Category: Motorsport

On many bikes the headers run right past your leg, boot and side covers. Motorcycle exhaust wrap cuts the heat that radiates off those pipes. You feel less of it at the lights, nearby plastics and wiring run cooler, and the bike gets the wrapped look plenty of riders are after.

This guide covers why riders wrap, the pros and cons, which wrap and colour to pick, how much to buy and a seven-step fitting method. You will find every material and roll size in the Kool Wrap exhaust heat wrap range.

Why riders wrap their exhaust

• Leg and boot heat. A wrapped header radiates less heat onto your leg, which you notice most in slow traffic on a hot day.
• Fairing and side cover heat. Plastics and painted panels near the headers see less radiant heat.
• Nearby parts. Wiring, sensor leads, hoses and fuel lines routed near the pipe run cooler.
• Looks. Wrap comes in black, white, natural and graphite black finishes.

Pros and cons of bike exhaust wrap

Two points matter more on a bike than a car. First, bikes get wet. Rain, washing and dew all soak into wrap. After a wet ride or a wash, ride long enough to get the pipes fully hot and dry the wrap out.

Second, wrap is not a burn guard. The outer surface still gets hot enough to burn skin, so do not rely on it to protect a pillion’s leg or a child’s calf.

Which wrap and which colour

Standard fibreglass

Standard fibreglass exhaust wrap is rated to 540°C continuous and 980°C intermittent. It comes in black, white and natural (light tan) at 1.5mm thick, in 25mm and 50mm widths. It is a good fit for road bikes that see normal riding.

Vermiculite coated fibreglass

Rated to 650°C continuous and 1,090°C intermittent, in graphite black. It comes in 50mm width only, so it suits bikes with larger pipes.

Titanium basalt fibre

Titanium basalt fibre exhaust wrap is rated to 980°C continuous, the highest in the range. It comes in natural and black, with 25mm rolls in 4.5m and 10m for pipes up to about 37mm, and 50mm rolls in 7.5m, 10m and 15m for larger headers. Choose it for high-performance bikes and track use.

Picking a colour

Black suits blacked-out and dark bikes. Natural gives a classic, retro look. White looks sharp when new but shows road grime and oil quickly.

Picking a width

Use 25mm wrap on pipes up to about 37mm (1.5in) diameter and 50mm on larger pipes. Narrow wrap follows tight header bends more neatly.

How much exhaust wrap for a motorcycle

Measure the length and diameter of each pipe you plan to wrap. Then use the wrap formula in our step-by-step exhaust wrap install guide and add about 10% for bends and tie-offs.

Here is how that works on a bike with 38mm headers, each about 1m long. At 38mm the pipe is just over the 37mm boundary, so 50mm wrap is the default.

Smaller pipes at or under about 37mm take 25mm wrap, which follows tight bends more neatly. It uses a lot more of it, roughly 7m per metre of pipe against 3.2m for 50mm, so budget for that if you choose the narrow wrap.

Roll lengths differ by material. Standard fibreglass has a 4.5m option, while vermiculite and 50mm titanium start at 7.5m. Measure the length and diameter of your own pipes before you order, because header runs vary a lot between bikes.

Allow at least two stainless ties per pipe, one at each end. Rolls include ties, and you can buy extra from the stainless steel ties range.

How to fit motorcycle exhaust wrap in 7 steps

1. Remove the headers

Let the bike cool completely, then undo the header nuts and hangers and take the pipes off. Wrapping on the bench is far neater than wrapping on the bike. If your bike has an O2 sensor in the header, remove it or mask the boss so you can leave that area bare.

2. Clean and paint

Degrease the pipes and wire brush any loose rust. Coat mild steel pipe with high-temperature exhaust paint and let it dry. Stainless pipe only needs to be clean.

3. Prepare the wrap and plan the route

Put on gloves and long sleeves. Dampening is optional, since Kool Wrap wraps do not need wetting, but a light spray makes the wrap easier to pull tight and keeps fibres down. If you dampen it, run the engine soon after so the heat dries the wrap out. Do not leave damp wrap sitting on the pipe. Mark where hangers and brackets sit so you know where to stop and restart.

4. Start at the narrowest end of the pipe

Fold the first few centimetres of wrap back on itself and lock the fold under the first turn. The cut end stays hidden and will not fray.

5. Wrap with even tension and about 6mm overlap

Pull firmly on every turn. Keep the outside of each bend fully covered. At a bracket or hanger, tie off on one side and restart on the other.

6. Tie off with stainless ties

Fit a tie at every start and finish point and pull it tight with pliers. Turn the lock to the back of the pipe, away from your boot, and trim the tail. Optionally seal the wrap with high-temperature exhaust paint to lock down loose fibres.

7. Refit and heat cycle

Refit the headers, using new exhaust gaskets if the old ones are crushed. Check the wrap clears fairings, side covers, the frame and the rear brake. Start the bike outdoors. Light smoke and a smell on the first ride are normal as binders in the wrap burn off, and they clear after the first few heat cycles. Recheck the ties after the first few rides.

Smoke that continues after that, or smells of oil or fuel, points to contamination or a leak. Find the source before you ride on.

Heat shields and heat sleeves near wiring

Wrap works on the pipe. For parts that sit close to it, use a product made for the part.

• Heat sleeves protect wiring, sensor leads, hoses and fuel lines. They come in open seam and closed seam versions, so check the product pages for the one that suits your loom.
• Fibreglass-backed aluminium tape suits the inside of motorcycle fairings. It reflects 95% of radiant heat and withstands up to 454°C radiant heat. Stick it on the panel, never on the pipe.
• Adhesive heat shields cover larger panels near the headers. Never stick an adhesive shield directly onto an exhaust pipe.

Motorcycle exhaust wrap FAQs

What does exhaust wrap do on a motorcycle?

It keeps heat inside the header instead of letting it radiate onto your leg, your boot and the panels around the pipe. Riders notice the difference most in slow traffic on a hot day. It also keeps wiring, sensor leads and fuel lines routed near the pipe cooler.

Why wrap a motorcycle exhaust?

Three reasons. Leg and boot heat in traffic, protecting plastics and wiring that sit close to the headers, and the wrapped look. On a bike the first reason is the one most riders act on.

How much exhaust wrap do I need for a motorcycle?

On typical 38mm headers about 1m long, allow around 3.2m of 50mm wrap per pipe once you add 10% for bends. A single cylinder takes a 4.5m roll, a twin about 6.4m and an inline four about 12.8m. Narrow 25mm wrap on smaller pipes needs roughly double that length. Measure your own pipes before you order.

How do you install exhaust wrap on a motorcycle?

Take the headers off, clean and paint mild steel, then start at the narrowest end with the first few centimetres folded back under the first turn. Wrap with even tension and about 6mm overlap, tie off with stainless ties at each end, and refit with fresh gaskets. Expect light smoke on the first ride.

Does motorcycle exhaust wrap cause rust?

Wrap does not cause rust, but it holds water against the pipe, and bikes get wet. On bare mild steel that speeds up rust. Paint mild steel headers with high-temperature exhaust paint before wrapping, and after a wet ride or a wash, ride long enough to dry the wrap out.

Will exhaust wrap stop my leg getting burnt?

No. Wrap lowers the radiant heat you feel from the pipe, but the outer surface still gets hot enough to burn skin on contact. Treat a wrapped pipe exactly like a bare one, and do not rely on it to protect a pillion.

Need help choosing?

Want to check how much wrap your bike needs, or which colour and width suit your pipes? Call Kool Wrap on 1300 44 33 34. For car and 4WD systems, and the full calculation method, see the step-by-step exhaust wrap install guide. Rolls, ties and paint are in the exhaust heat wrap range.