My dealer has just informed me Polaris has come out with a fix for the 06 models to replace the heat shield on the exhaust. Not sure what it includes... but I know of a couple of buddies that have an 05 800's that are going to look into getting it...

I will try and get more info when mine gets back from the shop... Needed a new waterpump....
Had to wait for parts...

If you own an 06 LE Private Message me... I can help you out...

 

I am going to give you the background story... It's long and winded....
I purchased an 05 Sportsman 800 EFI new to add to my collection of ATV's....
I mow about 2 Acres with a pull mower, plow snow, spray weeds, dethatch, and a number of other things...
I spent about an hour mowing on a Hot Afternoon right after I purchased the 800.... and found that the exhaust gives off considerably more heat than my 04.5 700 EFI...
When I say considerably more heat... I mean to the point I have to keep my leg up on that side, and my son can no longer sit with me while I mow. I informed the dealer and Polaris of the heat issue and tried to explain I had purchased an ATV for recreational use... and burning our legs wasn't very recreational... Polaris told me to sell it and take a loss, and my dealer said he would give me a very fair trade-in price....

I continued to use the ATV for mowing late one night and parked it in the garage when I was done.... When I returned I found that th removable panel on the right side had actually melted a hole clean through the plastic... the rear cab had also melted and the front cab had signs of beginning to melt....

I returned the unit to the dealer... and he simply replaced the front and rear cabs and the side panel and added a heat shield tape to the back...

Meantime... a friend of mine, my father, and my fathers girlfriend had noticed the heat issues... but not noticed the melting until reviewing the issue and knowing about mine... They have also had their plastics replaced with the tape and bracket added.

After recieving my wheeler back from the shop ... and I tried to just return the unit due to me use of the machine... but they didn't want to hear about that....

I then began to use it as normal... thinking the tape would help with the heat issues...
It Did Not!
It melted the rear cab and warped the side panel again!
Now a little on the angry side... I wanted answers... They replaced the rear cab again and the side panel with more tape and added a bracket to hold the rear cab a little further from the exhaust.... I picked up the machine again... and before the warranty ran out.. I traded the machine in on a 2006 800 EFI LE that seems to have the same problem... along with the water pump failing me already too.

My unit is still in the shop awaiting the arrival of the water pump and all new plastic along with Polaris new fix to the problem... in which they have stated they would add to the new 06 and probably not the 05... A better heat shield for the exhaust...

My dealer has informed me that this time he would install the heat shield and give me the plastic to keep and change out when I either trade or sell the machine...

Summary: If you have not had issues with the 800 yet... more than likely you will... If you have warranty great, but if you do not have a history of the heat at Polaris, when it does decide to fail you they will brush you off. I would recommend the new exhaust shield if it works, but I have not seen it yet.

I don't know if you have warranty anymore, but if you do... your best if you make sure your local dealer is informed of the heat issue and makes sure he adds it to the computer system... or you will be hung out to dry. If you still have warranty I can try and help you get new panels if interested...

Jon