Locked2007 polaris 800 Sportsman

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hickory hollow
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2012/09/20 16:58:59 (permalink)

2007 polaris 800 Sportsman

I have a 2007 Polaris Sportsman 800. I have had exhaust heat issues. The right side panel and seat have been damaged by the heat from the exhaust. I have also had to replace exhaust pipes and doughnuts. Does anyone know of a way to fix this issue. I understand it is a common problem.
post edited by hickory hollow - 2012/09/20 17:00:46
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    Sweet_Tooth
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    Re:2007 polaris 800 Sportsman 2012/09/20 17:06:19 (permalink)
    Three things.
     
    1. Welcome to the forum
    2. Get yourself some exhaust wrap, a radiator fuild additive like Purple Ice and stick with synthetic oils to keep temps low.
    3. This belongs on the manufacturer section but you are new here so no biggies.

    Lucas

    Fact: God hates fanboys!!

    * 07' Suzuki Vinson Manual w/ Lots of Goodies
    * 11' Polaris Sportsman 800 "Value" w/ some mods
    * 12' Polaris RZR S Liquid Silver LE w/ some mods
    * 12' Polaris Phoenix 200 with some mods (son's)
    * 09' Polaris Sportsman 850XP just a winch for now
    * 04' Honda Foreman 4x4 ES.. My current pain I mean restoration 

    There’s an unequal amount of good and bad in most things, trick is to figure out the ratio and act accordingly.
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    BridelessRacing
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    Re:2007 polaris 800 Sportsman 2012/09/20 17:09:55 (permalink)
    5 oz of JB engine tune up in oil
    5 oz of JB radiator cool in radiator
    Header wrap on exh head pipes
    From head all the way to muffler
    Doing these things is a noticeable help


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    hickory hollow
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    Re:2007 polaris 800 Sportsman 2012/09/20 17:14:07 (permalink)
    Thanks for the input. This will help with the heat issues but what will fix the problem with the exhaust pipes going out of round and causing the exhaust to be very noisy?
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    BridelessRacing
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    Re:2007 polaris 800 Sportsman 2012/09/20 17:33:20 (permalink)
    New donut gaskets yearly
    Unless pipe is bad


    2009 Yamaha griz eps project underway
    http://forum.highlifter.com/m4888660.aspx
    Don Oglesby on facebook

    http://forum.highlifter.com/hooptie-3-m4910341.aspx
    usefull
    http://forum.highlifter.com/lil-300-build-for-neighbors-kid-m4662713.aspx
    http://forum.highlifter.com/Marengo-upgrades-for-the-88-300-honda-m4746992.aspx
    [link=http://forum.highlifter.com/kids-tire-true-mud-tire
    420 gr
    [link=http://forum.highlifter.com/tm.aspx?Honda-420-secondary-gear-reduction-install-info&m=3935365&high=420+gear+reduction+install&mpage=1]http://forum.highlifter.com/tm.aspx?Honda-420-secondary-gear-reduction-i
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    Sweet_Tooth
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    Re:2007 polaris 800 Sportsman 2012/09/20 22:27:13 (permalink)
    BridelessRacing

    New donut gaskets yearly
    Unless pipe is bad


    ^Agreed and I'm leaning towards a bad pipe cause of the constant heating and cooling cycles specialy if the bike was running on the water.

    Lucas

    Fact: God hates fanboys!!

    * 07' Suzuki Vinson Manual w/ Lots of Goodies
    * 11' Polaris Sportsman 800 "Value" w/ some mods
    * 12' Polaris RZR S Liquid Silver LE w/ some mods
    * 12' Polaris Phoenix 200 with some mods (son's)
    * 09' Polaris Sportsman 850XP just a winch for now
    * 04' Honda Foreman 4x4 ES.. My current pain I mean restoration 

    There’s an unequal amount of good and bad in most things, trick is to figure out the ratio and act accordingly.
    #6
    switzomatic
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    Re:2007 polaris 800 Sportsman 2012/09/21 02:31:39 (permalink)
    Went through the same issue (minus the pipe warping) with my  05 800. Hounded Polaris enough (was well out of warranty) that they gave me the upgraded heat shield and new side/rear plastic with upgraded heat tape on them. Polaris knew about the heat problem from the start so keep on them! Also, going to a true dual exhaust helps a lot-did that on my 09.

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