melting plastic - Polaris Riders
 
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post #1 of 6 (permalink) Old 07-15-2007, 03:27 PM Thread Starter
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Join Date: Jan 2006
Location: Frankfort
Posts: 800
melting plastic

After riding yesterday and cleaning my 800 today, I noticed that I have somehow melted some of the plastic that is under the side panel on the exhaust side. Has any one else had this problem.

We rode double all day, so I wonder if it was my fault where I was scooted up so far on the seat that I pushed it into the exhaust shield.

2005 Sportsman 800 Black and Silver,
Uni Air Filter, Spider Grips, Polaris Handgaurds, Quadovator 3-HL mod, Kolpin Jr. Fuel Pack, Front and Rear Stickstoppers, Bodygaurd Front & Rear racks, Bodygaurd Rear Brushgaurd, L&R Cargo Box w/ Backrest & cargo bags, Front Warn 2.5Ci Winch and rear Warn 2.5Ci Winch on custom mount plate, custom rear hitch w/ 12v outlet.(Elkbow Edition)

2006 GMC Yukon, DVD, Touch Screen Navigation, BOSE & XM radio, Leather, 3rd row seating, 285/70R17 (32x11.50) BFG All-Terrains, 15% Formaula-One Pinnacle Window Tinting
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post #2 of 6 (permalink) Old 07-15-2007, 05:15 PM
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Join Date: Feb 2006
Location: Jacksonville
Posts: 129
This is a common problem with the 700 and 800 Sportsmans. I went to High Lifter and searched "Melting Plastic" under the polaris section and it gave me pages of threads that people have started about it.

Here is a link to one of them I looked at:
http://www.highlifter.com/forum/m_1649799/mpage_1/key_melting%2cplastic/tm.htm#1650856

From what it looks like is that there is an updated new heat shield to install along with some new heat tape that fixes it. You can also header coated from jet-hot to keep it cooled downed.

Just read that thread and try some of those ideas.

Hope this helps some. Good luck and keep us updated!

04 Polaris Sportsman 500 HO. 4x4
27" Mudzillas, HL Lift Kit, Warn 2.5ci Winch, Polaris Double Tube Front & Rear Bumpers, Rear Tow Hook, K&N Air Filter w/Outerwear, Snorkeled Overflow Bottle & Moose Pro-Deluxe Bag.

Dirtbmw20 Radiator Relocate Bracket & Front Turner Cycles CV Axles on the way!

http://www.badsportsman.20m.com
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post #3 of 6 (permalink) Old 07-16-2007, 10:15 AM
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Join Date: Oct 2006
Location: Towanda
Posts: 427
I lost a piece of "tin" yesterday while riding. When I got home to wash the 800, it was laying down under the header on the frame. Not sure where it came from either. I am sure that I am going to have a melting issue if I dont find where it went and replace it.

06 Sportsman 800, handguards, gun scabbard, Polaris double tube front bumper, polaris double tube rear bumper, High lifter lift kit.
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post #4 of 6 (permalink) Old 07-18-2007, 07:33 PM Thread Starter
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Join Date: Jan 2006
Location: Frankfort
Posts: 800
I may make some brackets to keep the plastic away from the exhaust.

2005 Sportsman 800 Black and Silver,
Uni Air Filter, Spider Grips, Polaris Handgaurds, Quadovator 3-HL mod, Kolpin Jr. Fuel Pack, Front and Rear Stickstoppers, Bodygaurd Front & Rear racks, Bodygaurd Rear Brushgaurd, L&R Cargo Box w/ Backrest & cargo bags, Front Warn 2.5Ci Winch and rear Warn 2.5Ci Winch on custom mount plate, custom rear hitch w/ 12v outlet.(Elkbow Edition)

2006 GMC Yukon, DVD, Touch Screen Navigation, BOSE & XM radio, Leather, 3rd row seating, 285/70R17 (32x11.50) BFG All-Terrains, 15% Formaula-One Pinnacle Window Tinting
schneble_ky is offline  
post #5 of 6 (permalink) Old 12-21-2007, 07:30 PM
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Join Date: Jun 2007
Location: Dracut
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I have had this same problem on my 07 sportsman 500 H.O> Im kinda glad to hear that other people have this problem so i know it wasn't something i did.. i noticed this happened right after i bought the machine and told my buddy who sold it to me it happened.. he works at at a dealership never saw that before.. so ya the exhaust is screwing up that cover and melting it for sure. i even had to break the alignment plastic piece on it to get it off cause it had melted to the exhaust. lol
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post #6 of 6 (permalink) Old 12-22-2007, 10:12 PM
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Join Date: Jul 2006
Location: st. charles
Posts: 67
My 06 500 did the same thing. Melted that whole alignment snap off.

I just pushed the pipe over bending the mounting points a bit to get it farther from the plastic. A little too late but at least it aint melting it more. I have to use a screw to hold the side cover on now.

99 sp335
00 mag500
06 sp500HO
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