I thought my drive clutch was going bad because the clutch was rubbing so bad it could not start. I pulled the cover and noticed the cover seems to have lost some of it's shape and is rubbing the clutch. Without the cover the ATV starts up and runs great. New cover is expensive but why would it start rubbing with NOTHING having being done. That back mounting plate is a joke. it is not all that rigid either. Both are plastic or some composite.

It looks like it rubbed the inner cavity at the top and bottom but there is NO run-out on the clutch. Also a small mark from the center bolt but that seems like no issue. There is about 1/2" of play if I pull the clutch housing out when the ATV is off. Could the clutch be moving out too far? If yes, how to I reduce the stroke?

What gives??

Thanks!
Bill

 

Hey guys... Any thoughts?

 

when you start the engine with the cover off can you see the clutch spread out when you give it the throddle , if so how much does it move ? I don't have a polaris but i read a post awhile back ( Don't remember how long ago it was , but the post was about polaris changing over from plastic cover'e ; to aluminum ! i don't even remember what year model they were ! But it was about the belt case getting to hot, so hot they where melting the plastic cover's over time and causing them to leak among other thing's ; i think they were being covered under warrttee i hope this help's and maybe someone else that know's more about polaris will jump in with the info youneed ! .............

 

Yes the clutch spreads out. Yes the cover is plastic and it seems to have deformed from heat because it does not mesh up well allong the perimiter of it's mating half. The bolt holes ofcourse do line up because they were retained in position by the bolts... Sounds like the only way a cover could suddenly become and issue.

Thanks williebe... I doubt after 16 years that Polaris would do anything but I see there is an "Updated" cover for sale... Trouble is I think I saw it for $300...WOW

Thanks!
Bill

 

Yes it;s a crying shame they didn't know anybetter than to put plastic belt drive cover's instaed of Auminum cover's in the first place , anyone with a brain could've firgured out that all that heat over time would melt and distort those plastic cover's ; I'm sure there where other brand's who did the same trying to cut down on cost and weight reduction ! But how much weight could you acualy save from plastic over aluminum ! But Surely not enough to warrant the use of a mateial in a place that build's up this much heat , that anyone with a brain could see i ! ; even a dirt road at that ! I agree with you 100 percent that $300.00 is an alfull lot of money for somthing that should've never been used in the first place ! Bfisherman11 you could try ebay you may luck up and find a plaris someone is parting out and selling on ebay , however if you choose to buy something on ebay set up a paypal account to buy and sell off ebay or any internet site or ebay store or ; with a paypal account you are covered again't fraud from seller's and buyer's who misrepresent the product they're tring to sell and i can barely keep my eye's open i'll check back with tou tomorrow and see if you have found anything new and i'll check the internet for something on a good a aluminum cover used or new ; ill do whatever i can to help you out with this cover that i can do to help ! After all that's what the forums were started for is to help each other out , so have a good night or what's left of it ! I hope you can read this mess it's hard enough to make sense of some of my reply's when i'm not this tired ; so i'll type at you tomorrow ! williebee

 

Thanks williebee. I will go check eBay now!

Regards,
Bill

 

I found a used one being parted out (actually a 250 BUT same cover PT#, I checked) and I also found a new one for $130. Just wish I knew for sure this would fix it BUT it has too. There is no other logical answer..........

Bill

 

Be sure to check your motor mounts.