I got my new Polaris 800 EFI last week. I went camping and put 452 miles on (Saturday through Wednesday (today)). What a machine. I was riding a 500 HO Polaris before this. My only problem was with the exhaust hitting the engine at certain RPMs and engine loads. Common? It is now back at the dealer to correct. Sounded like the engine/transmission was coming apart when the parts were hitting.

 

welcome to 800 club. thats a good amount of milage for a trip. had mine since dec and only have maybe 250 miles w/ no problem as of yet. and i dont baby mine

 

Look HERE and HERE

 

The pictures you referenced show the exact same problem I am having. The dealer said it should be ready to pick up tomorrow, just in time for the weekend.

 

I had to buy a new pipe. The dealer said it was due to me getting the ceramic coating. Just an excuse to not pay! The Jet Hot ceramic coating is paper thin and did not cause this to happen. Good Luck. I have not had any problems with the new pipe.

 

So was it a bad bend from the factory?

 

Mine is due to a bad exhaust pipe bend from the factory or an unlucky install. When I dropped mine off at the dealer, I looked at another 800 on the showroom floor. It had considerably more clearance. The mechanic said he was going to see if there was slop in the bolt holes to move the exhaust up and out of contact with the engine. I'll keep you posted.

 

Been there, Tried that. No luck at all. Not sure about the bad bend from factory but the pipe never rattled until about 400 miles. I was riding with some friends then all of a sudden a very loud rattle. I litterly thought that I slung a rod. I did go through a couple of water holes with a hot pipe. I thought that maybe the thermal shock warped the pipe. Then I realized that I had been through the same holes a few months earlier when it was freezing out side with no problems. Yes my new pipe has close to 1/4" clearance.


Robert

 

Picked up my machine from the dealer today. All they had to do was loosen the manifold nuts and move the exhaust up in the bolt hole slop. Sounds good. No more contact with the engine. I'll be putting on 300-400 hundred miles over the 4th of July holiday so I'll find out if this is a permanent fix.