Exhaust seal replacement - Polaris ATV Forum
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post #1 of 27 (permalink) Old 03-03-2012, 05:28 PM Thread Starter
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Cool Exhaust seal replacement (Photos included)

I just thoguht I would fish for hints and suggestions before diving in blind.

I am planning to replace the seal between the y-pipe/header and the exhaust pipe on my wife's '07 Sportsman 700 EFI. It sounds very tinny and rattle-like when running. Nothing like my '04's throaty kinda growl. I can feel the exhaust coming out of this junction and it backfires when you let off the throttle if you are traveling very fast. (Strangly her's still goes faster than mine despite the exhaust leak, doesn't effect her performance at all)

I looked through the service manula. The only place it mentions exhaust is that when yourebuild the engine you should replace the seals, and how to clean the carbon out of the muffler during maintenance. Nowhere does it describe removal of or replacement of said seals. Looking at it, it looks fairly simple, but so have a couple of other projects I have almost gotten in over my head while working on.

Has anyone replaced this seal? Are there any tricks, hints, suggestions that I should have? Do I need to remove plastics? Can I just unhook the springs and pull it apart? Are there bolts to remove to get enough free play to allow this? Any notes I will gladly accept.

Thanks in advanvce.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)

Last edited by KICKER431; 03-12-2012 at 08:14 AM.
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post #2 of 27 (permalink) Old 03-03-2012, 05:43 PM
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i don't know but if she is having this issue now or you are addressing it now would be the time to put on aftermarket exhaust if you ever wanna go that route just an idea

2009 POLARIS SPORTSMAN 550 XP EFI
FULLY SNORKELED
CUSTOM AUDIO TUBE
UNI AIR FILTER
STALL SPRING
25.5" PITTBULL GROWLERS
FRONT AND REAR RACK RAILS

2011 YAMAHA GRIZZLY 550 EPS EFI
FULLY SNORKELED
CUSTOM AUDIO TUBE
UNI AIR FILTER
POWER EXHAUST TIP
27" INTERCO SUPER SWAMPER VAMPIRES
CUSTOM PAINTED STOCK RIMS
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post #3 of 27 (permalink) Old 03-04-2012, 03:40 AM
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just unhook springs, pull it apart and put it back together,, get it lined up straight
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post #4 of 27 (permalink) Old 03-04-2012, 04:33 AM Thread Starter
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Thanks Russ. I was truly hoping that would be it but couldn't find supporting documentation anywhere.
And MONSTER: thanks for the thought but I really am not interested in aftermarket. I am good with my machines in original condition. I like to accessorize but the mechanicals I am pretty happy to leave OEM.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #5 of 27 (permalink) Old 03-04-2012, 07:32 AM
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ok just thought id throw that out there and im not a fan of exhaust mods

2009 POLARIS SPORTSMAN 550 XP EFI
FULLY SNORKELED
CUSTOM AUDIO TUBE
UNI AIR FILTER
STALL SPRING
25.5" PITTBULL GROWLERS
FRONT AND REAR RACK RAILS

2011 YAMAHA GRIZZLY 550 EPS EFI
FULLY SNORKELED
CUSTOM AUDIO TUBE
UNI AIR FILTER
POWER EXHAUST TIP
27" INTERCO SUPER SWAMPER VAMPIRES
CUSTOM PAINTED STOCK RIMS
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post #6 of 27 (permalink) Old 03-12-2012, 07:51 AM Thread Starter
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Question Now I need Help



So I pulled the springs. Slipped the exhaust apart. Pulled out the wire mesh seal someone before me had stuffed in there (no wonder it wasn't sealed). Now I find my OEM seal wont fit because the header pipe is warped.

[IMG][/IMG]

No big deal right. New header pipe needed. EXCEPT. I can't get this one off. I have deduced it is a 6mm allen head bolt. But I can't get enough torque on any of the 4 bolts to get them loose. I've got them soaking in pb blaster right now, but does anybody have any hints or help on how to loosen these?

[IMG][/IMG]

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MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)

Last edited by KICKER431; 03-12-2012 at 08:11 AM.
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post #7 of 27 (permalink) Old 03-12-2012, 08:47 AM
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Just replaced my 06 700's seal last fall. That wire mesh exhaust seal you pulled out is what's left of a nice shiny one like the one you are putting in. Whatever material they impregnate the mesh with deteriorates over time and voila, you have a leak. Probably asbestos.

I have a set of allen wrenches that fit onto my ratchet. Makes whatever you are working on just like using a socket. Mine are Craftsman but surely others make them.

Stew

2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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post #8 of 27 (permalink) Old 03-12-2012, 09:08 AM Thread Starter
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That was the conclusion I had come to, just wanted advice from comeone who had done it before. So thanks for sharing the knowledge. I will get the Allen-sockets when I am next in town. Waiting on a new header pipe and seal from cheap cycle parts anyway.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
KICKER431 is offline  
post #9 of 27 (permalink) Old 03-12-2012, 09:18 AM
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The nice thing about working on your own machines is you save money AND you get to buy more toys you want...uh, I mean tools you need.

2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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post #10 of 27 (permalink) Old 03-12-2012, 09:20 AM
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I have a set of Stanley brand allen sockets that I got from Wal-Mart. probably not as strong as Craftsman, but they have worked fine for me so far.

2004 Sportsman 700, Warn winch, Polaris plow, Swamp Fox tires
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