Polaris Clutch Covers

Reply Subscribe

Thread Tools

Search this Thread

Jul 11, 2007 | 03:22 AM

#21

Trailboss725

Trailblazer

Joined: May 2005

Posts: 90

Likes: 0

Polaris Clutch Covers

so i have a question, i have a 1988 trailboss 250 4x4 and my outer cover warped completely looks like serious heat damage. but the inner is still good, R u saying that I can switch to a newer cover as long as i switch both inner and outer or ......??

Jul 11, 2007 | 05:51 PM

#22

Ludapower

Thread Starter

Trailblazer

Joined: Aug 2005

Posts: 62

Likes: 0

Polaris Clutch Covers

I never anything about that.
All I said was that I replaced my clutch cover.. the biggest part that you can see. I didn't bother taking the whole clutch assembly out just to replace the rear one when I knew it wasn't rubbing.

Jul 28, 2007 | 10:25 PM

#23

Ludapower

Thread Starter

Trailblazer

Joined: Aug 2005

Posts: 62

Likes: 0

Polaris Clutch Covers

Just updating for the hell of it.. I'm almost done with the quad... about 450$ in parts.
Changed all oils and greased all parts.
Found a busted CV boot on left side and at the same time I replaced both hub seals because one had been busted for about 5 years time with no oil in the hub lol
Clutch cover still holding up great.

Oct 10, 2011 | 04:13 PM

#24

MLC

Weekend Warrior

Joined: Oct 2011

Posts: 1

Likes: 0

From: Nova Scotia, Canada

I'll try anything at this point

Quote:

Originally Posted by Ludapower

Does everyones clutch cover from below the year 2000 (whatever year they stopped making that design) rub when at idle?
Mines been rubbing for 2 years now and we finally got tired of it. Damn thing is a complete rip off though.. 150$ for the cover.
Anyways while it fixed the problem of the original heat warped cover... I still noticed that the top left section of the cover has no support at all and could easily be moved around so the clutch could hit it from inside.

I made a bracket of 1/4" steel (by 1") going from the top left bolt hole of the bracket to the two bolt holes on the frame on top that normally attach the air breather for the clutch cover onto it.
It's really solid now and we shouldn't have a problem with it for a long time now.
Just wanted to mention it to those that'll need to get their covers replaced.

Thanks Ludapower,

Definitely going to give the "Bracket" a try. We have tried everything with mine, and still the annoying knocking on the clutch cover. You can tighten it up sometimes, and it will last until you go over uneven terrain, and there it is again! We have been fighting with it for over two years. I have a 99 Polaris 500 Remington Edition. Have gotten all the other quirks fixed up except for this one. My husband has an 04 Polaris 500 and does not have the same problem. They changed the clutch covers after 2000, and must have corrected the problem. I also was told about changing to the newer model (after 2000) inner and outer clutch covers, but is very expensive and I havent actually found anyone its worked for.

Did you install the new outer cover first, and then the bracket? Or.. did you try the bracket with your existing 'warped' cover first?

Oct 10, 2011 | 04:25 PM

#25

old polaris tech

Polaris ATV Expert
Retired and loving it!

Joined: Jun 2008

Posts: 24,350

Likes: 44

From: North Texas

When you get tired of messing with the brackets, replacement updated cover(#5433540) is $74.17 at Cycle Parts Warehouse!

Sometimes the brackets work,a lot of times the noise just keeps coming back as the cover distorts even more and you have to readjust brackets again OPT