i have an 800 header on my 700 and its wore off the glue on the back of the heatshield. its in a water hole somewhere.
in the heat, the plastic gets really flexible(the whole panel) but hasnt burned through or shown any marks as of yet.
my leg sure does get a lil warm after riding for a while, but i try only to concentrate on having fun. a lil dried and baked(pun) on mud aint too terrible.

it sucks they dont fix a problem thats been known for years.

 

shame, shame Polaris. are they really that greedy about getting these things to the showroom floor? sad their priorities are so screwed up. they can't afford this kind of bad publicity.

"Polaris, The Way Out, Just Make Sure You Bring A Buddy With A Japanese Model For The Trip Back!"

 

I recently purchased an 06 500 efi and, like so many others, found that the exhaust heat shield was rubbing the plastic behind the AWD sticker. Thanks to this forum I caught it before it got all the way through. The dealer said there wasn't a fix, only to put some more tape and header wrap. I wasn't impressed with that fix because I felt it would just wear through again eventually. I just took the heat shield off and molded the corner with a hammer so it wouldn't be rubbing on the plastic anymore. Its only aluminum, so it wasn't hard to beat it into shape. I have about a half inch gap now. Hopefully that will take care of it. I'm also getting another piece of plastic anyway from the dealer under warranty. Thanks for all the good info.

 

Zerowick and MT .. PLEASE! WE GET THE POINT! You both bought an ATV with known problems, and you've both stated the problems, TIME AND TIME AGAIN! .. ALMOST EVERYONE knows about these problems now. So please quit saying the same things over and over again! The issue will be resolved. Case closed. It takes time. I believe the '07 models will be available with the fix already on them, and a fix for all '06 models will be on its way. I just cant stand to hear all this complaining. Remember there are still PLENTY of people who havnt had any problems with Polaris. Like myself. And since this is a well known problem, ON THEIR BEST SELLING PRODUCT EVER (500 H.O.) I BELIEVE THAT THEY ARE WORKING ON A FIX FOR IT. Give them SOME credit.. damn. They're not that dumb.
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2004 Polaris Sportsman 700 (Green)
'27 ITP 589 M/S Tires
on ITP Type 5 Wheels
3000 lb. Warn Winch
3-Way Headlight Mod
High Lifter Lift Kit

2004 Polaris Sportsman 500 Mossy Oak - STOLEN
2001 Honda Rancher ES 350
Sold

 

When my wife rides with me I have to tuck a piece of sheep skin (purchased for M/C seat on long trips) under the rear rack, allowing it to hang down so that her leg can rest on it. It gets so hot she cannot let her leg rest on the plastic. Upon reading this post, I went down to the garage and looked/felt of the heat shield and it is touching the plastic. I suppose it is just a matter of time until it wears through the tape and melts the plastic. This is an 06 450 SP. with just over 200 miles. I will remove the seat tomorrow and see what I can do about it. No use letting this happen while waiting on the CO. to do something right?

 

I've given them plenty of credit, $6000 worth.

 

Ah, the awsome new plastic design that keeps us all so much cleaner and looks so much better. I love it. But not cutting any vent holes in the side panels to help some of the heat dispurse has played havik on the plastic. Here is one thing that helps some. Take off the floor board on the exhaust side and shim it up 3/8 inch or so. This will push the plastic up enough to allow for more room between it and the exhaust. It don't sound like much but it helps. It also allows more openng for more air to move through. Some pipe wrap that you can buy a local autoparts store can help too. Wrap the pipe in the area between the side panel and rear panel. Should help it out. Just make sure the wrap clears the plastic.