I let an inexperienced friend drive this machine and the next morning when I got on it there was a small hole in the housing and it clearly melted so that the clutch wheel was now rubbing on the housing. I'm wondering if he ran it at high speed in low gear - although he said he didn't. Got it home and took it appart and the belt didn't look too bad (there was a lot of belt dust though and is right at the replacement width of 1 1/8") and the clutch looks ok but I'm no mechanic and I have no idea how tell if the clutch has a problem. I'm going to go ahead and replace the belt and the housing and take it for a test ride but I would appreciate any info from an experienced polaris guy on the topic.

 

Older cluctch covers subject to warping when hot,replacement covers sturdier! Check newer models and clutch covers are not molded to shape of clutches,which eliminated this problem. Dont just blame HIM,could have happened to you to! Good luck.

 

OK thanks. Sounds like this isn't an uncommon problem. Will replace it and see how she runs.

 

belt dust is normal and you should blow out the clutches when you replace them both. actually if you run the bike at slow speeds in high is when the cutches w/ heat up. make sure the air intake for the cover isnt partly blocked as well.

 

thanks for the tips - that helps.

 

I just had to replace mine because it was warped then it started rubbing and it melted a hole in it. Got one off of ebay and it was as OPT said - NOT molded to fit clutches, it was a rounded style one and it matched up to my old back half. So if the back half is good just look for the outer half - I paid under 25 bucks for mine on ebay including shipping