Large Dents (Exhaust System) - Arctic Cat Cougar Service Manual

EXHAUST SYSTEM
2. Heat the area around the dent evenly with a
torch.
3. When the dent is heated to a uniform orange-
red color, operate the slide hammer to raise the
dent.
4. When the dent is removed, unscrew the slide
hammer and weld the drilled hole closed.
Large Dents
Large dents that are not crimped can be re-
moved with heat and a slide hammer as pre-
viously described. However, several holes must
267
be drilled along the center of the dent so that it
can be pulled out evenly.
If the dent is sharply crimped along the edges,
the affected section should be cut out with a
hacksaw, straightened with a body dolly and
hammer and welded back into place.
Before cutting the exhaust pipe apart, scribe
alignment marks across the area to be cut to
facilitate correct alignment when rewelding the
pipe.
After the welding is completed, wire brush
and clean up all welds. Paint the entire pipe with
a high-temperature paint to prevent rusting.
Table 1 TIGHTENING TORQUE
Exhaust manifold
1990-1992
1993-on
15-19
18-22
ft.-lb.
11-14
13-16