Hi
I posted this as a reply to an old post and hardly anyone seemed to notice. I think it deserves a new post because it is some good info. Hope it helps someone.

My 800 didn't start melting until I started using it to tow a heavy Swisher brush mower on 15 acres of hilly pasture. I called my dealer and they said "bring it in, we got a new heat shield". Well they put on a new longer one piece heat shield and replaced the rear cab for no charge. I thought "great, no more melting now!" Then I went back to mowing and experienced even worse meltdown than before, this time the rear cab melted again as well as the under side of the seat which allowed it to drop down onto the airbox breaking off one of the mounting tabs! I called the dealer back up and the service guy called Polaris who said they would have another fix coming and it would be about three weeks. This was about two months ago or so. So last week I called Polaris myself and complained. The next day I had a call back from the complaint resolution guy (Robby) who was very concerned with my problem. He said there is a third heat shield replacement out now along with a computer reflash that is supposed to fix the melting problem. He said the computer reflash advances the timing which causes more complete combustion and less heat in the exhaust. He said it is also good for a power boost and claimed thats where the increased power is coming from on the 08 800's. My quad is now back in the shop for these upgrades plus a new seat, rear cab, airbox and side panel. I do have to pay for 1 1/2 hours labor though ($90). Sounds fair to me since I have been out of warranty for two years!

 

So are you saying that your '05 is going to be flashed to '08 specs?

Also, you might want to take it one step further and send your header pipe to have it ceramic coated. Radiated heat is supposed to be reduced dramatically from this coating.

 

that's how he made it sound, 08 specs

 

Cutty, I'm waiting to hear the results. let us know, thanks.

 

i think hes putting you on a little since theres a few differnt engine part numbers for the 08' vs. the older ones but you can always hope its as much power. please post results.