Triumph Bonneville Full Exhaust Installation
Time: ~1 hour | Note: Always work on a cold engine.
Watch the Tutorial Installation Video
1. What’s in the Kit
| Qty | Part | Notes |
|---|---|---|
| 1 | Exhaust | Clamp pre-installed |
| 1 | Rear mounting strap + spacer | Bolts to pillion-peg boss |
| 1 | Spring(s) | Collector → silencer |
| 1 | 4.2 mm HSS drill bit | Labelled “4.2 mm” |
| 1 | M5 × 0.8 tap | Labelled “M5×0.8 ” |
| 1 | T12C stopper stud | Side-stand stop |
| – | Stainless fasteners | Various sizes |
2. Tools You’ll Need
- Ratchet + 10–14 mm sockets
- 4 mm & 5 mm Allen keys
- Torque wrench (10–40 N·m)
- Low-speed drill
- Masking tape & marker
- Medium thread-locker & copper anti-seize
- Pliers (for collar pin)
3. Remove the Stock Muffler
- Stabilize bike on center-stand or paddock stand.
- Loosen collector clamp.
- Undo rear hanger bolt.
- Slide OEM muffler straight back and off.
4. Trial-Fit Your New Silencer
- Slip silencer onto collector.
- Hook rear strap + spacer onto pillion-peg boss; finger-tighten bolt.
- Leave all fasteners loose for adjustments.
5. Install Side-Stand Stopper Stud
The high-mount pipe may interfere with your stand. The T12C stud ensures clearance.
- Locate contact point: Lower side-stand, mark where it grazes silencer.
- Drill: Mask paint, clamp stand tube, drill with 4.2 mm bit.
- Tap: Cut M5 × 0.8 threads, clear shavings.
- Fit stud: Thread-lock T12C stud, leave ~3 mm protruding; verify 2–3 mm pipe clearance.
6. Final Alignment & Torque
- Align assembly so it clears swing-arm & wheel.
- Torque in order:
• Header flanges → 20 N·m
• Silencer clamp → 10 N·m
• Rear strap bolt → 25 N·m - Re-hook springs; wipe fingerprints off stainless.
7. Level Left & Right
- On center-stand, measure from floor to identical point on each outlet.
- If unequal, loosen four outlet-bracket bolts slightly.
- Remove collar pin, rotate collar one notch, re-insert pin.
- Re-measure until both sides match ±1 mm; torque bolts to 20 N·m.
8. Final Checks
- Cold-start: check for leaks at flange & clamp.
- Fold stand / press pedal: ensure no contact.
- After 50–100 km: re-torque all fasteners and stud clearance.