WOW thats a monster! I think the updated one will be fine, no reason to change the backing plate as well. My quad is actually missing the breather tube so i wanted to get a piece of tubing and run it up by the pod so it is as high as possible. The I never worry about dirt and junk getting in there. Right now i have a piece of cloth clamped over it. Looks pretty redneck

 

so as long as it has the 5433542 number i am good?

 

Yep you'd be fine.. As far as the tubing,why not a cheap 13 buck output duct. This cover and output duct was used on a bunch of year models. https://www.ebay.com/p/Polaris-Sport....c100005.m1851

Usage : 5432615 (Output Duct)
Year Product Model Assembly
2003 ATV TRAIL BLAZER 400 CLUTCH COVER - A03BA38CA (4982568256C01)
2002 ATV SCRAMBLER 400 2X4 CLUTCH COVER - A02BA38CA (4969936993C01)
2002 ATV SCRAMBLER 400 4X4 CLUTCH COVER - A02BG38CA (4974677467A12)
2001 ATV SCRAMBLER 400 2X4 CLUTCH COVER - A01BA38CA (4968366836C001)
2001 ATV XPLORER 400 CLUTCH COVER - A01CG38CA (4963916391C005)
2000 ATV SCRAMBLER 2X4 CLUTCH COVER - A00BA38CA (4954835483C003)
2000 ATV SCRAMBLER 400 CLUTCH COVER - A00BG38CA (4954845484C007)
2000 ATV XPLORER 400 CLUTCH COVER - A00CG38CA (4954875487C009)
1999 ATV SPORT 400 CLUTCH COVER - A99BA38CA (4949534953c004)
1999 ATV SCRAMBLER 400 CLUTCH COVER - A99BG38CA (4949664966c006)
1999 ATV SCRAMBLER 400 CLUTCH COVER - A99BG38CB (4952505250c006)
1999 ATV XPLORER 400 CLUTCH COVER - A99CG38CA (4949634963C008)
1998 ATV MAGNUM 4X4 CLUTCH COVER - W98AC42A (4945214521C002)
1998 ATV NORWEGIAN MAGNUM 4X4 CLUTCH COVER - W98AC42A (4945214521C002)
1998 ATV SWEDISH MAGNUM 4X4 CLUTCH COVER - W98AC42A (4945214521C002)
1998 ATV MAGNUM 2X4 CLUTCH COVER Magnum 2X4 W98AA42A (4945524552B013)
1998 ATV SCRAMBLER 400 CLUTCH COVER Scrambler 400 W98BC38C (4947254725C006)
1998 ATV SPORT 400L CLUTCH COVER Sport 400L W98BA38C (4947234723C003)
1998 ATV XPLORER 400L CLUTCH COVER XPLORER 400L W98CC38C (4945414541C004)
1997 ATV MAGNUM 6X6 CLUTCH COVER Magnum 6X6 W97AE42A and Swedish Magnum 6X6 S97AE42E (4940754075C012)
1997 ATV SWEDISH MAGNUM 6X6 CLUTCH COVER Magnum 6X6 W97AE42A and Swedish Magnum 6X6 S97AE42E (4940754075C012)
1997 ATV SCRAMBLER 500 CLUTCH COVER Scrambler 500 W97BC50A (4943074307C007)
1997 ATV XPRESS 300 CLUTCH COVER (400L) XPRESS 400L W97CA38C (4939603960C008)
1997 ATV XPRESS 400 CLUTCH COVER (400L) XPRESS 400L W97CA38C (4939603960C008)
1997 ATV SPORT 400L CLUTCH COVER (SPORT) Sport 400L W97BA38C (4940124012C005)
1997 ATV TRAIL BLAZER CLUTCH COVER (SPORT) Sport 400L W97BA38C (4940124012C005)
1997 ATV Big Boss 6x6 400L CLUTCH COVER BIG BOSS 6X6 400L W97AE38A (4940814081C007)
1997 ATV BIG BOSS 6X6 400L CLUTCH COVER BIG BOSS 6X6 400L W97AE38A (4940814081C007)
1997 ATV MAGNUM 2X4 CLUTCH COVER Magnum 2X4 W97AA42A (4940704070B013)
1997 ATV MAGNUM 4X4 CLUTCH COVER Magnum 4X4 W97AC42A, Swedish Magnum 4X4 S97AC42E and Norwegian (4940834083C001)
1997 ATV NORWEGIAN MAGNUM 4X4 CLUTCH COVER Magnum 4X4 W97AC42A, Swedish Magnum 4X4 S97AC42E and Norwegian (4940834083C001)
1997 ATV SWEDISH MAGNUM 4X4 CLUTCH COVER Magnum 4X4 W97AC42A, Swedish Magnum 4X4 S97AC42E and Norwegian (4940834083C001)
1997 ATV SCRAMBER 400L CLUTCH COVER Scrambler 400L W97BC38C (4939893989C006)
1997 ATV SPORTSMAN 400L CLUTCH COVER Sportsman 400L W97AC38C (4939673967C006)
1997 ATV XPLORER 400L CLUTCH COVER XPLORER 400L W97CC38C (4939753975C004)

 

Ok. Yeah I may do that if it will breath better or something. Is that part of the reason for the size, to allow more air to circulate? The firs time i pulled out that clutch it was hot to the touch. seemed a little warm to me.

 

Hardly any air circulating is why the covers would get hot and droop down and touch the primary clutch. Plus the clutches and belt would run hotter. Newer cover plus I'd get the used duct I posted a link to that directs dust and heat down as running a tube close to the pod would just allow belt dust,dirt to accumulate there. Plus you'd feel the heat and smell it..

 

K. Yeah I should probably throw that in too i suppose. I did some figuring and I am still super cheap for what i have put into this things so its probably gonna be good for the long haul to do it right.

 

Here is the cover I am looking at, plus brake cylinder. Cover

 

Where is the air intake for the clutches? Assuming there is one

 

Cover and m/cylinder ok. IF you don't want the manual you can at least see where things are using the parts break down... Air inlet duct at the lower front of the engine. #35...

 

Oh tht has the coolant overflow on it. Right. Where does the air go from there to the clutches? Wondering if there could be any blockage