While it is no secret that this occurs, the answers have been the same . A) Wrap it with something or B) Oh well Polaris would not admit that there was a problem. SO! Here is the secret and you have to promise not to tell anyone.

Work hard with your dealership and stay after them. After having my plastic replaced the second time and they put some rubber snubber on the frame to keep it away from the exhaust I was about to say O Well. However when I went to wrap the exhaust and the snubber had broke the new plastic THAT WAS IT!!

I called them back up...Well It seems that Polaris HAS NOW ADMITTED..That "maybe" they did have some problems with some of the pipes being bent wrong. So with 1300 + miles and over 175 hours on my 05 800 they are going to replace the plastic, Decals and the exhaust pipe. So there you have try to talk to your dealer I live in small town america and My local dealer has always worked with me... So Before you go calling week or so until I get mine back from the dealership

Good Luck!