Section 15 - Exhaust System; Muffler; Muffler Removal; Muffler Installation - Club Car FE350 2005 Maintenance Service Supplement

SECTION 15 – EXHAUST SYSTEM
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DANGER
• See General Warning, Section 10, Page 10-1.
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WARNING
• See General Warning, Section 10, Page 10-1.

MUFFLER

MUFFLER REMOVAL

1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 10, Page 10-1.
2. Disconnect the spark plug wire from the spark plug. See WARNING "To avoid unintentionally start-
ing..." in General Warning, Section 10, Page 10-1.
3. Remove the hex nuts (10) and lock washers (11) (Figure 15-1, Page 15-2).
4. Remove the hex-head cap screw (7), lock washer (8), and flat washer (9) from mounting bracket. Retain
the governor cable bracket (13).
5. Remove the muffler clamp (6) from the muffler bracket (2).
6. Remove the muffler (1) from the vehicle.

MUFFLER INSTALLATION

NOTE: Any time the muffler is removed from the vehicle, install a new muffler clamp (6) (CCI P/N
1017689) and muffler gasket (12) (Figure 15-1, Page 15-2).
1. Place a new gasket (12) on the cylinder block exhaust stud bolts.
2. Loosely secure muffler (1) to muffler bracket (2) with clamp (6).
3. Attach muffler manifold with lock washers (11) and hex nuts (10) and finger tighten.
4. Loosely secure muffler (1), mounting bracket, and governor cable bracket (13) using hex-head cap
screw (7), lock washer (8), and flat washer (9).
5. Tighten manifold hex nuts (10) to 11 ft-lb (14.9 N·m).
6. Tighten the hex cap screw (7) to 14 ft-lb (18.9 N·m).
7. Tighten the muffler clamp (6) to 40 in-lb (4.5 N·m).
NOTE: Removing and installing the governor cable bracket may change the RPM setting. See Pedal-
Start vehicles:, Section 14, Page 14-10.
8. Connect the spark plug wire.
2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
15
Page 15-1