Hey guys,

On my 2007 Polaris Sportsman 800 i have had a recoccuring exhaust donut problem. I dont know what actually happens to it but after about a month or 2 of use it begin to let air out again and crack apart chunks at a time untill all that is left is a metal mesh type thing. It makes my machine backfire and sputter when engine braking and also makes it alot louder. Has anyone else had this problem and how should i go about fixing it for good. I'm hoping its a recall of some sort.

 

Check motor mounts for damage(engine torqueing excessively),locktite exhaust manifold bolts,check for spring stretch and also underneath pipe there is a pipe support bolt and small rubber insulator, make sure it supports pipe snug! Good luck

 

There is an update for 05-07 800's where they reprogram the computer to lower exhaust temps.Don't know if yours has it or not,but might be worth checking into.

 

thats news to me about the computer reprogram. its not a recall or anything im guessing and this is the first ive heard about it.

 

<div class="FTQUOTE"><begin quote>Originally posted by: stendori

thats news to me about the computer reprogram. its not a recall or anything im guessing and this is the first ive heard about it.</end quote></div>

I just read in another thread about the new 800 heat megashield from Breese Lawn and Garden and in it they say about the new calibration for lower running temps.

 

They remap the computer and make them richer wich lowers temp.

 

Thanks alot guys i think ill start by changing the springs, getting a new donut and checking all the engine mounts. However if it happens again i think ill go with this reprograming. How do i go about getting it reprogrammed for lower temps and does it cost me anything?

 

It's the heat. You have 2 cylinders of exhaust coming out of the manifold verses just 1 on the single cylinders. I hate to say it would be called normal but it can be expected. You have that happen on single cylinders as well but not near as often. If you are running too lean it will cause more heat. A friend replaces his exhaust donut atleast once a year.

 

I have to change the donut almost once a month though, and what are some signs of your engine running lean and some signs of your engine running rich maybe one of these is the problem.