Hey has anyone out there been having problems with melting plastic?? My 700EFI just about caught fire the other day. The plastic cover melted so bad that I can't snap a new cover on. Just wondering if anyone else has been having problem? cuz now I have problems riding without burning my thighs. Let me know if you too have had problems. Polaris doesn't seem to think that this is a defect -- HELLO ever hear of heat sheilds????

Yes. My new Polaris Sportsman 450 had the exhaust pipe melt through the plastic causing an injury (burn to leg). By searching, I've found many other owners with the same problem on several models. Almost everyone I've seen at the dealer's have the pipe up against the plastic where your leg rests. I also found that Polaris has had issues with the Consumer Product Safety Commission for not reporting or addressing serious issues like this that can obviously cause injury.

I made a report to the CPSC, and I suggest you do to before another person gets burned. You can do it on-line:

http://www.cpsc.gov/talk.html

I just picked up an '06 700 EFI, and want to make sure I don't have this problem. Do you know where I can pick up some heat shielding material and install it myself?

Thanks!
Mike