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I need a suggestion on what I’m doing wrong. What seems like a straight forward installation of a stock 360 muffler has me stumped. I looked at the exhaust parts diagram and it’s not entirely clear to me what the order of the mounting parts is.
To me, the muffler bracket should mount on the tool box post first and then the large washer/\rubber grommet/cap washer/washer/nut follow.
The muffler bracket is about 2mm short of going onto the tool box mounting post. I don’t find anything that could be obstructing the muffler from moving the extra 2mm. The pipe is fully seated into the exhaust flange.
I can bolt the muffler on if I put the rubber grommet and large washer on the tool box mounting post first and then put the muffler bracket on last. But this does not seem like a logical orientation.
Any thoughts are appreciated.
Thanks
 

I'll try and post photos of mine.

Be aware that the online parts lists are wrong for the two special washers encompassing the grommet - the inner one is, I think, M8 inner diameter and the outer one is 6mm. I drilled out one a bit larger to fit.









 

Thanks for the pictures, Gr8uncleal.
Now I need to figure out why my muffler bracket is just shy of reaching the mounting post so I can get it installed and try to start the bike. I could drill out the bracket hole to make it fit but I don’t want to do that. The muffler was obviously mounted properly when I removed it and rebuilt the engine.
I’m baffled (pardon the muffler pun) by this. Same motor with top end rebuild, same exhaust flange that was not removed from the engine, same frame and same muffler.
Please chime in if you can give me any ideas.

 Thanks 
 

Have you packed a lot of exhaust sealing string into the flange on the cylinder which would pull the pipe forward, [that's stretching the imagination a bit though].
Is there enough play in the engine mounts to loosen the & pull the motor back as hard as you can then tighten.
Look forward to what fixes it apart from severe methods.
I've not looked at your pics yet.

Thanks for your thoughts. I finally got the muffler mounted correctly. It was wrestling it into just the right position and the bracket slid over the mounting post. I just need more perseverance.
And Gr8uncleal’s pics were good to let me know I was correct in the order of the fasteners.
 Regards

I fought with mine too. I eventually won…. But the idea is to remember… gotta burn out the exhaust pipe in the fire pit a few times during its life
Sneezles61

Really?
Do not know about that. Is it just to decarbonize the internal chamber?

Yup. Some how it needs to be cleared of it…
Sneezles61

Exhaust gets soaked inside in the internal packing along the walls (if it's still there & not blown out in little bits over 50 years) then being oil soaked it will smoke terribly when hot. If yours was ok before then it should be ok now.
Worst case it'll get restricted with carbon enough to to reduce performance in increasing severity until you complain. You'll know when it gets that bad.
Sorry playing on my vintage mini iPad which is struggling so hope it posts.

Hey RT325 where’s your video?