I had the infamous "exhaust so hot it melts the plastic issue" on my '06 X2, but resolved it thanks to DSLKSL's recommendation earlier in this thread. I utilized DEI brand header wrap, stainless steel ties, silcone heat spray, and reflective tape to implement a complete heat reduction/control protocol. Time consuming to do it right, but I followed all the instructions faithfully. Bottom line, it works GREAT! I'll report back to the group on how it continues to work...

 

Guys I would not pay anything to fix this problem. meaning paying for coating, heat shield tape, or any kind of pipe wraps.

This is a very large problem, polaris should be the one to come up with the fix not us. They have a new one pipe head pipe instead of the old two pipe ehaust. the one pipe allows for alot more room between the plastic and the exhaust. Should greatly help to solve the problem.

I have had the front , rear, and side panels replaced on mine. They put on a new one piece heat shield that is way to big, it rubs the shift linkage causing a rattle. So far the plastic melting has been greatly slowed by the new shield, but the seat is now melting. The seat was not melting before the new heat shield was put on.

I am going to run it until it melts the crap out of the seat and plastic again. Then maybe they will give us the new head pipe. I have the extended warranty, but this is not an extended warranty problem. I have no intentions for paying any amount of money to fix this problem. If we keep pushing polaris they will eventually take care of this problem for us. For the guys who have paid some money trying to stop the problem or plastic, I would strongly suggest you keep up with your bills and bug the fire out of polaris customer servicve.

Me and my buddy have reported the melting problem and the heat that gets to your leg to a consumer saftey man for the government. He came and took pictures of the melted plastic and asked a slew of questions. He seems very intent on helping get polaris resolve the problem.

sorry for the long post just trying to get enough people to speak up so that polaris will take care of our problem

 

canyoncrawler
you said your prev Sportsman had a smell of gas. I was just wondering what YEAR and SIZE it was?
thanks.
~MT

 

I have an '05 700 efi Hunter special and love it, and I believe that it has only one pipe from the motor to the muffler...I believe this is good right? I want to look at the machine tonight, where is the plastic melting, is it the side panel or the rear fender. Mine has what looks to be heat reflective tape on the inside of the side panels, don't know about the fender though. Thanks for the insight...and you are right, Polaris should do something to fix this "known" problem. Keep us posted on what you find out!

Pat

 

what year of 800's are giving all you the heat problems? i have about 500km on my '07 and there has not been a heat issue yet. i have travelled at slow speeds for work and no problems. mabey there is some small difference on the '07's that corrected the heat problems. if there is that big of an issue with the older models, we all need to contact our local dealers and relay the problems so Polaris will see that it is a "wide spread" problem and issue a fix. sorry about your troubles guys.[img]i/expressions/face-icon-small-shocked.gif[/img]

 

No trouble here either to report yet. I'm about to hit 600 miles.

 

It happened to my 05 700 at about 500 miles and Polaris replaced my plastic. Then it happened again at 600 miles, only worse, and once again polaris replaced my plastic. I then took my new plastic and stored it in my basement for future use (put on when I sell or trade). I'll just run my melted plastic until then (why ruin another set because Polaris might not replace it again). My bro-in-laws 06 800 hit 500 miles and started melting severely. Polaris bought him new plastic.

 

canyoncrawler if you want to solve this problem call Summit racing up and tell them you want Part # DEI-010120...Boom, end of problem........go have fun with your new EFI.

 

I put the 800 header on my 700 EFI and before bolting the footrest back down I stole the "Ove Glove"(oven mit in the form of a glove)my wife bought off an infomercial and placed it between the heat shield and the plastic...I'll probably wish I had just let the plastic melt when she finds out where her oven mit went..

 

Just one of many reviews

Name any ATV made and I will find a review from a owners who had no luck with them. They all have there problems thats really whats this forum about,to help out.
The vast majority of people having no problems with there ATV would not have much to talk or post about on this forum would they?
OR THIS ONE


What do you ride Gang Green ? I can show you dissatisfied owners of them in no time.