2016 T120 Motone x-pipe install issue - Triumph Forum: Triumph Rat Motorcycle Forums
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post #1 of 37 (permalink) Old 08-31-2019, 01:53 PM Thread Starter
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2016 T120 Motone x-pipe install issue

Hi, so I just spent a half day installing the Motone x-pipe on my 2016 T120. Goes fine until I attempt to reinstall left side header pipe, which isn’t lining up properly. If I slide it into the x-pipe port first, it’s a good 1/3 Inch below lining up properly on the header port. If I install header port first, it chews into the graphite gasket and still won’t go on. I’ve unbolted and resecured the frame rail thinking I somehow didn’t bolt it back on correctly, checked everything else for obvious signs of misalignment but don’t see any issues. There’s only so much any of it (rail or x-pipe) can move once secured. Anyone run into this before or have advice on what to check next? The right side header and silencer re-installed fine, left side silencer as well. I’m at a loss
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post #2 of 37 (permalink) Old 08-31-2019, 04:39 PM
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Iíd check the x-pipe measurements..... remove the x-pipe, look at left and right side distances between the two centers of the x-pipe. Seen some shocking manufacturers of the x-pipe and you need to rule out the x-pipe as the culprit before moving on.....

Mick

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post #3 of 37 (permalink) Old 08-31-2019, 05:19 PM
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Are you leaving any connections you make loose until everything is connected? I think you will need to have the header pipe connected at the head or at least in place. At least that how it worked for me.

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post #4 of 37 (permalink) Old 08-31-2019, 06:28 PM Thread Starter
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Originally Posted by T120 Mick View Post
Iíd check the x-pipe measurements..... remove the x-pipe, look at left and right side distances between the two centers of the x-pipe. Seen some shocking manufacturers of the x-pipe and you need to rule out the x-pipe as the culprit before moving on.....

Mick
Havenít done this yet, but will definitely do so. Thanks
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post #5 of 37 (permalink) Old 08-31-2019, 06:31 PM Thread Starter
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Quote:
Originally Posted by Hookalatch View Post
Are you leaving any connections you make loose until everything is connected? I think you will need to have the header pipe connected at the head or at least in place. At least that how it worked for me.

Chuck
Chuck, do you mean connecting all exhaust components before tightening them all down down? If so, then yes. If youíre talking about frame rail also, I did tighten it down first, but not torqued.
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post #6 of 37 (permalink) Old 08-31-2019, 09:36 PM Thread Starter
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Originally Posted by T120 Mick View Post
Iíd check the x-pipe measurements..... remove the x-pipe, look at left and right side distances between the two centers of the x-pipe. Seen some shocking manufacturers of the x-pipe and you need to rule out the x-pipe as the culprit before moving on.....

Mick
Mick, I pulled the x-pipe and it does seem to be off spec just slightly. Iím sending back for replacement and will follow up after I get a new one on. If that ends up being the issue, Motone shouldíve caught this in QC. What a pain in the ass to get into it and discover a flaw that shouldnít have left the manufacturing floor.
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post #7 of 37 (permalink) Old 08-31-2019, 09:38 PM
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IIRC, the Motone is like the TEC in that it uses the original cat mount. I removed the entire exhaust system to install the Tec X-pipe. I think it's critical to install the header pipe openings straight onto the X-pipe, being really careful not to damage the graphite mesh gaskets. With the pipes hanging on their head studs and fitted onto the X-pipe, I cinched the header pipes to each other with wraps of masking tape across the X-pipe, to hold the header pipes together while I got the V clamps on their flanges. Otherwise, I was running out of hands and the header pipes would spring apart before I could get the clamps on. With the V clamps in place, slide the mufflers straight on, again being careful with the gaskets. Hang them with their hardware. Now, wiggle and tighten, wiggle and tighten, until everything is back where it needs to be, and tight.

If there's gasket damage, new exhaust leaks will show up as discoloration and sooting at the gaskets.

Be really careful with the O2 sensors on the headers. IIRC, each requires five complete turns to install. First, turn the sensor five turns in the LOOSE direction before threading on and tightening. Otherwise, the wires will kink and eventually break from the stresses. Pull the insulation away from the wires to be sure they are not twisted.

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post #8 of 37 (permalink) Old 09-01-2019, 01:21 AM
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Quote:
Originally Posted by trturner View Post
Mick, I pulled the x-pipe and it does seem to be off spec just slightly. Iím sending back for replacement and will follow up after I get a new one on. If that ends up being the issue, Motone shouldíve caught this in QC. What a pain in the ass to get into it and discover a flaw that shouldnít have left the manufacturing floor.
Would like to see a steel rule up each side, checking for square as well....

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Originally Posted by tsmgguy View Post
IIRC, the Motone is like the TEC in that it uses the original cat mount. I removed the entire exhaust system to install the Tec X-pipe. I think it's critical to install the header pipe openings straight onto the X-pipe, being really careful not to damage the graphite mesh gaskets. With the pipes hanging on their head studs and fitted onto the X-pipe, I cinched the header pipes to each other with wraps of masking tape across the X-pipe, to hold the header pipes together while I got the V clamps on their flanges. Otherwise, I was running out of hands and the header pipes would spring apart before I could get the clamps on. With the V clamps in place, slide the mufflers straight on, again being careful with the gaskets. Hang them with their hardware. Now, wiggle and tighten, wiggle and tighten, until everything is back where it needs to be, and tight.

If there's gasket damage, new exhaust leaks will show up as discoloration and sooting at the gaskets.

Be really careful with the O2 sensors on the headers. IIRC, each requires five complete turns to install. First, turn the sensor five turns in the LOOSE direction before threading on and tightening. Otherwise, the wires will kink and eventually break from the stresses. Pull the insulation away from the wires to be sure they are not twisted.

FWIW
Yep agree with that lot, I removed the tank and 02 sensors from that end, made life easy. Also used masking tape on the underside of the header clamps (100mm / 4Ē )so that I could easily move the loose clamps and header pipes around without damaging the headers, imperative that you donít damage seals as mentioned.

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post #9 of 37 (permalink) Old 09-01-2019, 02:38 AM
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The Motone instruction video shows that you can remove the header clamps, then put the bottom one back on. This loosens the header enough to replace the cat without removing the O2 sensor.
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post #10 of 37 (permalink) Old 09-01-2019, 04:45 AM
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Quote:
Originally Posted by Dougl1000 View Post
The Motone instruction video shows that you can remove the header clamps, then put the bottom one back on. This loosens the header enough to replace the cat without removing the O2 sensor.
There wasnít any instruction media at all when I did the first two, maybe I just like pullíin sh*t apart

It certainly was suck it and see.....like most things that can be pulled apart, itís great to have a manual, parts lists are great too,


Mick

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