3.7
Maintenance
3
ENGINE MAINTENANCE
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.
NOTE: To obtain maximum exhaust valve
performance, Polaris recommends using Polaris
VES Gold Synthetic Two-Stroke engine oil.
Never mix different brands of engine oil.
Surge Tank
Keep the level of the coolant inside the surge tank at the FULL
COLD level mark when the coolant is at room temperature.
Always add coolant when the cooling system is COLD.
Recommended Coolant
Use Polaris Premium 60 / 40 pre-mix antifreeze. This premium
antifreeze is rated for temperatures down to -62°F (-52°C).
Cooling System Bleeding
1. Allow the cooling system to cool completely.
2. Verify the coolant level in the surge tank is at the COLD
mark. Fill the surge tank if required. Loosely install the
pressure cap.
3. Open the thermostat housing bleed screw. Wrap a clean
shop towel around the housing to absorb any coolant that
may flow out of the bleed screw.
4. Elevate the front of the machine slightly.
5. Apply the parking brake and start the engine.
6. Allow the engine idle time to stabilize.
7. Immediately add coolant to the surge tank if the coolant
level dropped significantly after the engine started. Watch
the level and add more coolant until the level stops
dropping.
NOTE: Squeeze the coolant hoses to purge air from
the cooling system.
8. Secure the pressure cap and bleed screw after the
thermostat begins to open and coolant begins to flow out
of the bleed screw.
9. Verify the tunnel coolers begin to warm up as the engine
continues to run.
10. To remove air from the tunnel cooling system, the vehicle
should be pivoted upwards in four directions (nose up, left
side up, rear bumper up, and right side up) to move any air
pockets in the system to the surge tank.
= T
Exhaust Valve Housing Fasteners
12 Ft.Lbs. (16 Nm) - Apply Loctite 242
GASKET
EV ASSEMBLY
FASTENERS
CAUTION
Never remove the surge tank pressure cap when the cooling
system is warm. Severe burns to skin may occur from escaping
coolant or steam.
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