Aluminum intake manifold for 2002 FC550 to fit Keihin

Hi,

I wasn't satisfied with the way a Keihin carburetor fits to the standard intake manifold and decided to go for an aluminum intake manifold with an original KTM intake boot. The manifold's groove is copied from a KTM cylinder head. This way the Keihin fits perfectly. I'm using the intake boot with a small angle to correct the Keihin's alignment with the air filter box (it's in a sidecar chassis). Also the original clamps will be used.

Regards,
Stephan

Hi all,

I was a little busy fixing the last issues with the bike. Our workshop closed recently and cleaning up/moving out everything was quite a lot of work. I finished the bike at a different location. But today I started it the first time
With the newer model auto-decomp and Keihin carb starting was a piece of cake, even with sneakers and no manual or kickstart activated decomp! Even easier then those old day Maico 490s.
The engine's sound is different, fuller like a good dark strong ale, smooth and power full. Difficult to explain but there's definitely a difference. It was too late to take the bike out to the nearest track, they closed early.

The snow has started to melt last week and friends of me, riding this weekend, switched already from spikes to regular tires. In the South of Finland the tracks are getting softer now.

The machine shop could do only a circular groove and because they didn't had the Husaberg cylinder head, they had no idea if there was space for this shape of O-ring. Maybe next model. I'm using a paper gasket for now.

I used the KTM SX engine's cylinder head as a model to have the correct support for the intake boot. I'll take some pictures when the bike is outside the truck to show how this looks like when installed.

Tomorrow I'll check for some holiday I feel I need very much now, you know where to find me :wink:

Regards,
Stephan

Hi ElSnorro,

KTM part # 59436044000 rubber clamp 450SX '03. Take care to use the original clamps too, 2 x 59030061000 (D=56mm B=9mm). This way the carb fits perfectly and the rubber boot will be correctly tightened. The rubber boot is also available as a straight type, depends on the air filter boot which one suits best.

Best regards,
Stephan