Raptor 30/50 v2 assembly manual
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Now it is time to install the engine, but first check over the bolts and nuts of the engine. The factory might have not tightened all the bolts. BTW: I'm not just talking about TT engines, this applies to all engines. Don't over torque any, afterall it's threaded into aluminum and will strip out. Do make sure all bolts on the head and back plate are on snug. Ideally take them each out and put blue loctite on. When tightening the head bolts use a star pattern, don't tighten one beside another like in a circle pattern. Check the nut that holds the throttle arm on (again, blue loctite). Also check the fuel nipple on the carb. And the small bolt that keeps the carb arm/barrel from coming out.
Next loosely bolt the engine to the engine mount (4) with bolts (1) and blue loctite. The end of the mount with the bolt holes closer will be the bottom. Slide the engine into position. Use four more bolts (1) with washers (3) on each to bolt the engine mount* in place. Remember the bolts holding the engine to the mount are still loose. Rotate the start shaft coupler (the hex start on top of the start shaft) backwards. You should feel very little resistance if any. If it's good then tighten the bolts and check again. If the coupler does not turn freely then twist the engine to find the best position. If this helps but is still not enough, then go ahead and tighten the bolts and then loosen the engine mount bolts and twist the engine slightly one way or the other to find the position that offers little resistance to the start coupler. Tighten the bolts and recheck. What this does is align the engine to the start shaft.
Now it's time for the muffler. If you have a two piece muffler like in the picture then make sure you get the bolt tight that runs through the center of the muffler. It helps to tighten the bolt after it's hot from the first run. If the two half's get loose, this will cause the engine to run lean. Also check the pressure nipple. I recommend to install it with JB Weld. Make sure the hole through the center of the nipple was drilled all the way. Sometimes during mass manufacturing, flaws like this can occur.
Bolt the muffler to the engine. Use loctite unless the muffler has nyloc nuts that the bolts screw into. BTW: If the bolts screw directly into aluminum threads that are part of the muffler then usually you will find after taking the bolts in/out many times that the threads strip out. In that case just use a longer bolt that will go through the holes and out the other side. Then use nyloc nuts to secure the muffler to the engine.
PS: Notice I did not say to install a gasket? In my experience it always seems they do one of two things... break down and leak and/or cause the bolts to get loose because of the different expansion/contraction rates between the aluminum and the gasket material. I just make sure the surface of the engine and muffler exhaust flanges are clean and flat and just bolt them straight together. This has worked much better then any gasket I have ever used.
Next hook up the pressure line from the top nipple of the tank to the muffler. Also hook up the one from the tank to the engine.

*If using the TT glow plug extension 3808, then put the glow extension plate in place of the bottom right washer (3). Also if installing on a Raptor 50 then you may need to put a bend in the plate to angle the wire so it does not touch the engine. Also remember not to flood any bolt with loctite, just use a drop. The 3808 extension depends on the ground connection through the engine mount bolt. So if you have too much loctite then it may not work. You can use a metal brush tip on a dremel to clean off excess loctite and remove some of the enamel coating on the bolt so the bolt will conduct good.

Tip: After the first run, re-tighten the muffler bolts while it's still hot. This will help keep it from loosening and falling off later :)

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