How far do you wrap the header, I have a 700 efi. Do you wrap all the way from the head to the muffler or stop at the end of the fender?

 

I wraped mine from the flange to the where it goes into the muffler. Than I also sprayed it with the silcone spray.
Then took the leftovers and used black wood stove silocne and made a liner on the plastic.

I have no complaints so far.

 

It is not just happening to the 800's I have an 05 500 HO and I had the plastic replaced once already and now it is melted right through again, but it is off warranty.

 

Just wondering still what YEAR SP you had the fuel leak?

You out there CANYONCRAWLER?

 

I don't think it makes a difference that you are out of warranty. You are entitled to a proper repair!......and obviously you didn't get one!

 

I have an 05 800, and have had the same problem with mine They have replaced the plastic 2 times Once when it was under warranty and then again because I have a great dealer that was abhle to get warranty for me. One of the things the Factory recommended was some sort of snubber to hold the plastic away from the Exhaust. It was a part from a Ranger. well it worked great until the pressure againt the plastic broke the plasrtic and agin it was melting.. Yes this is an ongoing problem I am printing off this page and taking it with me on my next trip to the dealership. So far My Dealer has done everything they know to do. I have recently wrapped the exhaust with Header wrap. I havent had out long enough since that time to see how it helps.
Good luck Keep informing your dealer!!

 

hurry up n put me down in your will for the sportsman ........lol