• Staintune 3-4-2-1 exhaust system for 98-99 models with lower water pipe
• Triumph part #2200019-T0301, 3 each, copper cylinder head to exhaust gasket
• Triumph part #3600036-T0301, 1 each, lower water pipe O-ring
• Triumph part #3550042-T0301, 2 each, copper sealing washer (M6), crankcase and water pump drain plug
• Anti-seize compound (optional)
• 2.8 liters 50% antifreeze mixture
• 10, 12, 13 and 14 mm open/closed end wrenches, 3/8 drive sockets and ratchets
• 3/8 drive Torque wrench calibrated for Newton Meters (Nm)
• catch pan for old antifreeze

Steps:

Remove the system from the box and marvel at its beauty

1. Fit the two downpipe sections together
2. Fit the SP un-silencer to the downpipe assembly
3. Notice how tightly the pieces fit.
4. Get ready to get dirty

Drain the cooling system

1. Open the

Remove the OE lower water pipe and install the Staintune water pipe with the new O-ring

1. Tighten bolt to 8 Nm

Remove the OE exhaust system

1. Loosen  the clamps holding the silencers to the downpipes. The nuts are on the opposite side of the decorative covers. Once loose, remove the decorative covers. NOTE:  Vibration from normal operation may have caused the "L" brackets for  the covers to crack and separate.
2. Remove the right pillion footrest to release the silencer hanger.
3. Leave the two silencers attached to the hanger and remove the set from the downpipes by gently pulling back with a up and down rocking motion. NOTE:  It's not unheard of for the mounting bolts to become rusted to the rivnuts in the silencer. In this case attempting to remove the mounting bolts will cause the rivnut to break free from the silencer and spin with the seized bolt.
4. Remove the nuts holding the downpipes to the cylinder head and then remove the the downpipes. The nuts are torqued to 20 Nm, in two steps, but are very easy to remove. NOTE: If the nuts are not easy to remove be careful not to exert to much effort in their removal. The stud that they are on is threaded into the cylinder head and may loosen.
5. With a small slotted screwdriver or pick remove the copper downpipe gaskets for each exhaust pipe. NOTE: Note which way the gasket lays against the head. There is a flat side and a seamed side to the gasket. I didn't take note so when the Haynes manual referred to a flanged side. I chose the flat side. The Triumph manual only mentions using new gaskets.

Install the Staintune exhaust system

1. This is where fitting the system together on the living room floor comes in. I feel that it is important that you have a vision of how the individual pieces will fit together at this point. While not outlined in the Staintune information sheet supplied with the system, confirmation was received that use of a copper based sealer at the joints won't hurt.
2. Prior to fitting the two sections that make up the downpipes run a small bead of sealer in the female sections. As the male sections are inserted the sealer will provide some lubrication and spread to seal to joint.
3. Fit the two sections together.
4. Haynes recommends a smear of grease  to the *flanged* side of the copper gasket to hold it in place. Place the exhaust gaskets *flanged* side inwards into the cylinder head  port.

Refill cooling system

Back to How Do I?