Ok fellas, I need your wisdom. I have 1994 400L. Within the last year, a rubbing noise has developed from the belt housing. It only makes the noise at idle. If you give it some throttle the noise goes away, but as soon as it idles back down the noise returns. If you place your foot on the belt housing, it goes away. I replaced the blet, but it made no difference. Any ideas guys? Thanks for your input.

 

your clutch cover is worped probley from heat and old age mine did the same thing i replased it and all was good

 

Older model covers would distort from heat and rub drive clutch,have seen some almost melted! Just replace cover,part # supercedes to strengthened cover. check pvt seal behind front clutch while cover off to see if damaged. Newer machines allow more room for clutches,not molded close to contour of clutches. Havent seen but have heard of some replacing with latest style cover,holes may not align and exhaust duct connector may or may not have to be modified,but simpler to go with updated one for your machine. Good luck

 

Ours is doing the same thing. Our cover is definately warped but for a quick fix see if you can bend the bottom front bracket. You may be able to get it to quit rubbing for now. I have yet to replace ours cause I'm trading it in this winter. However I know the next time the wife hits the mud hole she's gonna be slipping when she get's out b/c the cover has gaps around the seal. Best thing to do is order the cover and try what I said for a quick fix til it comes in.

 

This is definately a common thing on polaris quads,I took mine off and used a heat gun to straighten out any distortion from age and now everything is fine.Mine to has a large gap around the crankshaft,I have tried to fix it with screwing rubber to the backingplate but gets cought up in the clutch and rips right off.This is my first polaris and probably my last,to much upkeep,almost constant.If I get another its gonna be a yamaha,all my buddies have yamahas from various years and all they do is put gas in them and ride.Ive spent more time repairing my polaris than riding it!!! No more belts for me!!!!

 

Believe it or not Polaris has made improvements in the last 20+ years. If you buy a new one you won't have as many problems as with a 22 year old Polaris.

 

Will a newer cover fit, or does it have to model specific?

 

Just order for your 94, will get updated cover that fits exactly as your old one,then rubbing problems should be over. Use low range anytime under a load or slow travel and you should not have belt problems.