I decided to replace the inner clutch cover because it had aluminum inserts in the outer attachment points for the outer clutch cover. These inserts had corroded and were bound to the attachment bolts which caused them to turn in the plastic when trying to remove the original outer clutch cover. I also did not like the metal clips that were used along the bottom instead of bolts like on newer models.
The 2012 500 clutch cover I bought off ebay did come with an inner clutch cover but the mounting holes weren’t even close and the air inlet at the front was too far back towards the rear.
The original 1997 Polaris Xpress 400 Inner Clutch Cover
The Inner Clutch Cover was from a 1997 Polaris Xpress 400 and had to be slightly modified. The length of the 3 standoffs for the transmission mounts had to be cut down.
The Modified 1997 Polaris Xpress 400 Inner Clutch Cover
You could easily see how far to trim these down by the marks made on the assembly from the mold. I think the original 1994 300 mold was used and the support mounting holes were just drilled a little deeper. As seen in the pics below the height of the 2 mounts are level with the height of the large diameter cup in the assembly. The 3rd mount is level with the lower stepped portion of the original mount.
The Modified 1997 Polaris Xpress 400 Inner Clutch Cover
The Modified 1997 Polaris Xpress 400 Inner Clutch Cover