Warping of the cover Is very common and Is usually caused by alot of things. The newer covers are made thicker bacause of so many problems with warping. Causes could be from belt slipping heating up cover, clogged air intake tube, accidental resting on cover while riding of leg or foot etc., worn belt, clutches out of align, I am sure there are more reasons, but I think these are the most common.

 

Oh yeah, If It rubs just a little now and then, I wouldn't really worry about It. But I would make sure you are not accidently leaning your leg on It.

 

If you want to make sure that its not a clutch vib just jack it up with the cover off and rev it out and watch for anything unusual. For that matter you could probably just rev it out in neutral and not jack it up, your clutch will still shift out. If it is just a belt slap on the cover when you take the cover off you can usually see where the belt slaps or rubs the cover to identify it. If it is belt slap and not the clutch rubbing you may want to check your belt deflection ( did you put a new belt on with the rebuilt driven clutch) I think the deflection should 1 1/8 to 1 1/4 (could someone please verify that) if its beyond that you have to remove shimms from your driven clutch. The new style cover does have alot more room and I think it would help keep things cooler to prevent warpage, but like I said you are going to have to snorkel at least the exhaust duct and I was planning on doing something with the clutch intake also to benefit from the bigger cover.

 

hey skid, i did replace the belt while i had everything apart fixin it glad i did, i didnt know if i left the old one on it might ride rough. ok now what u mean by the exhaust duct needs to be snorkeled, u saying that the exhaust duct is bigger on the 03 covers?


Thanks, haz!

 

On the new style cover the exhaust port is probably near three inches ( have'nt put a ruler to it) where the old cover exhaust port is about 1.5". I'm not sure if you could hook your old exhaust duct to it or not, you would need a reducer and by doing that you would restrict all that extra air flow you could have coming through there. Maybe you could use the exhaust duct from a 03 HO and modify it to fit, I'm not sure. Right now I'm trying to decide if I want to tear into the engine and have not messed with the cover.

 

cool thanks, hey how many wheelers do u own? do u just have the 400 xplorer like mine or what else do u have, got any pics, id love to check em out! [img]i/expressions/face-icon-small-smile.gif[/img]


thanks, Haz!

 

All I have is the Xplorer, no digital camera. I am storing my brother inlaws 01 500HO as he is deployed right now, I take it out for a spin once in a while. That thing will run pretty close with me and maybe even take me on the topend so I can't wait to see his reaction when I get the mods done and blow his doors off.

 

LOL yea, hey i was wondering what type of problems do u have with ur beloved xplorer, i had to take off my right side cv boots and the hole hub cuz i heard some odd sounds in the front end so i took it apart and u know how theres little ***** that are held in by a thingy-maggig (idk what to call it) was broke and there was a few pieces i piked out, my old sportsman 400 did this a time or two but the time it happened before we sold it it brok the hole deal (the small shaft in the hub i beleive) and the hole hub and tire came off while i was on it of course lol not good, ive got her all taken apart though and ready to head to my dealer, again, but thats ok in some ways i like to work on mine kinda gives me knowledge like i said it happened on my old wheeler so i know how to do this its kinda nice i guess, i mean i ride with 2 guys that ride precious little hondas and nothing ever seems to happen to them and there kinda the people that have never taken anything apart in there life and just act like they know it, but i tell u what my explorer will cruise through nice and easy with my "TRUE" awd in mud where them hondas seem to have to speed through cuz they only got like 3 wheel drive LOLOLOL ahh jeeze, but Polaris always gets the bad wrap![img]i/expressions/face-icon-small-sad.gif[/img] well please contact me on what type of probs u have on ur xplorer i wud like to know so i can watch for it[img]i/expressions/face-icon-small-smile.gif[/img]


thanks, Haz!

 

I have not really had any problems with my Xplorer other than tie rod ends, steering post bushing, and the halifax (speed) sensor. I replaced the Steering post bushing with one from hot seat and got the sensor and tie rod ends from the dealer under warranty. I have had to do some chain and sprocket maintenance but that was from someone dumping a bunch of gravel in a mud hole thinking they could firm the bottom up. All it did was mix with the mud and got between my front sprocket and chain and busted some teeth. I thought that the swing arm bushings were going out but it turned out that the bolt for the left side was comming loose.

I'm between a rock and a hard place now on my warranty. I want to mod the engine but if I do there goes the warranty that would cover all the stuff like my hubs, gearboxes, u-joints, swing arm, ect. My thinking is to cancel it because with all the more I have got to ride in the past two years I probably will not have those kind of troubles untill the warranty expires anyhow. Although like I've said for the last two years I plan on riding alot more this summer.

I already ordered a stage one kit from RCR. RCR does not make a pipe for the 2000 Xplorer, but he does have one for the 99 and I've seen other guys on here that have installed it and he said that he has a close dealership that puts them on and all you have to do is open the bend it the pipe like a halh inch. The post I saw on here said you didn't even have to really bend the pipe more like spring it open to line it up. We'll see. But with that he said I should really get the stock piston out and if I'm going to do that I want to get a light trail port and the head shaved also. With all that it should run like a totally different machine. It will be a coulpe of weeks until its all done if I go all the way. Wether or not I do just the pipe or the whole engine I'll post my results back here.

 

sweet thanks man u have been nothing but FANTASTIC HELP! Keep it up man[img]i/expressions/face-icon-small-smile.gif[/img]


Thanks, Haz!