Section 15 - Exhaust System; Muffler; Muffler Removal; Muffler Installation - Pioneer 1200 Maintenance Service Manual

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

MUFFLER

MUFFLER REMOVAL

1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-1.
3. Remove the spark plug wire. See WARNING "To avoid unintentionally starting..." in General Warn-
ing, Section 1, Page 1-1
4. Remove the hex nuts (10) and lock washers (11) from the manifold (Figure 15-1, Page 15-2).
5. Remove the hex-head cap screw (7), lock washer (8), and flat washer (9) from mounting bracket. Retain
the governor cable bracket (13).
6. Remove bolts (5), lock washers (4), and flat washers (3) from the muffler clamp bracket (2).
7. Remove the muffler (1) and clamp bracket assembly (2) from the vehicle.
8. Remove the muffler clamp (6) from the muffler clamp bracket (2).

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. Use the muffler clamp (6) to attach the muffler bracket (2) to the muffler (Figure 15-1, Page 15-2). Leave
the muffler clamp loose.
2. Place a new gasket (12) on the exhaust manifold mounting flange as shown.
3. Position the muffler and bracket assembly, and the governor cable bracket (13) and install the bolts (5),
lock washers (4), and flat washers (3). Thread the bolts in only enough to support the muffler and bracket
assembly.
4. Install the lock washers (11) and hex nuts (10) on the manifold bolts. Tighten the nuts finger-tight.
5. Install hex-head cap screw (7), lock washer (8), and flat washer (9). Tighten the cap screw finger-tight.
6. Tighten the manifold hex nuts (10) to 11 ft-lb (14.9 N·m).
7. Tighten the muffler bracket hex cap screw (7) to 14 ft-lb (18.9 N·m).
8. Tighten the muffler clamp bracket mounting bolts (5) to 75 in-lb (8.5 N·m).
9. Tighten the muffler clamp (6) to 40 in-lb (4.5 N·m).
10. Connect the spark plug wire.
11. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter-
minals with Battery Terminal Protector Spray (CCI P/N 1014305).
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
15
Page 15-1