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XCR 800 - Broken Power Valve Bolt
- Bolt (Captive Nut) that holds Bellows
started by jasonmc98
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January 3rd 2008 at 7:28 AM
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jasonmc98
New Member
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59 Posts 
Group: Members
Member Since: January 15th 2007
Location: Dexter, MI, USA
Current Sled: 2001 XCR 800
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I've seen this question answered on here before, but I ran a search and couldn't find it.
I was cleaning the power valves on my XCR last night and noticed that 2 out of 3 bellows were cracked - (Looks like I found my top end bog).
I broke one of the nuts trying to replace it and now I have to get a new exhaust valve for that one, I'd reather not do the same to the other. Does anyone know of any tricks to remove the bolt (nut) with out breaking it, can it be heated?
Ride Naked, Show the world yer NUTZ
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Site Supporter
Group: Site Supporters
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January 3rd 2008 at 7:46 AM
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polaris1man
Average Member
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738 Posts 
Group: Members
Member Since: December 22nd 2007
Location: Nashwauk, Minnesota, USA
Current Sled: Polaris SKS700
2008-2009 Miles: not many
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Quote originally posted by jasonmc98
I've seen this question answered on here before, but I ran a search and couldn't find it.
I was cleaning the power valves on my XCR last night and noticed that 2 out of 3 bellows were cracked - (Looks like I found my top end bog).
I broke one of the nuts trying to replace it and now I have to get a new exhaust valve for that one, I'd reather not do the same to the other. Does anyone know of any tricks to remove the bolt (nut) with out breaking it, can it be heated?
Wow, someone else had the same problem!! Can you imagine that the threads on the bolt and nut are not a match? After breaking two of the three, I went into the Polaris dealer and showed them, plus had them snap the third one off to get three new ones and send in the defective ones. As for cleaning the gillutines, a mild grease remover product is all that should be needed, no solvent based products, check the spring tension for spec, special care with the rubber boot too.
Three-1999 Polaris SKS700's
2000 Polaris SKS700
2000 Polaris Ranger 6x6
2007 Polaris Sportsman 800 EFI X2
2000 Yamaha YZ 250
1996 Yamaha WR250
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January 3rd 2008 at 1:51 PM
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ACEXLT
THREE FOR ALL
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5668 Posts 
Group: Members
Member Since: September 17th 2002
Location: Greenfield, WI, USA
Current Sled: '01 XCR 800
2008-2009 Miles: 1326
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PM Zrxpilot on here. He broke one too on his XCR 800 valves. I believe he found a solution to getting the other 2 off. Problem is Polaris used red loctite on these
which your supposed to use heat to get them off.
'01 XCR 800
'00 Indy Triumph
TRIPLES RULE!!
TWINS HAVE NO BALLS!!
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January 3rd 2008 at 2:56 PM
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jasonmc98
New Member
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59 Posts
Group: Members
Member Since: January 15th 2007
Location: Dexter, MI, USA
Current Sled: 2001 XCR 800
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Thanks! Ace. I just wasn't sure if I was suposed to use heat on them or not, but I supose its not going to hurt anything if the bellows is already blown out.
I had no idea they used loctite, I barley gave it a turn and it just snapped. And after looking everywhere today for a replacement exhaust valve, this is good knowlege to have since they are not easy to come by.
Which by the way - if anyone knows of where to get one fast, please let me know. I've ordered one but the soonest I'll have it is the 14th of this month.
Ride Naked, Show the world yer NUTZ
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January 3rd 2008 at 6:13 PM
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Ultra680
Senior Member
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2235 Posts
Group: Members
Member Since: June 5th 2004
Location: Anywhere, Everywhere, USA
Current Sled: 2000 XCR 800
2008-2009 Miles: 1300
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Heat is the answer. Red locktite will release with heat. Takes a little practice but the only way to get them apart without snapping.
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January 3rd 2008 at 7:30 PM
[ Modified January 3rd 2008 at 7:32 PM
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Zrxpilot
Advanced Member
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1623 Posts 
Group: Members
Member Since: October 3rd 2005
Location: Bumphuc Egypt, Mi, USA
Current Sled: 97 Indy Lite Deluxe
2008-2009 Miles: Over 600
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Unless you have a torn bellow, dont take them apart all the way to clean. Ever.
The fix is one of them little pencil size propane torches. Just a second on the head and it comes off.
If you have a tap and die you can fix yours by shaving the threaded portion clear down to the shoulder and drill and tap with whatever size bolt you can find that closely matches the head on the stock one. Or just run without it.
Quote from Riley~
"Little slushy out here innit?"
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January 6th 2008 at 8:34 AM
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1fastxc
Junior Member
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177 Posts 
Group: Members
Member Since: May 21st 2006
Location: little suamico, wisconsin, USA
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I've fixed some valves before. Just do like stated above, shave down, drill and tap, and put threaded rod in it. I belive it was M8x1.25 if i remember right.
Slightly stock with extra sauce
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January 6th 2008 at 9:09 AM
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i got lucky and needed new valves any how. so when the first one broke the stud off in it i didnt worry, until you see that polaris gets 20 dollars for each nut. so I cut the base of the nut off each one and then used a regular nut.
nothing goes like 3 holes!!
Aaen Performance!!!!
High performance engineering
millennium technologies
brtech hoods
price performance
Got Speed Racing
320-629-4889
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January 6th 2008 at 8:46 PM
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gbaronet
Average Member
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841 Posts
Group: Members
Member Since: November 16th 2002
Location: Kitchener, Ontario, Canada
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Mine was just under 11k, two of mine were torn too.
Propane torch heat to loosen loctite. No issues
When in Doubt, gas it
01 XCR 136 Edge 12k stock
00 XCR 136 Edge Flannery/HTG
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January 18th 2008 at 3:25 PM
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Boaski
Starting Member
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39 Posts
Group: Members
Member Since: February 4th 2007
Location: Edison, Ohio
Current Sled: '02 XC700SP and old ones
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Mine broke when I was putting the nut back on. I thought I wanted it just a little tighter... I ended going and getting a M8-1.25 bolt, tapping the VES stem 5/16-24 (since I didn't have a M8 1.25 tap), Loctited the bolt in place and then cut the head off.
What spring pressure do you guys run on your VES caps?
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January 18th 2008 at 3:41 PM
[ Modified January 18th 2008 at 3:43 PM
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boody1981
Junior Member
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424 Posts
Group: Members
Member Since: February 6th 2006
Location: The Pas, MB, Canada
Current Sled: 00' XCR 800
2008-2009 Miles: 0 inKuwait
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Exactly the cure, cut flush and re-tap, but use a steel M8 bolt not another aluminum one or it will just snap again. I actually loctited both ends when I put it back together and with a steel stud I was able to crank on that nut really tight, haven't had a problem since.
I know the mechanic at the LD torques them to spec and snaps them,....thats rediculous
DO NOT GO BUY A NEW VALVE!!
does the spring tension do anything??????????? I can't see it making a difference
1995 Indy lite
1996 Indy super sport
1997 Indy 500
1998 Indy 500
1999 Yamaha SRX 600
2000 Polaris XCR 800
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