1987 Trail Boss front clutch cover does not fit tightly on rear clutch cover
 

Hi All,
My front clutch cover (p/n 5430771, big and bulbous) does not fit tightly to the rear clutch cover (p/n 5430772, flat and mounts against the engine/transmission). These parts are supposed to fit together tightly and I have two rear covers and they both have the same problem with the front cover. When a bolt is installed at one end of the covers a bolt at the other end is off by 1/4". I was able to manipulate the covers to get all the bolts to align but when you tighten the bolts the front cover separates from the rear cover creating a gap where there is no seal.

Any suggestions beyond keep purchasing front clutch covers until one fits?

Thanks
https://cimg3.ibsrv.net/gimg/atvconn...3e31d55e4f.jpg
https://cimg5.ibsrv.net/gimg/atvconn...e294f2f687.jpg
https://cimg6.ibsrv.net/gimg/atvconn...6c6dad499c.jpg

the covers were known to have warping issues which makes not fit together such as yours. not a real good design since clutches expel a lot of heat in them causing the warping issues.

Hi Stendori,
Really appreciate your response and I totally agree, what a poor design. They obviously didn't account for tolerance stack up and clutch heating of the covers.

I've ordered the three clutch cover clips (p/n 7670051) and will see if I can squeeze the cover on with a c-clamp to install the clips. Hopefully that will make it fit better. If it doesn't I will probably use clear silicone RTV to seal the gaps. It will be kind of a pain if I need to take the outer cover off but after all the work I've done to get the inner cover sealed on the engine and against the transmission, I am not going to go half ass on the outer cover.

Thanks!

you nailed what I was going to suggest that a lot of us did which is using the rtv gasket material or silicone to prevent water getting in as that is a belt killer. good luck with it for sure.

Glad to hear others have taken a similar approach to what I am going to try.

Thanks again

Warping
 

They had a bad issue for several years I ended up buying a new one you could see they redesigned it.

I know they came up with a better cover for the Gen. IV ATVs like my older Sportsman 500s, but that was a Gen. II and I haven't heard if they made a better cover for those or not. Or if the Gen. VI cover would fit that too.

Help
 

How do you ask questions in here

Hi Jim,
You just did it. Do you have a question on clutch cover case fitment or something else? If it is something else, search the threads first to see if it has been answered. If your question hasn't been answered perviously, then open a new thread and ask away.

Let us know if you need more help.