800 Arctic Cat - 2001-03 Exhaust System Installation

  1. Remove entire stock exhaust system.
  2. Remove stock muffler mounting bracket.
  3. Remove stock exhaust manifold.
  4. Using stock manifold bolts and gaskets, install exhaust flanges onto cylinders.
  5. Drill a 1/4" hole in belly pan an 1 ½" in front of exhaust outlet hole.
  6. Using a 1/4" bolt and lock nut secure spring clip (provided in kit) in place.
  7. Stretch spring between floor and mufflers. (It will be easier before pipes are in position)
  8. Place aluminum shield over shock tower. Bend to fit and securely rivet into place.
  9. Place a bead of high-temperature silicone around exhaust manifolds to prevent leakage. Also place a bead around stingers where pipes and mufflers join.
  10. Place pipes into position beginning with the magneto pipe making sure that the flanges slide all the way together both at the manifold and the mufflers. Then install PTO pipe.
  11. Using stock springs, spring joints together.
  12. Gut the air box, by removing the shelf. Lift the needle one position.

Recommended Clutching and Jetting Instructions

MODEL

0-4,000 ft Elevation 4-6,000 ft Elevation

6-8,000 ft Elevation

8-10,000 ft Elevation

 800 AC,
2001-03

400-430 main jets, depending on temp, use 66 gram weights 380 & 390 main jets, use stock weights

360 Main jets, 62 gram weights, stock driven clutch, 49 degree driven cam

340 & 350 jets, 60 g weights, 51 degree driven cam