melting plastic - Polaris Riders


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Old 07-15-2007, 03:27 PM   #1 (permalink)
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Default 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.
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Old 07-15-2007, 05:15 PM   #2 (permalink)
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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!
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Old 07-16-2007, 10:15 AM   #3 (permalink)
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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.
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Old 07-18-2007, 07:33 PM   #4 (permalink)
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I may make some brackets to keep the plastic away from the exhaust.
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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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Old 12-21-2007, 07:30 PM   #5 (permalink)
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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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Old 12-22-2007, 10:12 PM   #6 (permalink)
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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.
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