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as far as i can tell from my 06' 800 to my 08' is that the heat sheild is bigger and the radaitor is bigger as it hold a little more antifreeze i think. no issues w/ melting on mine but only had 175 miles when i put it up. thanks sheep, ill be awaiting your results. thats some serious hot temps that your showing for sure.
just found this out two weeks ago polaris has a service bulliton NOT A RECALL for 2005 2007 machines if your having hot exhuast problems or melting plastics dealers are to replace heat shields with better protective ones and they will reflash your computer on your machine to give it more fuel to cool down exhuast temp. this is the BIG problem they sent these machines out the door running so lean to meet emission regs that everybody is melting plastics off. I have had 2005 with two rear fenders replaced one side panel and no answer to why that machine ran so hot so dumped that got an 06 better but started to same problems just not as bad found out about this service bulliton and dealer put new heat shields on that really work and reflashed my computer and let me tell you a little more fuel gives you hole lot more pulling power. my exhuast temp before having this done running at an idle was 660 now its at 518,520 runing under load it would tach out my temp guage at 900 now it running at560 to 580 and it runs so much better that it not even funny it amazing. you guys with the o8 models already got these goodys. hope this helps some poeple out have seen alot of problems out there over the years now one of them is being fixed. also if your warrenty is up they will still fix they did for me
The last time I checked at my dealer about this, they didn't have a clue about reflashing. If you have access to this service bulletin, please get a copy of it so we can all see it. I'll even host it for you if need be. Short of that, I think a lot of us will be out of luck if we just walk into our dealers and say we read it somewhere. Without any actual proof, we won't be able to make any progress with them.