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Greg Thompson Posted on Apr 18, 2018
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How do you replace exhaust donut on pipe to muffler. 2009 500 X2 Polaris

1 Answer

Kardoc

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  • Polaris Master 7,503 Answers
  • Posted on Mar 02, 2019
Kardoc
Polaris Master
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Joined: Sep 18, 2010
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Disconnect the pipe from the manifold. Take off the brackets and move the pipe backward far enough to remove and install a new donut.

5 Related Answers

Anonymous

  • 45 Answers
  • Posted on Aug 12, 2008

SOURCE: 98 Honda Civic EX Exhaust.

Donut gasket. You need 2 of them.

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Molson02536

Harvey N Tawatao

  • 3854 Answers
  • Posted on May 11, 2009

SOURCE: Exhaust pipe rattles when car idles. Had muffler

Check the heat shield on the Catalytic Converter, after a few years they start to rust off and rattle. Crawl under the Pathfinder and bang along the Converter and muffler area and see where it's coming from.   Good chances are, it's from the heat shield since you already had everything changed from the Cat back.
Good luck and hope this helps.

emissionwiz

Marvin

  • 85242 Answers
  • Posted on Nov 10, 2009

SOURCE: is there a gasket between the exhaust manifold and

the donut is cast into the exhaust manifold.

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Anonymous

  • 2309 Answers
  • Posted on Nov 26, 2009

SOURCE: I have a 1999 ford f150 exhaust pipe and muffler

did the flange come apart or did the pipe break, if the pipe broke then you will have to replace the system fron the flange back, these exhaust systems look good but corrode from the inside out, get a new system i will probably come in three pieces, and new hangers, its pretty straightforward

Anonymous

  • 20 Answers
  • Posted on Apr 10, 2010

SOURCE: Exhaust Pipe broke/Rust on muffler

Flex pipe will work, or if it's a straight section of pipe you can buy a universal piece of exhaust tubing with flared ends, trim off the rusty ends on your original pipe with a hacksaw or Sawzall and slip in the new section. Clamp it with 2 muffler clamps and you're set. Total cost should be under $40.

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1answer

Have 250 2stroke polaris runs great on top end but sluggish on low end seems like it should rap faster

Remember it is only a 250 but a couple things will cause that problem I have found that 2 stroke engines tend to stop up the exhaust pipe try taking it off replace it with a shorty pipe to test it if it runs like a striped ape the pipe is probably stopped up take out the baffle and clean pipe and muffler good reassemble
then there is the chance that it is low on compression this would constatute a top end rebuild
Feb 09, 2019 • Polaris ATV
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2007 Polaris Sportsman 800 X2 4x4 glowing red exhaust in one minute of idling

its running lean. fix it asap or it'll ruin the motor.
Nov 30, 2016 • Polaris ATV
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Where can I find instruction on how to replace rear prop shaft yoke and u joint on a 2012 Polaris ranger 500 side by side.

Rear Drive Shaft - YouTube

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www.youtube.com/watch?v=WpRjFnBf0ZQ
Dec 1, 2012 - Uploaded by Charles Humphrey
Is this excessive play in the rear drive shaft where it connects to the ... Published on Dec 1, 2012 ... It was the ...

Polaris Sportsman propshaft u-joint replacement - YouTube

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Polaris sportsman 500 HO shows hot check engin? what must i do

check your timing advance. It may be advanced a little too much. If that is okay, then make sure your spark plug is the proper one and not a sub. Most ATV's use DENSO plugs and these seem to work the best. (Having a spark with a higher heat range will cause the overheat condition). The other thing is your mixture... you may be running a tad rich.. lean it up 1/8 of a turn. Finally, remove the exhaust pipe and see if they is carbon build-up at the exhaust port... lean it over and remove all you can, careful not to allow any to fall into the engine. (Blocking the exhaust will cause a dramatic temperature increase.)
0helpful
2answers

700 twin o3 sportman will not open up and wen letting off throttle pops through muffler

This is a timing issue. The crank and cam are out of time. It might be excessive wear,
Aug 22, 2014 • Polaris ATV
1helpful
1answer

2012 1700 classic vulcan exhaust

The VTX 1800 is fuel injected which requires the additional sensors (oxygen, throttle position, etc). However the VTX 1300 is carbureted, which takes the sensors out of the equation. If you are changing the exhaust with a:
Slip on-muffler
  • remove old mufflers, and slip on new ones
  • could add a better air filter, and you get a better sound, minimal power gain
Full Exhaust System
  • Remove old pipes from the cylinder heads (i.e. jugs) and use a rag to wipe off the seat and block the opening.
  • once both pipes have been pulled from the jugs, prep your new pipes with windex. Clean them well, finger oil and other gunk can cause bluing spots
  • Install the pipes, torque them in place, re-clean the pipes and use a chrome polish.
  • Purchase carburetor jetting kit, and either take it to a shop to do it, or you do it. If you have never re-jetted a carburetor before, I suggest you go to a reputable shop and get it done.
  • With the carb completed, a new air filter (high flow K&N is what I use - I have gone through the same exhaust system replacement procedure on my sled)
If you replace the exhaust without completing the carb/air cleaner, there is a very high probability that you will get backfires every time you ride. This will happen especially on deceleration, and will eventually blow out your valve seat, causing the engine to feel weak due to lost compression.
1helpful
3answers

99 Polaris Sportsman 335, idles fine but when you give it gas it sounds like it bogging out. We have replaced plug and needle and seat. Runs even worse with the air cleaner on. Help

It sounds like the camshaft is going flat. The exhaust lobe on the camshaft is the first to wear. Basically the exhaust isn't opening the entire duration it needs to expel the exhaust. This will cause the bogging issue. Polaris uses an overhead camshaft, which fortunately, makes it easier to replace. To check the camshaft:
1. Remove spark plug
2. Remove the large bolt on top of the recoil starter
3. Rotate the engine with the pull rope until the "T" mark on the flywheel is visible through the hole the bolt was removed from
4. Remove 8 screws on valve cover, fuel tank removal is not necessary but gives you more room
5. Remove 4 bolts from rocker arms, lift rocker arms off camshaft
6. Rotate engine again with pull rope to inspect camshaft. The center of the camshaft is the exhaust lobe, intake lobes are on the outsides of cam. The exhaust lobe should be about the same height as the intake lobes, and will be noticeably flat
To replace the camshaft:
1. Remove camshaft gear access cover on right side of engine
2. Rotate engine again until the "T" mark on flywheel is visible, 2 dots on the camshaft gear should be at the top of the gear and will be parallel to the mating surface of the valve cover
3. Locate the chain tensioner, 2 small bolts holding tensioner to cylinder and 1 large bolt in the center. Remove the large center bolt to remove tension. There will be a spring and pin inside tensioner so be careful not to let it fly out.
4. Remove screws holding gear to camshaft, leave the gear on the chain
5. On the left side of the engine, clamp the coolant hose going into the thermostat cover
6. Remove thermostat cover, some coolant will come out but is ok
7. There will be a round cover on left side of engine with 3 screws, remove that cover and pull the camshaft out through that hole.
8. Install new camshaft, make sure the automatic decompression lever does not come out while handling. Keep pressure on decompression lever and hold cam so that the little ball inside the cam is facing downwards, this will help to keep the lever inside the cam
9. Install cover on the left side
10. Install cam gear on camshaft
11. Remove exhaust rocker arm from the shaft and replace with a new exhaust rocker arm
12. Install spring, pin, and bolt in tensioner once the gear is in place
13. Install rocker arms, set valve clearance to .006 in for intake and exhaust
14. Reinstall covers and thermostat cover
15. Option B is to take it to a Polaris dealer to avoid the hassle of trying to do it yourself!
Hope this helps, if you need any more assistance let me know, Daniel
Oct 04, 2011 • Polaris ATV
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