A little bit of a vent session
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  1. #21
    Senior Member KTMATVHQ Addict
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    Quote Originally Posted by sheriff525 View Post
    The intake valves were way too tight and chattering like a sack of hammers. I also was screwing around with things to see what they did and I didn't realize that the idle was so far out of whack. Learning experience!
    Not trying to be one of those guys, but technically the adjusters were too loose if they were making a lot of noise. Too tight and they don't make any noise at all. Make sure the lock nuts are nice and tight. I learned a hard lesson there this past week. Both of the intake nuts came off and dropped down in the engine.

    Have you had a chance to check the idle air adjustment? This is something that you should learn how to adjust. It
    helps a lot with the proper idle and off idle response. I changed mine out with a Tusk adjuster so I can adjust it with my fingers instead of a small screwdriver that's hard to get in there.
    2008 KTM 450xc
    Thumper 540 kit with CP piston at 12.5 compression, 8/33 cam, High Flow water pump, SX seat, SX a-arms and Rath hubs rear, SX intake, 14/37 gearing, Hiper wheels, Gafer brake lines, dash delete. SX pipe
    2009 Can Am Renegade 800


  2. #22
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    I will look into that!

  3. #23
    Senior Member KTMATVHQ Guru
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    Good to hear that you found some local guys to help you out! I wouldn't weld the header pipe straight to the flange as it will likely make the vibrations in the exhaust worse. Which won't help with your cracking problem.
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

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  5. #24
    Senior Member KTMATVHQ Addict
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    Quote Originally Posted by quad97 View Post
    Good to hear that you found some local guys to help you out! I wouldn't weld the header pipe straight to the flange as it will likely make the vibrations in the exhaust worse. Which won't help with your cracking problem.
    I agree. Having it held with springs and just fitted allows for some vibration movement. You'll never have a crack problem at the header if it's not welded.

    I ground down the welds just a bit and did everything I could to get it to fit better and tighter and now we rarely have a decal pop. Only when very high on the RPM and then chop the throttle. A little bit doesn't bother me at all. I just don't like it when it's all the time and excessive.
    2008 KTM 450xc
    Thumper 540 kit with CP piston at 12.5 compression, 8/33 cam, High Flow water pump, SX seat, SX a-arms and Rath hubs rear, SX intake, 14/37 gearing, Hiper wheels, Gafer brake lines, dash delete. SX pipe
    2009 Can Am Renegade 800


  6. #25
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    It is all the time right now. When my outlaw did this I had it powder coated and it added just enough on to the header that it sealed up really nicely and rarely popped. The cracks are also on the pipe in the back. I think by the lower tab. I think I will get that welded and that should help I am sure.

  7. #26
    Administrator KTMATVHQ Guru
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    the header air leak is due to the outer pipe sleeve being a fraction to long, the inner stubs do not "bottom" into the end of the header section, rather they pull up and hit the welds around the outside the stubs flange. exhaust gets around the end of the stubs and blows out between the two. Others have good luck trimming 1/4 off the outer slip over header pipes, then the stubs can bottom in to the end of the header at the step down and seal properly like they where intended to do. Worth looking at.

    SX muffler is a low cost upgrade, bolts straight up, straight through and not to noisy (compared to allot of after market cans) and addes power, and looks gen - stock to boot............. good cans SX cans often come up for cheap............
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  8. #27
    Senior Member KTMATVHQ Addict
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    Quote Originally Posted by kiwi-craig View Post

    SX muffler is a low cost upgrade, bolts straight up, straight through and not to noisy (compared to allot of after market cans) and addes power, and looks gen - stock to boot............. good cans SX cans often come up for cheap............
    I didn't know this. This sounds like a great idea. I'm going to look into this. You would say they are louder than the XC but not as bad as aftermarket?
    2008 KTM 450xc
    Thumper 540 kit with CP piston at 12.5 compression, 8/33 cam, High Flow water pump, SX seat, SX a-arms and Rath hubs rear, SX intake, 14/37 gearing, Hiper wheels, Gafer brake lines, dash delete. SX pipe
    2009 Can Am Renegade 800


  9. #28
    Administrator KTMATVHQ Guru
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    Yup and adds power across the range and has the oem quality as well.
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  10. #29
    Junior Member Rookie
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    Dec 2010
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    Quote Originally Posted by kiwi-craig View Post
    the header air leak is due to the outer pipe sleeve being a fraction to long, the inner stubs do not "bottom" into the end of the header section, rather they pull up and hit the welds around the outside the stubs flange. exhaust gets around the end of the stubs and blows out between the two. Others have good luck trimming 1/4 off the outer slip over header pipes, then the stubs can bottom in to the end of the header at the step down and seal properly like they where intended to do. Worth looking at.

    SX muffler is a low cost upgrade, bolts straight up, straight through and not to noisy (compared to allot of after market cans) and addes power, and looks gen - stock to boot............. good cans SX cans often come up for cheap............
    1/4 in?
    Having the popping for 5 years now tired of it lol..


    Sent from my SPH-L720 using Tapatalk
    Wreck Shit

  11. #30
    Senior Member KTMATVHQ Addict
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    May 2009
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    Yuma, AZ
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    Quote Originally Posted by jayhawkjones View Post
    1/4 in?
    Having the popping for 5 years now tired of it lol..


    Sent from my SPH-L720 using Tapatalk
    Try this: KTM Part Number SXS02540506 is the Akro Manifold and is still available through your local KTM Dealers

    A little bit of a vent session-exhaustmanifold.jpg

    http://www.ktmatvhq.com/forum/xc-eng...ge-gasket.html

  12. #31
    Administrator KTMATVHQ Guru
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    awesome that its still available…….
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  13. #32
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    May 2014
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    Southern Illinois
    Posts
    185
    Quote Originally Posted by KantTopMe View Post
    I didn't know this. This sounds like a great idea. I'm going to look into this. You would say they are louder than the XC but not as bad as aftermarket?
    Is that just for the can or change to the sx header as well?
    08 KTM 450 xc. So far completely stock, for now >: )
    Brown wire unplugged
    Hiperfind's intake stiffner mod
    AP o-ring mod
    Baffle taken out of stock xc can.

    07 Raptor 700 - SOLD....
    Big gun slip on
    Bored .25
    Sti tech 4 tires

    Wifes
    09 Can-Am Outlander 650xt
    Stock- sold

    2012 Honda rancher 420 4x4

  14. #33
    Senior Member KTMATVHQ Guru
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    Billings, MT
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    Quote Originally Posted by doubleA_Ron View Post
    Is that just for the can or change to the sx header as well?
    Can only. SX header is single inlet while XC is dual inlet.
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

  15. #34
    Senior Member KTMATVHQ Member
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    Oct 2009
    Location
    Wisconsin
    Posts
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    Hey Sheriff525, I got some extra KTM parts I'm going to be putting up for sale soon. Let me know what you need and I'll see if I have it.
    2009 KTM450SX Racer

  16. #35
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    May 2014
    Location
    Southern Illinois
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    Quote Originally Posted by quad97 View Post
    Can only. SX header is single inlet while XC is dual inlet.
    Thank you Quad97, this is probably a dumb question, if you change to the sx can, does it still meet the db for xc racing? Which for my area is 94-99db. Thanks.
    08 KTM 450 xc. So far completely stock, for now >: )
    Brown wire unplugged
    Hiperfind's intake stiffner mod
    AP o-ring mod
    Baffle taken out of stock xc can.

    07 Raptor 700 - SOLD....
    Big gun slip on
    Bored .25
    Sti tech 4 tires

    Wifes
    09 Can-Am Outlander 650xt
    Stock- sold

    2012 Honda rancher 420 4x4

  17. #36
    Administrator KTMATVHQ Guru
    Join Date
    Feb 2008
    Location
    Auckland, New Zealand
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    it should do if the packing is good. right around 98 I think ?
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !


 
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