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Discussion Starter #221 (Edited)
that is an option too...I was worried that the metal part of the connector was grounding out on the cover.

I'll try removing the outer insulator piece. that seems to be where it's getting hung up.
 

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Discussion Starter #223
sawed the old muffler apart. internal baffle chamber completely blocked inside. hot exhaust gases could not escape. that's why it was getting so hot.
 

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Caused you a lot of trouble.
 
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