Domnick Hunter Maxigas 104, Service Manual

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3.4.9 Exhaust Valve Replacement
The Exhaust valve assembly is located below the inlet manifold as shown.
Unscrew the exhaust silencer assembly from the exhaust flange plate and
remove.
Remove the pneumatic tubing from the cylinders.
Whilst supporting the exhaust valve assembly, remove the 8 off M10 Hex HD
bolts that hold the assembly onto the manifold.
Note: The M10 bolts are accessed from the underside of the valve assembly.
Access is limited.
When the bolts are removed, carefully withdraw the assembly and place it onto a
clean surface.
Remove the two endplates by unscrewing the M10 Hex bolts (4 per plate).
To remove the valve disc assemblies from the cylinders, extend the cylinder
shaft slightly and attach a No
X spanner onto the machined flat on the cylinder
shaft.
With the cylinder shaft held securely, loosen the M6 Binx nut that holds the discs
onto the shaft.
Remove the cylinders from the assembly by unscrewing the M6 socket head
screws (4 per cylinder).
Fit the replacement cylinder to the plate ensuring that the nose o-ring is in place.
Torque the bolts down to 20Nm (15ft lb)
Extend the cylinder shafts and assemble the valve discs onto the shaft in the
following order:
35mm Poly disc
31mm Poly disc
20mm ALU disc
M6 anti vibration washer.
Secure the valve disc onto the shaft using the M6 Binx nut.
Replace the o-rings on the endplates and refit them on to the assembly.
Torque the bolts down to 34Nm (25ft lb)
Replace the 14 o-rings located in the machined grooves of the assembly and re-
attach it to the manifold using the 8 off M10 bolts.
Torque the bolts down to 34Nm (25ft lb)
Reconnect the tubing to the cylinder and refit the exhaust silencer