverse), new dash light (N & R), replaced prestone, rebuilt radiator fan motor (completely seized & caused it to overheat), plastic fenders fixed (pop rivets).
I think that's about it for now. Not much left to do.. should be more fun and less worry free next time I drive it [img]i/expressions/face-icon-small-happy.gif[/img]

I hope the pics will help people in the future.

 

looks good on the bracket.Can I make a little sugestion?Why not drill the bracket and mount a nut and bolt to got through and stay on the bracket and then through the covers with a way to add some adjustment to the bracket wher you can move it in a little or out a little.Get what I am trying to say?

 

I did drill through the cover. Notice the bolt is different than the rest. It goes all the way through the covers and then through a hole in the bracket with a washer/nut in the back.
There shouldn't be any point for adjustment though.. that can be made while bending the bracket. I just hit the bracket really hard with a hammer for adjustment lol.

You could always add or remove a bunch of washers though for adjustment. Being 1/4".. the bracket is solid enough so it doesn't flex.
Thanks for the suggestion anyways [img]i/expressions/face-icon-small-happy.gif[/img]


Oh ok.. you thought the cover was just resting on the bracket right.