Cleaning exhaust valves, how to

mountainhorse · Dec 9, 2008

Polaris recommends cleaning the valves every 500 miles... Its a good idea!!

Remove and discard the gasket (do not be tempted to reuse the old one... no matter what. (#5)

Reverse the procedure...with new gaskets

900's and 2006 700 (755's)

NOTE: If you have the original Bellows in your 2005... change them out to the newer models that are more tear resistant.
Part number #5412733 for the updated one... about $22 each

EDIT: The updated bellows are Orange in color... the orginal bellows in the 2005 sleds were Black... replace the black bellows if you have them.

NOTE: Exhaust valve springs are spring loaded. Hold cover in place until all bolts are removed.
If the spring stays in the cover, hold the cover and twist the spring in a counterclockwise direction
while pulling the spring. Do not distort the spring upon removal.

900/755 LIBERTY VES DISASSEMBLY
1. Carefully remove theVES cover bolts (A) cover (B) and spring (C), do not distort the springwhen removing it from the cover.
Spring is under pressure, hold cover tightly against the assembly when removing the cover.
2. Remove the bellows nut (E), bellows (E) and bellows washer (F).
3. Remove the base bolts (K) and remove the base assembly (G) and guillotine (J) from the cylinder.
4. Remove the gasket (H) from the VES base (G) and clean the guillotine (J) with carbon clean or oven cleaner.
900/755 LIBERTY VES ASSEMBLY
1. Place a new gasket (H) on the valve base (G).
2. Place the guillotine (J) in the valve base.
3. Insert the base bolts (K) and torque to 12 ft. lbs. (16 Nm).
4. Place the bellows washer (F) and the bellows (E) on the valve base.
5. Apply Loctite 242 to the bellows nut (D) and torque to 12 ft. lbs. (16 Nm).
6. Install spring (C) and valve cap (B) on to the base and torque the cover bolts (A) to 9 ft.lbs. (12 Nm).

Exhaust Valve Cleaning
The exhaust valve guillotines must be cleaned to ensure
maximum engine performance and throttle response.

-- Carefully extract the guillotine out of the cylinder. Discard
the gasket.
-- Using a clean rag or shop towel, remove the oil residue from
the cylinder, guillotine, and EV base.
-- Inspect the guillotine for signs of damage. Replace
guillotine if damage is found, and inspect the cylinder and
piston for damage.
--Clean the guillotine with brake cleaner and a piece of fine
steel wool. Clean only to remove hardened carbon deposits.
--Once clean, rinse blade with mild detergent and water. Dry
completely.
-- Install a new gasket, then reinstall the EV assembly. Apply
Loctite 242 to the fastener threads, then torque to
specification.
-- Reconnect the vent hose.

Exhaust Valve Housing Fasteners
12 Ft.Lbs. (16 Nm) - Apply Loctite 242

mountainhorse · Dec 9, 2008

Small block Polaris

Exhaust Valve Disassembly
1. Remove the vent hose from the base.
2. Remove the two horizontal cover fasteners securing the
valve assembly to the cylinder. (#10)
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. (to release the locktite on there... heat ONLY the 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.

Exhaust Valve Cleaning
The exhaust valve guillotines must be cleaned to ensure
maximum engine performance and throttle response.
1. Remove the vent hose from the EV base fitting.
2. Remove the two fasteners that secure the valve assembly
to the cylinder, but not the two screws that secure the cover
to the EV base.
3. Carefully extract the guillotine out of the cylinder. Discard
the gasket.
4. Using a clean rag or shop towel, remove the oil residue from
the cylinder, guillotine, and EV base.
5. Inspect the guillotine for signs of damage. Replace
guillotine if damage is found, and inspect the cylinder and
piston for damage.
6. Clean the guillotine with brake cleaner and a piece of fine
steel wool. Clean only to remove hardened carbon deposits.
7. Once clean, rinse blade with mild detergent and water. Dry
completely.
8. Install a new gasket, then reinstall the EV assembly. Apply
Loctite 242 to the fastener threads, then torque to
specification.
9. Reconnect the vent hose.

Guillotine Cap Nut Torque: 16 Ft.Lbs. (22 Nm)

Ex-Member · Dec 9, 2008

definately. I plan on doing mine mid-season, they were way gunked up this summer.

Order a few gaskets and keep 'em on hand.... i should have done that before.

Oven cleaner works wonders on that buildup.

shortstop20 · Dec 9, 2008

Why not reuse the gaskets?

skibreeze · Dec 9, 2008

I just looked at my 08 yesterday and the bellows on it are orange. I've never replaced the gaskets unless they tore coming off.

HUNDO · Dec 9, 2008

...and make sure to break the outer lip of the bellows free before removing the center nut. Otherwise, you may twist a hole in it.

My stock 06s are orange too:beer;

guidoxpress · Dec 9, 2008

GREAT INFO MH..

I JUST did this to my wifes 06 rmk 700 about 2 weeks ago..

the bellows that were in it were orange. and had 2-3 small tears in each one..

took the "new part number" to polaris and they gave me another set of orange ones..

so either i messed up the NEW p/n, or the news ones are orange..threw the stinking plastic with the info away already

shortstop20 · Dec 9, 2008

Orange is the newest, "updated" bellows for the 800 VES, not sure about the 900 CFI, I would expect the color code to stay the same though.

Super Dave3 · Dec 9, 2008

I have'nt seen black bellows for a few years now.
All the bellows are now orange.

GMCRMK · Dec 10, 2008

I'm still gonna make a new post asking "how do I clean my VES valves?"

Thanks for the OEM version.

freak58trio · Dec 10, 2008

Just cleaned mine today 2 years no cleaning first year Polaris blue oil second year Walmart's super tech 2 stroke and compared to what i've seen before they are relatively clean.
my thinking is if you run the sled hard meaning not just idling around the valves will stay fairly clean due to the heat.
It would be interesting to see what a set look like under the same circumstances but ran with synthetic oil.

wyo-rmk · Dec 10, 2008

i cleaned the guillotines, replaced gaskets and bellows but managed to over-torque the cap that goes on the guillotine and broke the threads off. ordered a new one and it is stainless steel but the old one is aluminum i believe...is it alright to have an aluminum guillotine and a s.s. one? asked the parts guy at polaris he said it'd be fine just want to make sure

Polarismaster26 · Dec 10, 2008

I just got done cleaning mine today after getting the new gasket and damn they were dirty. alot of oven cleaner and wire brushing and soaking in the solvent tank.

jetnfool · Dec 11, 2008

Exhaust valve

Is there a way to test the seal while its on the sled?
like with a vacume tester? I tried both mine and they wont pull any vacume, is this normal?

Dogmeat · Dec 29, 2008

When you guys clean these, what do you use to clean it? It says oven cleaner .... like Simple Green? Brake parts cleaner?

Also do you guys think a sticky exhaust valve could be the cause for my sled to sputter at 5300 rpm and only 5300 rpm?

Ex-Member · Dec 29, 2008

I used this stuff... store-brand version ,but same stuff. Foams up when you spray it on. Wipe off what comes off, had to scrape off the heavier stuff.

Not sure why exactly 5K3 RPM... clutching OK?

Garrett · Dec 29, 2008

Here is my valves on my 2009 800 after 499 miles

with Motul Full syntec, Snow Power

Nelson · Dec 29, 2008

shortstop20 said:
Why not reuse the gaskets?

I've had them tear just a little every time I've removed them, generally they will leak when not replaced and I like the peace of mind. Easy Off work great, I still end up using the 3M pads and scrapers for the finishing touches.

diamonddave · Jun 12, 2009

Make sure you wear rubber gloves if you plan on using oven cleaner.

Nasty stuff. It'll strip the skin right off your hands.

Mineral spirits will work fine, solvents, etc.

05900 · Jun 13, 2009

Got to go easy with the scotch brites..hand use only as they will move metal.

Also good time to check/replace springs..they get rusty.

Cleaning exhaust valves, how to

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