[Trailbuster]

Removing the exhaust on my quads is fairly easy. I sand them down with a 220 grit and then once over with steel whool, dust off and wipe down with denatured alchahol, paint with high heat black. Im a winter rider so need to maintain once a year. Rusty exhaust just stands out to much.

 

[Sporty500HO]

I used header paint by VHT on my muffler after I modified it. It supposed to stand up to 2000 degrees!! Picked it up at O'reily's auto parts for around 8 bucks a can. Comes to many different colors. I used flat black

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[wolf]

I never should have started reading this . I have a 2003 sportsman 700 twin, after reading this I think im going to give my exhaust a make over, can you tell me how much trouble it is to take the exhaust off this bike.

 

[Clinebo]

I think our models are similar enough. I had almost all my plastic off,but I was doing a valve check and clutches too. For just the exhaust I'd pop off the side cover, and unbolt the shifter rods from the front shifter handle box. You might want to go ahead and pull the rear rack off and unbolt the rear plastic so you can move it out of the way. A spring tool helps get those pesky springs off and back on. Harbor Freight had them for a few $$$.

 

[wolf]

Thanks Clinebo. Im going to give it a go next week.

 

[KICKER431]

I never should have started reading this . I have a 2003 sportsman 700 twin, after reading this I think im going to give my exhaust a make over, can you tell me how much trouble it is to take the exhaust off this bike.

Ha. same thing happened to me. Except I already had mine disconnected to change the header pipe. But while I am waiting on the header pipe .... Now I have an appointment to meet a friend in the morning to use his sandblaster.

Your machine is a little older than the one I am doing but I was able to take the springs off that are holding the exhaust together. Then loosen the bolts holding the muffler on and slide it off. (HINT: you don't have to pull the bolts completely off. The holders on the muffler are notched to slide out from under the bolt heads once it is loosened. I thought that was way cool).
I pulled the side panel off and loosened the rear plastics by pulling the fasteners where it attaches to the frame by the battery. Oh yeah, and I had to remove the shift linkage from the lever to the tranny. but that is easy.
From there I was able to snake out, twist out, pry out, and generallymuscle the exhaust out the back without too much trouble.
Good luck.

 

[Clinebo]

"Endeavor to Persevere"

 

[Kalani938]

Wow, didn't think this would be such a popular thread when I started it! LOL. Sorry guys I still haven't found the time to remove mine, but I have been scoping out some high heat paint to use for the job. I think I'm spoiled b/c removing the exhaust on my YZ450F motocross bike used to be so easy. LOL

 

[Amccoy]

Wow, didn't think this would be such a popular thread when I started it! LOL. Sorry guys I still haven't found the time to remove mine, but I have been scoping out some high heat paint to use for the job. I think I'm spoiled b/c removing the exhaust on my YZ450F motocross bike used to be so easy. LOL

I used rustoleum high heat and it has worked great.
Sandpaper-wipe clean-spray 3 coats. Easy!
Of course removing your specific exhaust might be more difficult...

 

[KICKER431]

yeah, way to go Kalani. You ask a simple question form Texas. Next thing you know some poor schmuck in Northern New York is spending 2 hours of his Saturday Morning sandblasting his wife's exhaust. It was a really great suggestion though. Thanks.

 

[wolf]

Well guys I picked up a couple cans of Tremclad High Heat Enamel (flat black) going to give it a go over the weekend.

 

[5254]

Thanks for the ideas, and pics. Was the exhaust hard to get off?

 

[KICKER431]

The axhaust is easy as pie to get off. Especially if you have a spring tool. ( Headlight/Brake Spring Hook ) There are 2 springs holding the pipe to the header, one holding to to the bushing/ vibration dampener, and 2 holding to to the muffler. The muffler has 2 bolts that you you only need loosen, not remove, and the muffler then pivots and slides off. After that, as long as there is no rear bumper in the way, you can twist and cajole the pipe out the back with only some minor prying around ther rear fender. Oh, you do have to disconnect the shifter linkage but that doesn't even require tools. If you are removing the header pipe, I highly recommend a ball end, long, hex socket. Basically a long ball ended allen wrench on a sicket so you can hook it to your ratchet. The only way to reach the allen bolts holding the header pipe on the engine block. Soak them good with PB Blaster a day or two before you try to pull the header pipe.

 

[domsmith]

Rusted Exhaust

Hello..
The rust is caused through oxidation. Most of the rust on this exhaust seems to be accumulating right here. The reason we have this corrosion is 'cause we have dissimilar metals. The pipe and the bolt are two different metals--similar, but different. And that's where the oxidation takes place. Thanks..
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Have a look at: plastic pipe | square plastic tube

 

[5254]

So, would it be a good idea to pull an exhaust bolt out of the head, and get good quality stainless steel, so it is easier to get out later on?

 

[Clinebo]

Or put a little Anti-seize on the threads when you put the bolt back in.

 

[5254]

Or put a little Anti-seize on the threads when you put the bolt back in.

Copper antiseize?

 

[polarisinnepa]

Ok THANX for feeding my OCD..

Hey kalani.. thanx.. thought i had just about everything about my quad maintained and under control 'till i read ur thread.. I immediately went to the garage and looked at the exhaust and said "holy s**t" that looks terrible .. LOL.. Now, one week later the entire exhaust is off the quad, sanded, scrubbed,cleaned with denatured alcohol, primed and painted with high temperature header paint and waiting to cure so i can put her back together .. gonna look great.. again THANX:top:

 

[Kalani938]

Question, is there a high heat primer that needs to be used or just a regular primer with high heat paint? It would be cool if someone could make a step by step tutorial with pics to post on here

 

[5254]

Question, is there a high heat primer that needs to be used or just a regular primer with high heat paint? It would be cool if someone could make a step by step tutorial with pics to post on here

I would love to see that also.