Does anyone know why my Polaris 700 eats exhaust donuts? I put a new donut and springs on this thing and within a couple of rides it has blown out. I did notice while pushing snow at night that the exhaust gets cherry red. Polaris dealer said that this was normal. I have put two new donuts on in two weeks. And , no the head pipe is not cracked.

 

Mine did the same thing. Turned out that the exhaust pipe warped. Put a new pipe on and things have been great. I think I went through 7 one year when I use to ride it hard.

 

A new head pipe? Or a new exhaust pipe? Did you ever notice how cherry red the exhaust get's under load,in low? Run's great, but first time pushing snow and the donuts are not lasting. I am buying them from a local car parts store because they are only $4.00 a piece. Polaris wants $17.00. I thought maybe polaris's donut might withstand higher heat and vibration but not the case. I took the donut from the parts house with me and there is no difference.

 

I ended up replacing both the y-pipe/head pipe and exhaust pipe. Mine does get really red/hot when I ride it in low, but since I replaced the exhaust pipe everythings been OK. Mine has 4500 miles now and they there was some adjustment made to the carb needle back at about 3500 miles.

Sounds like a similar problem to mine. I would put new springs and donut in and it would still eat them up.

If its getting really hot/red may want to make it run a little richer.

 

What kind of exhaust did you end up running? And about what can I expect to shell? Thanks....... This thing really runs great and beats my buddy's 2005 EFI Sportsman 700 hands down, He hasn't had any exhaust problems with his,,,,,yet. I also upgraded my stator with the same setup as the 2004 Sportsman 700. My CDI or ignition control burned up and Polaris had them on backorder untill end of Feb. Found this kit that changes the 02 two a 04. Came with new and different stator-new rectifier-flywheel-and added a coil which it didn't have before. Or I should say the coil was in with the CDI. Polaris knows about the problems with the 02's appearently, but no help on the price to make it right.

 

I put a stock back on, but I will be putting on a dual setup off an 800 in the future. All we could figure is that the y-pipe and exhaust didn't seat right causing the donuts to burn out.

 

i too have burnt through a donut gasket recently. i noticed my exhaust pipe where it bends around the the engine was over bent, bent it out a little and so far i have had no problems.

 

After I put my turbo on I also had problems with the donut gasket. I found the cure for mine was to add 2 more springs. What seems to happen is the exhaust pressure pushes on the pipe and and lets the donut gasket just spin around wearing it out. After adding the springs I've not had to change the first donut gasket.

 

Where did you get the extra springs, please tell me it wasn't a dealer? When I bought my used 95' it was missing a spring, and I never replaced it, I haven't had any problems, but I'm going to put it on now, after reading this.

 

Yeah I got the extra springs from the stealer.