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post #11 of 66 (permalink) Old 03-14-2012, 10:20 AM
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I'd love to paint mine, but think it's to far gone to bother with It is starting to separate at the end seam where the pipe connects to exhaust, but the paint job loos great!

1996 Sportsman 500--- Old be dependable... starts and runs good, just needs tweaking

ITP 25" XL Mudlites
STI HD2 Matte Black Alloy Wheels
48" Polaris Plow
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post #12 of 66 (permalink) Old 03-14-2012, 03:51 PM
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I've actually considered this but had concerns about how long it would last.

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2002 Sportsman 400
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post #13 of 66 (permalink) Old 03-14-2012, 06:04 PM
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Alright. I guess I'll jump in too. My wife's '07 is really shaping up with all the work I have put into over the last year. I currently have the exhaust disconnected. I was trying to replace the front exhaust seal and found the header pipe was warped. New header pipe on order. So how hard is it to thread that exhaust out to clean and paint it. I really don't want to pull it all apart. What's the best way to get it out?

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #14 of 66 (permalink) Old 03-14-2012, 08:07 PM
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Clinebo, CW, anyone? How much disassembly do I have to do to get the whole exhaust off? Do I have to pull the plastics off? Remove the front rack? Pull the radiator? What's it take to get that pipe out for painting? Right now I just have it disconnected so I can reach in and pull the header pipe from the left front wheel well. Don't really see that it is possible to snake it out without some further disassembly. But if it is too much of a pain, I'll leave it alone.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #15 of 66 (permalink) Old 03-14-2012, 08:33 PM
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Mine is the older generation body so its not bad to take the plastic off. In my case I had it all off for the work I was doing, so the exhaust was kind of in the way for other jobs. While I was waiting for parts I just went ahead and did it too. It went back together fast. I had the whole thing back together in 4 hours.

2002 Sportsman 500 HO
Warn 25XT + Bumper
25" Grim Reapers
GoldFinger left hand throttle
and other stuff...
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post #16 of 66 (permalink) Old 03-15-2012, 07:04 PM
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I got a chance to look at this today. I was able to thread the exhaust pipe out after removing the muffler. I had to pull a couple of body fasteners holding the rear plastic on the left side up by the battery. With those out though I was able to twist, turn, and just plain muscle the pipe out. Got the muffler cleaned up with a wire wheel. Going to buy paint and rust converter tomorrow. I will clean the pipe Saturday and hopefully get it painted. Still waiting on the new header pipe.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #17 of 66 (permalink) Old 03-15-2012, 07:09 PM
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[QUOTE=Nitro;174500]I've actually considered this but had concerns about how long it would last.

I did the exhaust on my sled 2 yrs ago and they still look good! It will last longer if you do a good job prepping the metal. The Rust-o-leum paint says on the can that it 'kills' rust. And its rated to 1200 degrees.

2002 Sportsman 500 HO
Warn 25XT + Bumper
25" Grim Reapers
GoldFinger left hand throttle
and other stuff...
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post #18 of 66 (permalink) Old 03-15-2012, 07:17 PM
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Clinebo: I see you said you heated your pipe before painting it. Does that help with paint adhesion?

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #19 of 66 (permalink) Old 03-15-2012, 07:23 PM
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Spray can paint usually says to use at a certain temperature or above. Since its been fairly cold here lately I heated them up a bit. After the first coat I let them sit & dry while I did some other stuff, then gave them a second coat.

2002 Sportsman 500 HO
Warn 25XT + Bumper
25" Grim Reapers
GoldFinger left hand throttle
and other stuff...
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post #20 of 66 (permalink) Old 03-15-2012, 07:48 PM
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Here is what I used...either got it at Wally World or NAPA. Anywho it works good for me. Your mileage may vary......
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2002 Sportsman 500 HO
Warn 25XT + Bumper
25" Grim Reapers
GoldFinger left hand throttle
and other stuff...
Clinebo is offline  
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