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May 21st, 2010, 10:11 PM   #1
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Match porting.

Whilst marking up the inlet port for matching to carb/inlet rubber I noticed the inlet rubber hole is not round.
3/4 of the hole is ok but the 6 oclock to 9 oclock area is quiet deficient in rubber raising the question, has anybody else noticed this?
The bother is that it makes it a little harder to flow everything through. A couple of solutions spring to mind but i thought I'd see if this was common (and therefore possibly intentional to induce some kind of ?) or if i just got a dud and should find another.
The part number of mine is KTM 590.36.044.100.

any input anyone?
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May 21st, 2010, 10:56 PM   #2
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Re: Match porting.

I just did mine, didn't notice it being out of round on the head but was weird on the carb side, Ill check when I get a chance as I have a spare to look at as well.
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May 21st, 2010, 11:16 PM   #3
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Re: Match porting.

Cheers for that bushie
Yeah looking from the head side out it doesn't look too bad, certainly not as obvious as when looking from carb side. but it was the odd shaped mark that i left with the felt tip that alerted me.
I'll be interested to know the part no stamped on your inlet manifold too m8.
cheers bro.
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May 21st, 2010, 11:36 PM   #4
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Re: Match porting.

both mine have the same number as yours

there is a different one for the 450/501/550 800 36 044 000

looks like what they are doing is trying to match up to the carb bore being offset to the carb spigot, "problem" is with the carb so to speak.

the ID of the rubber thingy is about 43mm great! just bore out the carb to 43mm
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May 21st, 2010, 11:42 PM   #5
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Re: Match porting.

Sweet as. ill just give the 42 mm hole saw a wiggle as i run it through eh? posting.php?mode=reply&f=5&t=12567# should do it .
So is that 43mm on the round bit or the oval bit?
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May 22nd, 2010, 12:03 AM   #6
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Re: Match porting.

43mm on the smallest bit, they're not oval I think, just off centre because the carb OD and ID are off centre
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May 22nd, 2010, 10:18 PM   #7
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Re: Match porting.

xelent. cheers mate.
Was suziberg just a photoshop exercise or does it exist? looks fairly smart. I couldn't see the grinder marks. hehe.
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May 23rd, 2010, 01:29 AM   #8
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Re: Match porting.

just photoshop

the "new bike" berg pic has the grinder marks, 50mm extended frame and relocated shock upper mount. 25mm lower than stock and 3 kgs heavier

new Cromoly frame will be 50mm lower than stock and 6-7 kgs lighter, carbon tank/airbox with a more suzi like rake/trail.
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May 23rd, 2010, 08:25 PM   #9
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Re: Match porting.

Ya "new bike" sounds like it should be a weapon in the rough.
One of the other threads you mentioned a torquey cam which takes a bit off the top end, thats gotta be the cam you use with 16/40 gearing surley.
My bike came with motard gearing (16/40) and 18 inch rear which meant top was no good unless over 120km/h which got me thinking about your set up until I saw the Torquey cam thread.
that setup must bring the overall wear down as I am a firm believer that revs kill motors.
Next mental picture I am struggling with is you doin somewhere over 180ks across a dessert with ya paddle putting up a monster rooster tail...... Koooooool.
Oh to have more time and creativity....... and a dessart out back.
Keep up the good work.


This site is becoming a habit.
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