I saw a thread here the other day which said that a person was having problems with the plastic melting on their two 500efi's. Well I took a hard look at mine and found that the heat shield on the right side of quad is butted up against the plastic right inside of the all wheel drive sticker. The heat shield wore a hole through the heat shielding tape and burned about a 1 inch by half inch area. I couldn't see this until I pulled back the plastic from the heat shield and saw that it burned about half way through the plastic. I couldn't believe how thick that camo plastic is. You guys should take a look at yours so you can correct it before it burns all the way though. I took a piece of asbestos and put it over the area that it burned and put heat shielding tape over that.

 

OMG! here we go again!

just another problem to add to the list!

GREAT Quality Control Polaris!

one would think they would have learned from the 800EFI's melting issues LAST YEAR!

~MT

 

Now reports of the 2006SP...i am not suprised..wait until this summer when it really melts.......

 

come on Polaris, are you listening?!

this problem seemed to start in 05, right? my 04.5 is fine, heat tape is in place, runs in 90+ degees, no probs. what changed in 05 that is causing the melting? did that panel get closer to the exhaust? wonder if it is a plastic problem? I have a connection with a plastic manufacturer and a certain sales rep told me Polaris did not buy his plastic because it was too expensive. I'm not making this up. perhaps to save a buck Polaris screwed themselves?

 

the redesign was in '05. wider seat, gas tank, ect.

the nut in the plastic design dept didn't commumicate with the nut designing the exhaust one office over!

Polaris will learn to be more careful when there are no customers left that want to buy their DEFECTIVE products.

it's really too bad.

~MT

 

yup, too busy with bigger, better, more high tech. quality got lost in the shuffle! let's hope they don't do the same with KTM!

 

I don't think the quality of the plastic is an issue at all, it's their engineering. Their was heat tape on the panel, but because it was touching the heat shield it wore a hole through the heat tape and melted the plastic. If their was a quarter of an inch in space between the two it wouldn't have happened. We as customers shouldn't have to deal with this, they should have it figured out by now.

 

MOST DEFINATELY!

 

The issue is not the plastic.... The prototypes did not any of these issues, and they were in testing for over a yr. Many issues are never seen until mass production and the supplier has to live up to what they promised. The problem happens when the suppliers slack in their product. this happens not only with Polaris but all Brands, as many brands share the same suppliers for different things.


"SUBJECT: 2006 Sportsman 500 EFI Erratic Cooling Fan / ‘HOT’ Lamp Operation

PURPOSE:
Polaris has determined the 2006 Sportsman 500 EFIs listed above may encounter erratic fan operation in conjuction with a ‘HOT’ lamp
that illuminates excessively or when engine temperature is not sufficient to activate the ‘HOT’ lamp. Cooling fan start-up has been
identified as adversely affecting other cooling system controls. A Resistor Harness Kit, PN 2203193, has been created to resolve this
issue."


Have your dealer do this fix. He should have a notice from Polaris to do this as they come out of the crate, but the early ones do not have this. so if you have a early one get it checked. It is a very simple fix.

 

[quote]
Originally posted by: Sportsman6004X4
The prototypes did not any of these issues, and they were in testing for over a yr.q]

how do you know this info?
~MT