Has anyone heard the rumor that Polaris has a fix for this problem. My dealer had told me Polaris was in Arizona running test on a new heat shield that would be available the end of May. I called today and he hasn't recieved a bulletin yet and would get back to me in a few days with any info. I was wondering if anyone else had been told a similar story

 

i know on the 800's they put a differnt pipe and more heat sheilding to fix the problem.

 

on my new trail blazer they just put a piece of heat tape on the plastic above the end of the pipe.

Jim

 

i bought a 06 sportsman 500 3 weeks ago with this same problem. my dealer said Polaris is designing a whole new mold for the rear cab but didnt know when and if it would be ready.

 

how are you going to make plastic melt proof??

Jim

 

It's not a matter of makeing plastic melt proof, it is a matter of makeing modifications to keep the heat away from the meltable plastic.

 

I'm thinking about getting an 06 500, where is the plastic melting??? the rear fender over the muffler?? Do the 07 450s do the same??

 

No trouble with the 2006 Sportsman 450's .......Just to let you know............Not my two anyway!!!...Caper....

 

no problems with mine either Caper!

 

My 800 didn't start melting until I started using it to to a heavy Swisher brush mower on 15 acres of hilly pasture. I called my dealer and they said "bring it in, we got a new heat shield". Well they put on a new longer one piece heat shield and replaced the rear cab for no charge. I thought "great, no more melting now!" Then I went back to mowing and experienced even worse meltdown than before, this time the rear cab melted again as well as the under side of the seat which allowed it to drop down onto the airbox breaking off one of the mounting tabs! I called the dealer back up and the service guy called Polaris who said they would have another fix coming and it would be about three weeks. This was about two months ago or so. So last week I called Polaris myself and complained. The next day I had a call back from the complaint resolution guy (Robby) who was very concerned with my problem. He said there is a third heat shield replacement out now along with a computer reflash that is supposed to fix the melting problem. He said the computer reflash advances the timing which causes more complete combustion and less heat in the exhaust. He said it is also good for a power boost and claimed thats where the increased power is coming from on the 08 800's. My quad is now back in the shop for these upgrades plus a new seat, rear cab, airbox and side panel. I do have to pay for 1 1/2 hours labor though ($90). Sounds fair to me since I have been out of warranty for two years!