^Seeing as you're unable to rotate the muffler without it hitting either the swingarm or tyre, then I'm thinking that Kennon might have a very vali8d point - that the muffler is too long. I've two after-market mufflers, one a no-name cheapo brand and the other a IXIL hexagonal design, both mufflers I've fitted to my TR (TK). The cheapo muffler first before the IXIL. Both mufflers were designed for the Kwaka 650.
It's not easy to tell for certain based on the photos, but I'm pretty sure the mufflers I have aren't as long. I'll go measure both mufflers later on today and post up the measurements.
Both mufflers clear the swingarm and tyre.
Attachment 17265
No name muffler fitted. Note that the outlet is pretty much right beside the RHS edge of the rear tyre.
Attachment 17266
No name muffler, fitted with horizontal profile, meaning outlet directed outwards away from the bike.
Quick question Brian, did you make sure that the muffler was slid as far up the distal end of the header pipe as it could go? I ask because this was something that I found was not easy to achieve on both mufflers when I installed them at the time.
If the muffler is not forced as far as it can onto the pipe this would explain why it looks to be either longer than the usual aftermarket mufflers on all NK/TK's I've seen, or otherwise is sitting too far back.
If you fitted this muffler yourself, I think it's worth checking that the muffler has travelled as far as is possible into the pipe. I used a lubricant, a clean rag, small length of wood, rubber mallet. I applied lubricant to both the distal end of the header pipe and the muffler insert end. I used a lot of argy-bargy to manipulate the muffler onto the pipe. At times I used the rags and wood to absorb and soften blows from the rubber mallet to the end of the muffler.
The fit is very tight Brian and it might seem that the muffler is on the pipe, however when I thought I'd got the muffler on, I found that not to be the case for me. Oh, and I used a lot of tongue movements too.
