Polaris 800 ATV - year 2005 - Factory dual exhaust on right side overheats and melts plastic body parts when running below 7 mph

Ojai/Santa Paula California

Polaris 2005 Sportsman 800 –bought Feb. 2006

Factory dual exhaust on right side overheats and melts plastic body parts when running below 7 mph in low gear for extended periods of time.

Dealer has tried to remedy and installed a new Polaris heat shield with no beneficial results. Dealer also wrapped both exhaust pipes with ceramic “header” wrap with no beneficial results. Polaris corporate acknowledges problem, advised that future fixes are in the works (date unknown) and not available now. We requested they buy the ATV back and they won’t. This greatly limits our ability to use the ATV and exposes us to ongoing service issues depending on our use.

NOTE: Our Polaris 500 Sportsman has no similar problems under same use conditions

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I have a 2005 Polaris Sportsman 800 also. I went through the same problems as you are describing. I was told they arent goin to replace the plastic because I waited too long. The only possible solution I can come up with is go to Highlifter.com and get the heat fighter kit and possibly an aftermarket exhaust.