Club Car 2007 XRT 800, Maintenance Service Manual

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2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 17-1
17
SECTION 17 – EXHAUST SYSTEM: GASOLINE
VEHICLES
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DANGER
• See General Warning on page 1-1.
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WARNING
• See General Warning on page 1-1.
MUFFLER
MUFFLER REMOVAL
1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
2. Disconnect the spark plug wire from the spark plug. See WARNING “To avoid unintentionally start-
ing...” in General Warning on page 1-2.
3. Remove the muffler clamp (6) from the muffler (1) and clamp bracket (2) (Figure 17-1, Page 17-2) .
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 hex nuts (10) and lock washers (11) from the manifold.
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) FE290 (CCI P/N 1015330)
(Figure 17-1, Page 17-2) .
1. Loosely secure muffler (1) to muffler bracket (2) with clamp (6).
2. Place a new gasket (12) on the cylinder block exhaust stud bolts.
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 Engine
RPM Adjustment on page 16-12.
8. Connect the spark plug wire.