Fitment Guide For Full System On The Triumph Thruxton 1200RS
Fitment Guide: Triumph Thruxton 1200 RS Reverse Cone Full System
Our Reverse Cone Full System has been designed as a direct replacement for the original Triumph exhaust, using the factory mounting points throughout. With a little patience and the correct installation sequence, the system can be fitted by anyone with basic mechanical experience. Just take your time and don't force anything.
Below are a few tips that will make the installation easier and help you achieve the perfect fit.
Before You Start
- Allow the motorcycle to cool completely before beginning work.
- We recommend laying out all of the supplied components before removing the original exhaust.
- Keep all factory fasteners until installation is complete, as several are reused.
- Do not fully tighten any part of the new system until every component has been installed and correctly aligned.
Removing the Original Exhaust
Remove the complete OEM exhaust system, including the headers, catalytic converter and silencers.
Carefully disconnect the original oxygen (O2) sensors before removing the headers. Avoid twisting the sensor wiring, as this can damage the internal wiring.
Retain the original exhaust port studs and flange hardware, as these will be reused.
Installing the New Headers
Install both headers loosely using the original flange nuts. At this stage they should only be tightened enough to support the system while still allowing movement.
A small amount of copper grease on the header joints can make future removal easier.
O2 Sensor Installation
The system isn't supplied with replacement O2 sensors - reuse the original factory ones.
Install each sensor into the threaded bosses before routing the wiring back to the original connectors.
Take care that:
- The wiring follows the factory routing.
- The cables are not twisted during installation.
- The wiring is kept well away from the headers and crossover pipe.
- There is enough slack to allow for engine movement without the cable contacting hot exhaust components.
Fitting the Crossover Pipe
Slide the crossover pipe into both headers without tightening the clamps.
This section helps position the entire system, so it should remain free to move while the silencers are installed.
Installing the Reverse Cone Silencers
Fit both silencers using the supplied mounting hardware.
Leave the mounting bolts finger-tight so the silencers can be adjusted during alignment.
Once both sides are installed, check that:
- Both silencers sit evenly when viewed from the rear.
- The outlet angles match.
- Equal clearance is maintained around the swingarm and rear axle.
Frame Clearance Tips
Before tightening any fixings, inspect the entire system for clearance.
Pay particular attention to:
- The left-hand frame rail.
- The underside of the engine.
- The side stand bracket.
- Rear brake components.
- Swingarm clearance.
A few millimetres of adjustment at each joint can make a noticeable difference to the final fit. If something appears slightly close, loosen the surrounding joints, reposition the system and try again before tightening. Never force any component into position by tightening bolts.
Final Tightening Sequence
Once you are happy with the alignment, tighten the system in the following order:
- Header flange nuts.
- Crossover clamps.
- Silencer inlet clamps.
- Silencer mounting bolts.
- Any remaining brackets or fasteners.
Working from the front of the motorcycle towards the rear helps prevent unnecessary stress in the system.
Before the First Ride
Start the engine and allow it to idle.
Check for:
- Exhaust leaks around the header ports.
- Any rattles or contact with the frame.
- Clearance around moving parts as the engine vibrates.
As the system heats up, it may produce a slight smell from manufacturing oils and protective coatings. This is completely normal during the first heat cycle.
After the first ride, allow the exhaust to cool completely before rechecking all fasteners. Stainless steel exhaust systems naturally settle slightly after their initial heat cycles, so a quick inspection is recommended.
A Note on Performance
As with any free-flowing exhaust system, an ECU remap or professional tune is recommended to allow the engine to make the most of the improved exhaust flow and throttle response.
Take your time during installation, leave everything loose until the complete system is assembled, and the result will be an exhaust that fits cleanly, looks factory-finished and delivers the sound and performance the Thruxton deserves.
