Muffler fitment issues

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bread320i

New Member
I have been having problems reassembling my KO CT-70.
My biggest problem is the muffler. It about a 1/4" too long. I can barely get it to mount on the head and the hanger on the shock at the same time. Now that is on, my skip plate interferes with muffler and wont mount to the bottom of the engine.
This engine has been serviced during the project. I had a mechanic install new rings and valves. To the best of my knowledge the engine is correct, but I feel engine is to short which is throwing off the alignment of everything.

Any ideas? Can I take measurements and figure out if something is assembled wrong?
 
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bjatwood

120cc
Is a a original muffler, or aftermarket?
When I bought my OEM exhaust for my HKO there is definitely some
wrangling that needs to be done to get it to fit the first time.
Put the exhaust on the head first with the bolts very loose, then try to
put the shock mount stud on next. I even used a drillbit to enlarge the rear mount
hole a little also.
This was how I had to install my exhaust the first time.
Good Luck
 
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bread320i

New Member
After many hours of head scratching I finally figured it out. I knew all along it was operator error. Originally, I must have quickly looked at the diagram of the exhaust system and assembled it as shown.

I took it all off and though about what order the parts go in and bam... I had the spacers in before the exhaust pipe. Im not sure what I was thinking, or drinking but Im glad I got it on properly.
 
Last edited:
kmcrab

kmcrab

120cc
I'm glad you got it...What I have found works the best/easiest/fastest is if you mount the exhaust at the head and then remove the top motor mount bolt, leave the bottom one in so the engine will pivot up and down.(loosen the bottom bolt) Then just lift the motor up, slide the exhaust on the shock mount and gently lower the motor and put the motor mount bolt back in. Done.
 
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