I have a sp700 that has a exhaust leak I think. It makes like a whistle sound when its hot and cold. Took the AAEN muffler off and put the stock (modified) muffler back on and it has the same sound. So today I took the whole exhaust off and found a crack in the header so I welded it back. Put everything back on and it still does it whats wrong here. My patiences are running out and Im about to go off the deep end. Please help

2003 POLARIS SPORTSMAN 700 TWIN
MODIFCATIONS
1.SUPER DUTY HIGHLIFTER CLUTCH
2.AAEN EXHAUST
3.27'' GBC GATORS
4.DYNOJET KIT
5.REVERSE LIGHT
6.CUSTOM NERFBARS
7.FRONT BRUSHGAURD
8.REAR TUBE BUMPER
9.2500 LB RAMSEY WINCH
10.POLARIS HANDGAURDS
11.GEL GRIPS
12.FUEL GAUGE
13.K&N AIR FILTER
14.3'' WHEEL SPACERS
15.HEADLIGHT MODIFCATION
16.REVERSE OVERRIDE MODIFCATION
17.COIL SPACERS
18.1'' SPRING SPACERS

 

The leak may be on the intake, spray some starting fluid around the hoses to see. Also check the carb boot (adaptor), mine was cracked and badly "weathered".

 

If it was your intake you,d know it..It well run like crap if it runs at all.

 

I took the intake boot off last night while I was spraying oil into the carb trying to get it to smoke. It still had the same noise with the boot off. I'm STUMPED!


2003 POLARIS SPORTSMAN 700 TWIN
MODIFCATIONS
1.SUPER DUTY HIGHLIFTER CLUTCH
2.AAEN EXHAUST
3.27'' GBC GATORS
4.DYNOJET KIT
5.REVERSE LIGHT
6.CUSTOM NERFBARS
7.FRONT BRUSHGAURD
8.REAR TUBE BUMPER
9.2500 LB RAMSEY WINCH
10.POLARIS HANDGAURDS
11.GEL GRIPS
12.FUEL GAUGE
13.K&N AIR FILTER
14.3'' WHEEL SPACERS
15.HEADLIGHT MODIFCATION
16.REVERSE OVERRIDE MODIFCATION
17.COIL SPACERS
18.1'' SPRING SPACERS

 

I think if you took it all apart and there was no cracks and all your gastets look good and your springs are all in good shape .It mite not be in the exhaust...

 

I called my polaris dealer to see what he thought he said it sounds like a leak in the exhaust. SOOOO I'm once again going to take the whole thing back off. I seen the cracks in the header so I never checked the main pipe just assumed it had to be the header. So where else do you think the noise could be coming from. Thought about ordering new gaskets but the 3 are $50.00.


2003 POLARIS SPORTSMAN 700 TWIN
MODIFCATIONS
1.SUPER DUTY HIGHLIFTER CLUTCH
2.AAEN EXHAUST
3.27'' GBC GATORS
4.DYNOJET KIT
5.REVERSE LIGHT
6.CUSTOM NERFBARS
7.FRONT BRUSHGAURD
8.REAR TUBE BUMPER
9.2500 LB RAMSEY WINCH
10.POLARIS HANDGAURDS
11.GEL GRIPS
12.FUEL GAUGE
13.K&N AIR FILTER
14.3'' WHEEL SPACERS
15.HEADLIGHT MODIFCATION
16.REVERSE OVERRIDE MODIFCATION
17.COIL SPACERS
18.1'' SPRING SPACERS

 

Boy its hard to say.If you cover the exhaust with you hand[with a glove on]while its running dose the sound change?

 

Yeah it gets quieter when you do that.


2003 POLARIS SPORTSMAN 700 TWIN
MODIFCATIONS
1.SUPER DUTY HIGHLIFTER CLUTCH
2.AAEN EXHAUST
3.27'' GBC GATORS
4.DYNOJET KIT
5.REVERSE LIGHT
6.CUSTOM NERFBARS
7.FRONT BRUSHGAURD
8.REAR TUBE BUMPER
9.2500 LB RAMSEY WINCH
10.POLARIS HANDGAURDS
11.GEL GRIPS
12.FUEL GAUGE
13.K&N AIR FILTER
14.3'' WHEEL SPACERS
15.HEADLIGHT MODIFCATION
16.REVERSE OVERRIDE MODIFCATION
17.COIL SPACERS
18.1'' SPRING SPACERS