EXHAUST SYSTEM
Muffler
Page 15-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
15
MUFFLER
Read DANGER and WARNING on page 15-1.
MUFFLER REMOVAL
1. Disconnect the battery cables, negative (–) cable first (Figure 15-1, Page 15-2).
2. Disconnect the spark plug wire from the spark plug.
3. Remove the hex nuts (10) and lock washers (11) (Figure 15-2, Page 15-3).
4. Remove the hex head cap screw (7), lock washer (8), and flat washer (9).
5. Remove the retaining bolts (5), lock washers (4), and flat washers (3) from the muffler bracket (2).
6. Remove the muffler (1) and bracket assembly (2) from the vehicle.
7. Remove the muffler clamp (6) from the muffler bracket (2).
MUFFLER INSTALLATION
NOTE: Any time the muffler is removed from the vehicle, install a new muffler clamp (6) (CCI 1017689) and
muffler gasket (Figure 15-2, Page 15-3).
1. Use the muffler clamp (6) to attach the muffler bracket (2) to the muffler as shown (Figure 15-2, Page
15-3). Leave the muffler clamp loose enough to allow the muffler to move as the mounting hardware is
tightened. If installing a new muffler, use the old muffler as a positioning guide for the clamp and
bracket.
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. Do not tighten them.
4. Install the hex nuts (10) and lock washers (11). Tighten the nuts fingertight.
5. Install the hex head cap screw (7), lock washer (8), and flat washer (9). Tighten the cap screw finger-
tight.
Figure 15-1 FE350 Battery
FRONT
OF VEHICLE
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
REMOVE
NEGATIVE
CABLE FIRST
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE
