Exhaust System Removal/Installation; Chapter Eight - Arctic Cat Cougar Service Manual

Chapter Eight
Exhaust System
The exhaust system consists of the exhaust
manifold, or individual exhaust sockets, expan-
sion chamber(s) and a muffler.
This chapter includes service procedures for
all parts of the exhaust systems.
Removal/Installation
Refer to Figure 1
or
Figure 2 for this proce-
dure.
1. Open the hood.
WARNING
If the exhaust system is hot, wait until it
cools before removing it.
2. Detach the springs (Figure 3 or Figure 4) that
attach the expansion chamber(s) to the muffler.
NOTE
A hooked tool can be used to pull the
spring far enough to release one of the
hooked ends.
3. Disconnect the springs that attach the expan-
sion chamber(s) to the manifold (Figure 5) or
exhaust socket (Figure 6).
4. If so equipped, remove the long spring that
crosses the expansion chamber(s).
5. Remove the expansion chamber(s).
6. Unbolt and remove the muffler (Figure 7 or
Figure 8).
7.
Remove the nuts and washers holding the
exhaust manifold (Figure 9
or
Figure 10) or
exhaust socket (Figure 11) onto the cylinders.
Remove the exhaust manifold or exhaust socket.
8. Examine the expansion chamber(s), muffler,
manifold and exhaust sockets for cracks or other
damage. Repair as described in this chapter.
9. Install by reversing the removal procedure,
while observing the following:
a. Install new exhaust gaskets. The metal side
of the manifold gasket must be out as shown
in Figure 12.
b. Check the condition of all retaining springs
(Figure 13). Replace, as necessary.