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The exhaust system on some model axys's are not quite round. You have to remember that these exhaust systems are mass produced for Polaris then sent to them. When the workers put it on the sled during assembly,they don't check to see any to see if the holes are perfectly round and that's probably not part of their job any ways.
Seems like a few of these need tighter QC in my opinion. The holes should be checked to be somewhat perfectly round before assembly on sled.
A imperfect seal has a huge effect on the sled and usully always makes it down in power cause of this.This was all found out on the dyno with pipe temp showing on digital wrench.
The pipe female outlet on this particular model were it joins to y pipe was out of round more than 0.060" (about a 1/16"). This is a big deal as the seal cannot make up for this amount of a gap. If it was out maybe 0.020" or under the seal along with 1500f pipe sealant can probably seal it.
Also, the female outlet on the muffler were it excepts the pipe had a bad weld from factory that distorted the hole over 0.050" out of round.
These were all fixed and the seal is proper.
Without a proper seal the exhaust system isn't doing it's job. This one showing couldn't build up pipe heat on the dyno, and when you can't build up pipe heat, there is no power.
Check yours, the obvious signs are black oil inside your belly pan.
