I ride with a guy who has a Sportsman 600. His frame rubbed a hole in his radiator hose also. I wonder have you guys checked your plugs? If your running lean this can also cause the pipe to get real hot. Another thing if your trying heat shields and stuff. Look in Jegs or Summit racing for header wrap. I haven't used this stuff on a 4 wheeler. But on my drag car, I could change my plugs after a pass without getting burned. The headers were hot of course but they wouldn't burn you. Its a fiber insulated wrap and very easy to install.

 

I second the suggestion for header wrap. I have a pair of 2006 Sportsman 500 EFI and I just completed wrapping the pipe on one of them. I used the Thermo-Tec wrap with the spray stuff that you put on after it is wrapped. My initial impression is that it does a pretty good job of reducing the heat.

Regards,
chad

 

How does header wrap hold up to lots O mud and water ? ( I had a 70 nova with wrap but I "took care of it".) Ceramic coating seems like the best choice. 110 race gas does work nice in my 700- not sure of longterm and its costly,seems to run about 10deg less also!

 

This may be a place for someone that has actually tried it to step in, but I've read of a few people having problems with the the header wrap trapping in moisturing and basically the pipe rots. Too much water/mud compared to a street machine. Anyone ran into this? Again this is hear-say, but something to consider.

 

Cskidmore -

Where do you find the Thermo-Tek wrap?

 

I think Jegs carries it. The spray coating is important becasue it helps seal the warp to keep the wrap from getting impregnated by dirt and derbies. As for getting wet I'm not sure how that would casue rust considering it gets dried out in a matter on minutes. To be safe I would also suggest that you paint the pipes with some 1500 Deg paint before wraping to help eliminate the possiblity of rust. I'm betting the pipes just deterioate faster due to the fact that they do not disipate the heat and get hotter when wraped. The heating and cooling of the mild steel will casue it to rust. The moisture form the cumbustion of the fule will also casue rust on the inside of the pipe. In my experienc most exhaust system rust from the inside out.

 

I found the Thermo-Tec stuff at Napa.

chad

 

I'm assuming you would just wrap over
the muffler barrel? On my 450 the pipe exit of
the exhaust is short 1-2 ", How much and far would
you need to wrap it? Are these instructions provided
with Tek Wrap product?

Thanks,

R'

 

The thermo tek wrap would probably be the best for a 4 wheeler, cost wise. I really don't know the long term effects of this wrap on a 4 wheeler. I was just trying to give some ideas on the heat problem. But as far as wrapping the exhaust, I would do the entire exhaust. But it could be used just where you want a heat barrier. But if you can spring for the extra cash ceramic coating would by far be the best bet.

 

I have the thermo wrap on my 800. I also sprayed it with there silocone spray. I you get it wet it wont stay wet long if your riding it