My Dads clutch cover has sagged and rubs bad against the clutch. Is there a replacement for a 1992-93 250 trail boss?
Thanks
Keith

 

Common problem on all the 90s machines. They all went to the same upgraded cover,5433542 that will fit,but expensive.5433542 | eBay You might keep a look out for a used one from any model 98 and up that would work also. The newer bulbous type covers will work,but you have to find or modify a sleeve that will work with your small air exhaust duct on the larger cover opening.

 

Thanks for confirming this OPT. Now my Dad's cover clips on. Will I need to get the inner clutch cover to, or will the new one clip on to the old inner cover? Now it's been awhile since I took it off, so maybe there were some screws to??? Thanks

 

If you stay with the upgraded cover,5433542 you can use your existing backing plate. On the larger covers you'd have to get the inner cover and some of the engine mounting holes may not line up or even be there. The clips(two or three) that are used help,but screw holes are more important.

 

Thanks again! I found your post about the creeping clutch on my 01 sportsman very helpful!

 

With OPT's guidance I update my 94 300 to the newer bulbous cover. If you watch eBay you can find some really good deals on covers but be sure to look closely at the pics.

I used a 2012 500 outer clutch cover and a 97 400 inner clutch cover. I had to modify the standoffs (transmission) for the inner cover. My original cover let go of the screw inserts when trying to remove the screws for the outer cover and I didn't care for the clips that much.

I documented some of the info here Inner Clutch Cover - My ATV just so I'd have a reference. It might help some...

 

Thanks for that added information. At this point my Dad is willing to fork over the $$ to eliminate the noise. It has been going on for too long.

 

OPT, I messed up and took the clutch apart without marking the 3 main pieces. Is there another way to see how the clutch was balanced?? Will it be noticeable if assembled wrong?

 

Shoot, wrong thread, but basically my 01 500 sportsman was creeping so I pulled the clutch apart to replace #2 and #18. I didn't mark the orientation of the three sections of the clutch....doh!

 

X marks on the clutch align the spider. The clutch top cover engraved markings align with the X..