I have noticed when I am above half throttle for a while that my exhaust pipe gets orange in color. It happens right at the bend before it heads straight back. I don't think that this is normal as I am definitely moving down the trails at a decent speed. Is there a way I can tell if it is plugged? I tried to pull the plug on the muffler but couldn't not get it out. Is there a trick to getting that out? Any suggestions would be appreciated.

Also, are there any better lights we can put on these? I would like to get something that is a little brighter than the stock headlights.

Thanks
Jeff

 

Sounds like your running lean, did you just put in any aftermarket airfilters or do anything differant? I wouldnt run it to much like that before figuring out what the problem is. You might have to put in a bigger jet, stock is 162.5. As far as the exhaust cleanout, try pb blaster and put some a$$ into it, mine was REALLY tight, to the point I thought it was going to strip or break. Do a search for three headlight mod, it turns on hi and low beams when hi beam is selected, and low stays the same with just the bottom 2 lights on. You can buy a kit from ebay for like $5, but if you do a search im sure you will be able to do it without buying a kit. Good luck.

 

So, I have the wheeler like halfway apart right now. I have the plug pulled and the exhaust apart. The exhaust is clean, looks very good. The only thing I'm worried about is getting that plug back in. It looks stripped, but I think it will go. Maybe the previous owner had it out and stripped it while putting it back in. I'm not sure. The spark plug looks perfect and the gap is perfect. The only thing I noticed was that the model number on it was different than what the service manual says. The service manual says to use an NGK BKR5E. Mine has an NGK BKR6E in it. What is the difference in that? So, with all of that said...I'm still stumped as to why my exhaust gets orange hot. Any help is appreciated!

 

Thats funny, I just went riding with my bud last night. He has a brand new 800x2 and I noticed his headpipe was glowing also. He is gonna talk to the polaris dealer today. I will let you know what they say. The quad only has 25 miles on it, man was he jacked. What are you ridin anyway?

 

Hmm, that is very interesting! Please do let me know what they have to say. I have a 2001 Sportsman 500HO. I bought it used. I believe it has about 1400 miles on it.

 

I talked to my bud today, he said that the dealer told him that was normal. I hardly doubt that it is normal for the head pipe glow orange. I think they just dont want to mess with it even though it is brand new. I will let you know if I find anything else out.

 

Yeah, I've been kind of getting the same answer out of people I have been asking. I don't think it is normal though. I either here it is running lean or it is normal. I don't know what to think.

 

If I were you I would try the spark plug that it calls for and see if it does the same thing, if it does I would try putting in a 1 size bigger main jet. Like I said before stock should be a 162.5. Keep me posted

 

I put a new plug in it last night and ran it out in the field for a little bit. It still gets orange.