Exhaust Valve Maintenance - Polaris 340 LX 2007 Service Manual

EXHAUST VALVE MAINTENANCE

Exhaust Valve Assembly
HORIZONTAL SCREWS
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 two horizontal cover fasteners securing
the valve assembly to the cylinder.
2. Remove exhaust valve assembly from cylinder.
3. Remove the gasket and discard. Remove the two
vertical cover screws to access the spring and
bellows.
4. Secure the guillotine, then apply heat to remove the
bellows cap nut.
5. Separate the cap nut, bellows and bellows washer
from the guillotine.
6. Remove the guillotine from the base.
VERTICAL SCREWS
SPRING
COVER
CAP NUT
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
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)
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
LOAD
SPRING COLOR
7041704-01 Blue
7041704-02 Orange
7041704-03 Pink
7041704-04 Purple
7041704-05 Yellow
7041704-06 White
Engine Systems
= T
= T
@ .630
LOAD
@ 1
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
5.11
5