Termignoni 2-1-2 Exhaust
 

 
in progresss...
 

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In my opinion the Temignoni 2-1-2 exhaust is one of the best looking exhaust systems for the XR1200.  Yes their 2-into-1 exhaust looks good too, but I am partial to dual cans on the XR1200.  It is also a finely crafted exhaust system that is very easy to install and gives good access to the O2 sensors.  Even at that, it does have some minor issues like the locking nuts on the bands that hold the exhaust cans in place being a pain to work with, but the pipe still looks good.  It offers good performance in comparison to the OEM exhaust and a nice weight reduction.  Here are some notes on the Termignoni 2-1-2....
 
 
 
 
 
 

 
Weights
 

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Weighing the Termignoni Header Pipes

 
 
 
 
 
 
 
 
 
 
 
 
The weight of the stainless steel exhaust tubes is 9.10 lbs.  These pipes are beautifully made and have double sleeved collars on the ends.  The quality of these exhaust tubes is much higher than any of the other exhaust systems for the XR1200 - and with that comes a bit more weight, but tightly fitting joints.
 
 
 
 
 
 
 
 
 
 
 
 

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Termignoni Exhaust Can weight

 
 
 
 
 
 
 
 
 
 
 
 
 
The weight of a pair of the carbon fiber sleeved exhaust cans is 5.40 lbs.  This version of the exhaust system did not have the silencer tubes, so that weight is not included.
 
 
 
 
 
 
 
 
 
 
 
 
 

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Termignoni Miscellany Weight

 
 
 
 
 
 
 
 
 
 
 
 
All of the miscellaneous hardware and hanger brackets weigh 2.10 lbs.  The Termignoni uses its own brackets vice the rear passeng footrest mounting point, rear hanger, and HD front hanger at the bottom of the engine.
 
 
 
 
 
 
 
 
 
 
 
 
 

 
That puts the total weight of the installed Termignoni 2-1-2 exhaust system at 16.6 lbs, or about 23.4 lbs lighter than the stock exhaust when the rear footrests and other stock hangers are removed.
 

 
Installation of the Termignoni 2-1-2 Exhaust
 

 
The fit of the Termignoni exhaust pieces is excellent.  Even at that though, there are some issues with installation. 
 
The first thing to deal with is that Termignoni made the pipe to work with stock narrowband O2 sensors, and not with the slightly larger diameter wideband sensors that I am using with the Thundermax.  It is a relatively simple fix with the right tools.  The excess metal in the center of the bung needs to be ground away.  I did this with a drill press and some care.  The next picture shows the before and after of opening up the O2 sensor bungs.
 

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Opening up the Senosr Holes

 
Once the O2 sensor bungs are opened up, the individuala header pieces can be mounted.  The nice thing is that they give clearance to install the O2 sensors without having to undo or twist wires.  Here is the rear header piece, and then the rear pieces installed with the sensor.
 

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Rear header piece

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And the front header installed on the head.
 

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The above pictures show the retaining springs installed.  During installation though, it is good to spray all of the tube joints with lubricant, loosely install the header flanges, and leave the springs off until everything has been aligned.  It may take a little experimenting, but once done the bottom hanger bracket will line up, and their will be clearance between the pipe and the swingarm.
 

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5b_Clearance_to_swingarm.JPG

 
With the header pipe sections installed and loosely fastened, one can install the rear hanger bracket and exhaust cans.  To me, this is the toughest part of the installation.  The bands that hold the exhaust cans have destructive metal lock nuts.  They are difficult to align, and can not be backed out once they are started.  It pays to get this right the first time!
 

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Here is a look at the locking nuts on the mounting straps for the exhaust cans.  Positioning the straps and starting the bolts can be tricky, but it needs to be done right the first time.  The lock nuts use a destructive ring that can not be easily backed out. 
 

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9b_Can_mounting_plate.JPG

 
Once everything is aligned and tightened, the pipe can be cleaned with some brake cleaner to remove oils and prevent oil burning into the pipe, and the retaining springs and heat shields installed.
 

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Installed and looking good...
 

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Exhaust tube sizes
 

 
To give you an idea of the difference in diameter between the exhaust systems, the Termignoni headers start at an internal diameter of 1.572" and in about 3 1/4" it steps up to 2.038".  The pipe continues at the 2.038" diameter to the collector where it combines into a single 2.5" ID pipe that later separates into the system's dual exhaust cans.
 
The D&D 2-into-1 exhaust headers start with an ID of 1.450" which steps up after about 30" to an ID of about 1.6".  This diameter continues for approximately 12" to the collector where the headers combine into a single exhaust can. 
 
The "standard" Torque Hammer has an ID of 1.554".  (The larger diameter prototype Torque Hammer has an I.D. of 1.670", which appears to be the largest diameter tube which can fit through an OEM exhaust flange.). 

 
Noise Level
 

 
Using a digital sound meter (measured outside in free space, at 1 and 2 meters from the end of the exhaust can), the V&H Widow exhaust sytem measured:
 

 
Engine Speed

 
dB @ 1 meter
 

 
dB @ 2 meters
 

1,000 RPM

102 dB

98 dB

3,000 RPM

??? dB

?? dB

 
YES, this is one of the louder exhaust systems.  I do not think it is excessive, but some people might.
 

 
HP/TQ Dyno Numbers
 

 
The below are graphs of the Termignoni 2-1-2 exhaust system (RED) vs the D&D 2-into-1 header with the special exhaust can (BLUE), on the 1200 build with 575XR cams, CNC ported heads, and pistons to keep CR at 10.2  For comparison, I have added the stock engine with the OEM exhaust (GREEN).  Note that the D&D and Termi pipes on the 575 build were run with a 38 tooth primary gear and 29 tooth transmission pulley, while the stock build had the original 34 tooth primary gear and 28 tooth transmission pulley.
 
The Termignoni eaked out a few more peak HP than the D&D header, but the added Torque throughout most of the RPM band would make the D&D pipe an overall winner, power-wise, on the street.
 
 

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D&D vs Termignoni vs Stock Build with OEM pipe

 
Conclusion
 

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