If we are talking cooling, there are more cooling issues inherant to the design of this motor that drilling a hole in a thermastat isn't going to fix. It all stems from the guillitine style exhaust valve. It was driving me nuts trying to figure out what to do about it. I presented the question to IndyDan at Indy Specialties and wouldn't you know he has it figured out. Trust me it is worth giving him a call. Give him $25 for the idea. It may save your motor.
To me proper cooling is a fail safe. A better piece of mind if you will, but it's likely that something else is causing the melt downs. What is your coolant temp at when it burns down? I bet it never even boiled. Yet you can boil the coolant on a dirt bike and never even have the slightest damage. What is wrong with that picture? Insuffiecient cooling in critical areas.
I doubt the cause is going to be easy to find. They have been all over the board with these sleds and engine failures. And I still don't think Polaris has it figured out. What side of your piston seized?
Check your throttle body boots for delamination. This happens and the motor will suck in all kinds of belt dust and contaminents.
Crank seal was a good suggestion.
Voltage regulator failure.
Make sure the exhaust valve is opening fully.
Could be an injector or ECU issue.
Proper fueling from a PCV will surely help engine temps at certain rpms too.
If you are looking for a piece of mind. Get that green garbage out of the motor and replace it with
Engine Ice . A few years back dirt rider tested a bunch of different coolants. Engine ice showed significantly lower cylinder head temps. Plus it showed that is was dissipating more heat at the radiators. You can translate that into the heat exchangers on our sleds. Why take chances?
My sled runs 122deg 98% of the time. The highest I saw last season was 126 deg on the trail.
What was my piece of mind? Cap the exhaust valves so they can work and not hold heat in the exhaust port.
Aftermarket pistons that actually meet the piston to cylinder clearance that Polaris claims theirs are supposed to have.
IndyDan mod, crankcase mod, crank trueing, clutch balancing.
PCV is a not an option at this point. The piece of mind is worth it alone, but the performance gain will net you more than adding a pipe.
Relocate the capacitor to the shock tower so the voltage regulator can cool better. Also, removed the electronics cover for more airflow.
Sorry I'm babbling. Home sick. Keep us posted as to what you find.