Exhaust Valve Maintenance; Exhaust Valve Assembly; Exhaust Valve Disassembly; Optional Exhaust Valve Springs - Polaris IQ 2007 Service Manual

Engine and Cooling Systems

EXHAUST VALVE MAINTENANCE

Exhaust Valve Assembly

BELLOWS
BELLOWS WASHER
EV BASE w/FITTING
GASKET
GUILLOTINE

Exhaust Valve Disassembly

CAUTION
EV spring under tension. Use care when removing
housing from assembly base.
1. Remove the vent hose from the base.
2. Remove the two horizontal cover fasteners securing the
valve assembly to the cylinder.
3. Remove exhaust valve assembly from cylinder.
4. Remove the gasket and discard. Remove the two vertical
cover screws to access the spring and bellows.
5. Secure the guillotine, then apply heat to remove the bellows
cap nut.
6. Separate the cap nut, bellows and bellows washer from the
guillotine.
7. Remove the guillotine from the base.
Exhaust Valve Assembly
1. Clean the threads of the guillotine with Primer N.
2. Insert the base into the clean guillotine.
3. Apply Loctite 2760 to the first 3 threads on the guillotine.
4. Place the bellows washer, bellows and cap nut onto the
guillotine.
5. Torque the cap nut to specification.
Guillotine Cap Nut Torque: 16 Ft.Lbs. (22 Nm)
5.12
VERTICAL SCREWS
HORIZONTAL SCREWS
SPRING
COVER
CAP NUT
= T
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 vertical cover fasteners to specification.
Cover/Base Fastener Torque: 12 Ft.Lbs. (16 Nm)
10. Install a new gasket on the cylinder, then install the EV
assembly. The guillotine shaft will only fit into the cylinder
the correct way. If the shaft will not slide in, verify it is
installed correctly.
11. Torque the horizontal cover screws to specification.

Optional Exhaust Valve Springs

SPRING COLOR
7041704-01 Blue
7041704-02 Orange
7041704-03 Pink
7041704-04 Purple
7041704-05 Yellow
7041704-06 White
= T
@ .630
LOAD
@ 1
LOAD INCH
INCHES
( .)
LBS
(
LBS
4.0 6.0
5.5 8.3
4.7 7.1
3.1 4.7
2.4 3.6
1.6 2.8
.)