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I have a Polaris 500 2006 Sportsman. Ran it for first time last year, got a few 'bugs' out. Then this year, first ride out, my plastic fenders melted!! With some checking, it seems to happen a lot and a bit of a design flaw. The older models have a better design etc. A 'heat kit' has been...

I realize this post was way back but thought I would add my problem. I too have a Polaris 2006 500 Sportsman. I have had the fender melt in the same place. I have compared 2 older Polaris and they have better muffler protection, fenders are different, more clearance etc. they should have...