5.11
Engine Systems
5
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
EXHAUST VALVE MAINTENANCE
Exhaust Valve Assembly
Exhaust Valve Disassembly
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.
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.
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.
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
EV spring under tension. Use care when removing
housing from assembly base.
GUILLOTINE
GASKET
EV BASE w/FITTING
BELLOWS WASHER
BELLOWS
CAP NUT
SPRING
COVER
VERTICAL SCREWS
HORIZONTAL SCREWS
Guillotine Cap Nut Torque: 16 Ft.Lbs. (22 Nm)
Cover/Base Fastener Torque: 12 Ft.Lbs. (16 Nm)
SPRING COLOR
LOAD @ 1 INCH
(LBS.)
LOAD @ .630
INCHES
(LBS.)
7041704-01 Blue 4.0 6.0
7041704-02 Orange 5.5 8.3
7041704-03 Pink 4.7 7.1
7041704-04 Purple 3.1 4.7
7041704-05 Yellow 2.4 3.6
7041704-06 White 1.6 2.8
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