41+ Triumph Moto2 Exhaust

www.triumph-motorcycles.ca

Opening: Dreaming of Moto2 Sound and Style

Want to give your Triumph the aggressive look and throaty roar of a Moto2 race bike? Building your own exhaust system is a challenging but rewarding project. This guide will walk you through the essential steps, from planning to fabrication, to help you achieve that unique Moto2 aesthetic. Remember, safety first! Wear appropriate protective gear during all stages of this build.

Step 1: Research and Planning

Before you even pick up a tool, thorough research is crucial.

Evaluate Your Triumph Model: Understand the existing exhaust system configuration on your specific Triumph model (Street Triple, Daytona, etc.). Note pipe diameters, mounting points, and sensor locations (O2 sensors).

Moto2 Exhaust Design Study: Analyze images and videos of actual Moto2 exhaust systems. Pay close attention to the collector design, pipe routing, muffler shape, and overall aesthetic.

Material Selection: Choose high-quality exhaust tubing. Stainless steel (304 or 316 grade) is a common choice for its durability and heat resistance. Decide on the muffler material as well (stainless steel, carbon fiber, or titanium).

Dimension Planning: Estimate the required tube lengths and bend angles based on your bike's layout and the desired Moto2 style. This might involve creating a cardboard or wire mock-up to visualize the exhaust routing.

Tool and Equipment Assessment: Ensure you have access to a tube bender, welding machine (TIG preferred), cutting tools (angle grinder, chop saw), measuring tools, and safety equipment.

Step 2: Parts Acquisition

Now that you have a plan, gather the necessary components.

Exhaust Tubing: Purchase stainless steel exhaust tubing in the appropriate diameter and length. Consider buying pre-bent sections to save time and effort.

Collector: You can either fabricate your own collector or purchase a pre-made one. A pre-made collector will simplify the process significantly.

Muffler: Select a muffler that matches the Moto2 style you are aiming for. Shorty mufflers are a popular choice.

O2 Sensor Bungs: If your bike requires O2 sensors, purchase O2 sensor bungs that can be welded into the exhaust tubing.

Flanges and Mounting Hardware: Acquire flanges that match your bike's exhaust ports and any necessary mounting hardware (brackets, bolts, etc.).

Welding Rod/Wire: Choose the appropriate welding rod or wire for stainless steel (if using stainless steel tubing).

Step 3: Fabrication Cutting and Bending

This is where your fabrication skills come into play.

Cutting the Tubing: Carefully cut the exhaust tubing to the required lengths using a cutting tool (angle grinder or chop saw). Ensure the cuts are clean and precise.

Bending the Tubing: Use a tube bender to create the necessary bends in the tubing. Work slowly and carefully to avoid kinking or damaging the tubing. If using pre-bent sections, skip this step.

Test Fitting: Continuously test fit the tubing sections on your bike to ensure proper alignment and clearance. Make adjustments as needed.

Step 4: Collector Assembly

Assemble the collector, either by welding pre-made sections or fabricating it from individual pieces.

Welding the Collector: If fabricating your own collector, carefully weld the individual tubing sections together to form the collector. Ensure the welds are strong and leak-free.

Collector Placement: Position the collector in the desired location and tack weld it to the exhaust tubing.

Step 5: Welding and Assembly

The most crucial step, demanding precise welding skills.

Tack Welding: Tack weld all the exhaust tubing sections together, ensuring proper alignment and fitment.

Final Welding: Once you are satisfied with the fitment, fully weld all the joints, including the collector, muffler, and O2 sensor bungs (if applicable). Use a TIG welder for the best results and weld penetration. Clean all welds thoroughly after welding.

Mounting Brackets: Fabricate and weld mounting brackets to the exhaust system to secure it to the bike's frame.

Step 6: Finishing and Installation

Prepare the exhaust for installation and ensure a perfect fit.

Grinding and Polishing: Grind down any rough welds and polish the exhaust system for a clean and professional finish.

Installation: Carefully install the exhaust system on your bike, ensuring that all mounting points are secure and that there is adequate clearance from other components.

Leak Check: Start the engine and check for exhaust leaks. Repair any leaks immediately.

ECU Tuning (Important!): After installing the new exhaust, it is *highly* recommended to have your bike's ECU (Engine Control Unit) remapped. An aftermarket exhaust will change the air/fuel ratio, and a proper tune is essential for optimal performance and to prevent engine damage. Failing to do so can lead to performance issues, running lean, and potentially causing significant engine damage.

Conclusion: Roaring to Life

Congratulations! You've (hopefully) successfully built your own Moto2-style exhaust for your Triumph. This project requires skill, patience, and attention to detail, but the result is a unique and personalized exhaust system that will set your bike apart. Remember to prioritize safety and consult with professionals if you are unsure about any aspect of the build. Enjoy the new sound and style of your Triumph!

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