Exhaust system - renewal and repair
Renewal
1 The exhaust system fitted to all models is of two-piece construction but there are three different system types fitted, according to model type.
Exhaust systems
A OHV models B CVH models C XR2 models
2 The system can be renewed in sections, as coupling sleeves are supplied so that an old section can be cut out and a new one inserted without the need to renew the entire system at the same time.
3 It is recommended, when working on an exhaust system, that the complete assembly be removed from under the vehicle by releasing the downpipe from the manifold and unhooking the flexible suspension hangers.
Exhaust system flexible hanger
4 Assemble the complete system, but do not fully tighten the joint clips until the system is back in the vehicle. Use a new exhaust manifold/flange gasket and check that the flexible mountings are in good order.
5 Set the silencer and expansion box in their correct attitudes in relation to the rest of the system before finally tightening the joint clips.
6 Check that with reasonable deflection in either direction, the exhaust does not knock against any adjacent components.
Repair
7 Effective repairs to exhaust system can be made by using a proprietary repair kit.