After a very dusty ride of 55 miles, I feel the dust issue was made worse by the 1/2 height windshield. The air cleaner (Moose Racing foam/paper) was choked with dirt. The filter had 200 miles on it, trashed it and replaced with another Moose Filter. Have tried a Uni foam unit (found dust beyond the filter), also a stock filter with an aftermarket sock (clogged after 300 miles). I have never had a good experience with K&N air filters in any vehicle.
The stock air box was full of dust as was the CVT housing. Blew all the dust out of the clutch and replaced the belt (no appreciable wear, just erring on the side of caution). The stock air intake port is hopelessly undersized to provide adequate air flow to both the fuel injection and the CVT. I added the Grumpy Mod, a vast improvement in air flow!!!! Used a Fram CA3916 filter, will carry a spare so I don’t have to try to clean a K&N on the trail. Still looking too design a grill for the filter, or perhaps something aftermarket.
I used a K&N (KN-198) oil filter with the last change. Noticed excessive "clatter" from the engine for about 15-20 seconds every time after starting. The K&N lets the oil drain back into sump when the engine is stopped. Went back to the stock Polaris filter and the problem has been eliminated. I change all fluids every 1,000 miles.
Checked the exhaust pipe temps after running 10 minutes. 690 deg 2" from head exhaust port, 370 deg 16" from exhaust port, 270 deg at muffler 3" from inlet. Wrapped muffler with Cool-it exhaust tape, no change in pipe temps afterward, but muffler was 110 deg 3" from inlet. My 800 has a stock heat shield below the bed, but I may increase the size of it later on.
Like many others I found the slit in the PCV hose. It is pure hillbilly (the best I can say on a public forum) engineering. Covered the slit with heat shrink tubing. It rarely gets cold enough anywhere in Nevada to worry about freezing water in the hose. If it ever does, I won’t be riding on that day!!!!
Installed NGK Iridium plugs. The engine appears to run smoother. Will check fuel mileage on my next ride.
