'05 KTM Carb Needles

Discussion in 'Thumpers' started by Gerg, May 6, 2005.

  1. Gerg

    Gerg Gergy Bear

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    I know, I should have taken a picture BUT you cant move the needle on the '05 carb. There is a clip and two slots above the clip but below the clip is a nylon bushing that I could not budge! So I reverted to my Harley Days and dug out my #4 washers and put two of them in to raise the needle.

    I also did a canisterectomy. That was an adventure. I broke a bolt trying to get the side panel off. The one that holds the rack. Both sides were buggered up. Luckly there was enough sticking out that I could get a pair of vice grips on it. A little penetrating oil and it came out. The bolts almost look like they were bottomed. The last few threads on both bolts were really buggered.

    And I've added a Powerlet to run my air compressor. Now I get to put it all together tomorrow. What fun :dunno

    Anybody have the detail of the airbox mod. I cut a 2" square hole in the airbox cover and put a chunk of UNI Filter in it. When I reassembled it all it seems like there is no point to doing that. The side panel fits WAY to close to provide any air to that opening :dunno

    Do I need to cut a hole in the side panel as well as the airbox cover?

    Gerg
    #1
  2. creeper

    creeper Still alive...

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    The washer is a real tight fit on several of the BSTs I've run into. The needles are hard, so you can apply a good amount of pressure without fear of breaking one.
    #2
  3. Mack

    Mack Gone, but never forgotten. RIP, Mack...

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    Pic thanks to Arch

    [​IMG]

    KTMtalk.com seems to be down tonight, but if you search the hardparts listings, you should be able to find the screened airbox cover.

    EDIT: Site is back up:

    [​IMG]
    Hard Parts Catalog: Radiator Air Box, and Filters
    Part Number: 58406003200
    Description: AIRBOX COVER RACING LC4 640
    Retail: $29.95
    #3
  4. Gerg

    Gerg Gergy Bear

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    When you run that cover you don't put the side panel on?

    Thanks for the pics!

    Gerg
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  5. meat popsicle

    meat popsicle Ignostic

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    weird, can't imagine they did that on purpose... :scratch the replacement needles from Sudco are listed on a thread somewhere :cromag cugino pegaso listed them i think - nobody has tried them to my knowledge. if you got 65 bucks burning a hole in your pocket the north bay area here in cali has a shop called factory pro that makes a custom Ti needle for the BST :deal

    doesnt the one on the dash work? I used it w/ someones BMW pump at WARPED.



    Sommer KTM has tested with the side panel back on - air gets in there don't worry. Others like PASSMORE have the unipod filters going all the way thru the side panel - the question is getting the airbox and pipe mods balanced (w/ the carb tuning). If you do weird stuff like Passy then you will have to tinker with the extent of airbox modification, the carb tuning, and the pipe setup. :nod If you stay in more known territory then others work will get you close. :D
    #5
  6. AceRph

    AceRph Affluenza Free! Administrator

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    Geez gerg! How many thumbs to do you have on one hand?

    :lol3
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  7. Gerg

    Gerg Gergy Bear

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    :doh

    Well, I got that nylon shim to move this morning. Amazing what you can do with clean (and rested) hands :thumb

    Now the search for some mainjets (sound familair Meat?).

    She's a bit flat when you really try to honk it. There should be more grunt above 5500 RPM.

    Impatiently waiting for my IDS2 quiet core :evil (and the local Hardware store to open so I can finish putting her back together).

    Gerg
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  8. creeper

    creeper Still alive...

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    Harley shop... same as Mikuni HSR 40/42/45... bla bla bla :brow
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  9. Gerg

    Gerg Gergy Bear

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    Headed there at 9:00. I think I'll ride big orange :evil

    Gerg
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  10. Renazco

    Renazco Formerly AKA Boejangles

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    Assuming your relating to the inner panel not the outer right? In that case discard the inner panel.
    Also make sure you use something around the circumfrence of the new airbox vent. The new vent does not sit flush on the airbox and requires (improvision)
    I used some hard foam to prevent the cover from tweaking when you screw it down, it also eliminates larger particles from sneaking into your airbox.
    #10
  11. creeper

    creeper Still alive...

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    What James said. This is one I made from CF plate... the foam on the back is 1/4" closed cell. James knows way more about foam than I do, but this stuff is semi-soft and "conforms" to the airbox edge.

    [​IMG] [​IMG]
    #11
  12. Renazco

    Renazco Formerly AKA Boejangles

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    You lost me babe,, I was alluding to the KTM airbox mod :huh

    btw, the closed cell is not allowing any air in :dunno
    #12
  13. creeper

    creeper Still alive...

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    The closed cell stuff is the gasket... the air goes thru the UNI pop-ins. :lol3
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  14. Renazco

    Renazco Formerly AKA Boejangles

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    O.K. I studied the photo's again and see the foam layer,, I was expecting to see something around the circumfrence but looks like you just lined the whole thing..
    I also assumed you were alluding to using closed cell in place of the uni filters, my bad Doc :brow
    #14
  15. creeper

    creeper Still alive...

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    No biggie... it's easier to glue down a big panel of foam than a narrow edge gasket. When I was makeing rectangular screened ones, I did the same thing... used the foam to hold the screen in place. :evil

    HSR42? :dunno
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  16. Gerg

    Gerg Gergy Bear

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    Ok, Looks like I did Ok on the air box mod I did do. Could have been cleaner but it'll work. Might have to get the hardparts cover :nod

    Got a 155 jet installed. Moved the clip down one.
    WOW! If I didn't do it myself I'd have thought something else was done.

    How in the heck does richer jetting quell vibration:dunno Not only is it smoother but it's got way more snap and it pulls ALL the way to redline now (4th) Doesn't seem to run out of breath like it did before.

    I can't wait until the IDS2 is back in stock :evil I've got the 157.5 on order for the pipe mod :thumb

    Gerg
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  17. creeper

    creeper Still alive...

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    In simple terms, rich or lean combustion is an incomplete and inaccurately timed process... the engine is to a degree, "fighting" itself. By getting closer to a burn that the engine "likes" it will, asside from producing more power, become smoother.

    The engine will be smoothest when you find a happy balance between airbox, carburetion, combustion and exhaust flow.

    Wait... it gets better. :nod

    Oh yea... did you drill the slide?
    #17
  18. Gerg

    Gerg Gergy Bear

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    No, I didn't. I did that on my Harley and I didn't really like the results. But that was a slower to rev engine. Plus it was more obvious on the Harley. This carb looks WAY different. Are the hole(s) you drill the two that are each side of the needle?

    Gerg
    #18
  19. creeper

    creeper Still alive...

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    :nod... come on Gerg... all the cool kids are doin' it! :lol3

    But seriously folks... them's the holes. 3mm if ya' got one, 1/8" if ya' don't... or a number 32 or 31 if ya' got number drills... Hell, anywhere from about .116" to .125" is fine.

    Lets the vacuum piston respond to pressure changes a little more quickly.

    Just don't go over. :eek1

    :poser
    #19
  20. Gerg

    Gerg Gergy Bear

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    Update...

    Took a nice ride today. Some dirt (not a lot) and some twistys. Way less vibration. Much more punch in 4th and 5th gear and the ability to loft the front wheel in 1st at will.

    In the dirt swinging the rear end out is much easier and much easier to control now. It just seems more responsive. I gotta get some knobs on this beast.

    And it gets better:dunno

    Unfortunately I did not bring my camera. There was plenty to take pictures of. Snakes, Locomotives, flowers, and beautiful vistas. Oh well... The picture of me kicking the rattle snake in the tail to get him off the road would have been great (really). I saved him and a nice little gopher snake from getting run over. The rattler didn't appreciate my gesture at all.

    And I SHOULD have gotten a picture of the bike parked next to a couple of BIG locomotives (a dash 8 and a dash 9 if you know that stuff). They were BNSF painted in what's called the Pumpkin Scheme. Next to the little Pumpkin it would have been very cool.

    Man this bike is fun :nod 950 miles on her now and I'm just starting to figure it out :nod
    Gerg :gerg
    #20