I'm sorry if this has already been discussed, but why does the belt pulley/clutch rub on the cover (near the floorboard) when these machines get older (96 500) As soon as you hit the gas, the noise goes away.

 

I HAD THE SAME PROBLEM WITH MY 97 SCRAMBLER 500. I TOOK IT IN AND WAS TOLD THAT THEY ADDED SPACERS BETWEET THE COVER AND THE BELT. OF COURSE I HAD TO BUY A NEW COVER. JUST A NOTE I THINK THAT THEY USED A RUBER BUSHING ALONG THE BOTTOM.
i HAVE HEARD IT ONCE SINCE THIS WAS DONE. i WAS JUMPING AND LANDED HARD, BUT THE NOISE WENT AWAY AND HASN'T BEEN BACK

 

I have just encountered this problem recently and devised a solution. I cut a big piece of thin ( 1/8 inch ) plastic into 2 inch by 1 inch squares. I started stuffing them between the PVT back cover and the frame ( located near the PVT vent outlet ) until the noise dissapeared. I then glued the plastic pieces together ( like a stack ) and glued some rubber to one side ( to prevent rattling from the frame ). I then cleaned the PVT back cover with simple green or spray nine to remove the crud then mineral spirits to remove any remaining grease. I finally glued the stack to the back of the rear PVT cover. The noise hasn't been back since and my PVT cover is fine.

Chris Piccciotto
99 Scrambler 500