How many of you have this problem?? I have a 2006 sportsman 500 EFI???

 

hey stampers, did u have it in low

 

,TextYes, I have in it Low!!!!

 

thats ur problem, see if u have it in low for a long period of time goin a good amount of speed, it puts stress on the engine whitch causes it to heat up to an incredibly hot temperature, put it in high for fast speeds. low for small travels and low speed. plus use low for muddin but switch it back to high wen getting to another area

 

Is this the pipe getting super hot or the motor? I've been thinking about header tape.

 

im sorry ive been away, but yes that tape is wat u need. trust me on my express the muffler welded all the plastic around it.i had to break all off. like i said put it high for good speed and low for muddin and low speed

 

I am assuming the melting plastic is on the right side rear fender where the pipe is at its closest point visible after you remove the pull off panel. I have an 800 and it did the same thing and it has nothing to do with low vs. high gear. It has to do with the proximity of the pipe to the rear fender at the point I described. I have seen several posts with the 500's doing this. Why all do noy do it has to do with the pipe assembly at the factory/dealer on a specific model. The 800 problem is widespread and is fixed with a replacement cab and slight movement of the pipes with additional heat tape. The 500's are not as widespread but have had this prolem and your dealer should know about it as Polaris conducted a school about 3 mos. ago addressing this issue. This is a warranty issue and you should take it to your dealer asap and require that they fix it.

 

I had a similar problem on a Xplorer with a HSP performance pipe. I welded a contoured standoff to the pipe at the point where the plastic melted. I made the spacing approximately 1/2 inch. It was pretty easy to do just be careful not to burn thru the pipe . I insulated the contact areas with leather attached by a couple of flathead bolts. It is the best material that I had on hand. I expect that if you had some other insulating material it would work as well.

Hope that helps.