Exhaust Valve Disassembly; Exhaust Valve Assembly; Optional Exhaust Valve Springs; Reed Valve Disassembly - Polaris 2007 Two Stroke Service Manual

Exhaust Valve Disassembly

CAUTION
EV spring under tension. Use care when removing
housing from assembly base.
1. Remove the vent lines from the exhaust valve base(s).
2. Remove the four cover fasteners (1) securing housing and
the valve assembly onto the cylinder.
3. Remove exhaust valve assembly from cylinder.
4. Remove the exhaust valve base gasket(s) (8) and discard.
5. To remove the guillotine (9), secure the guillotine, then
apply heat to remove the bellows retaining nut cap nut (4).
6. Separate the cap nut, bellows (5) and bellows washer (6)
from the guillotine.
7. Remove the guillotine from the base (7).

Exhaust Valve Assembly

1. Clean the threads of the guillotine with Primer N.
2. Insert the base (7) into the clean guillotine (9).
3. Apply Loctite 242 to first 3 threads on the guillotine.
4. Place the bellows washer (6), bellows (5) and cap nut (4)
onto the guillotine.
5. Torque the cap nut(s) to 16 ft-lb (22 N-m).
Guillotine Cap Nut Torque: 16ft.lb. (22 N-m)
6. Lubricate the guillotine blade and shaft with engine oil.
7. Actuate the guillotine to ensure full and free motion.
8. Install the spring, and cover.
9. Torque the cover/base fasteners to 12 ft-lb (16 N-m).
Cover/Base Fastener Torque: 12 ft.lb. (16 N-m)
= T
= T

Optional Exhaust Valve Springs

SPRING # COLOR
7041704-01 Blue
7041704-02 Orange
7041704-03 Pink
7041704-04 Purple
7041704-05 Yellow
7041704-06 White

Reed Valve Disassembly

1
2
9 ft-lb
(12.2 N-m)
4
5
1
1. Loosen up the hose clamps (1)
2. Remove the carburetor(s) or the throttle body from the
intake boots (4).
3. Remove the intake boot fasteners (2) and hose holders (3)
(if applicable).
4. Remove the intake assembly (4-7).
ENGINE
FREE LENGTH
1.752
1.729
1.734
1.726
1.734
1.537
3
6
7
600 Carb
2
4
5
6
7
600 CFI
5.3
5