Intake Boot upgrades
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  1. #1
    Administrator KTMATVHQ Guru
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    Intake Boot upgrades

    Thanks to the various guys who posted details and pic's i've summarized here into one spot

    KTM have been through an upgrade now, KTM parts numbers often end in -100, supersedes then go -200, -300 etc as the part is revised over it's life

    the -100 and then -200 part number boot was originally used on the 2006 450 SX & XC-G models (factory 41mm carb)

    59436044100 original boot that has caused allot of problems, the factory updated this in mid 2006, but gave us the crap part on the quad it seems……………….

    59436044200 updated boot, 2006 SX and XC-G updated part.

    So all this bull about a factory fix, just a quick rummage around to find they already had this problem in 06 and had updated the part…….. WTF………. maybe they had a warehouse full of em, dunno…...


    Left is new one (59436044200), Right is the old one (59436044100)

    Intake Boot upgrades-dscn1347.jpg

    would appear the same boot clamps are used -100 and -200 setups


    KTM Other suggestions are, but no guarantee it works:

    KTM part 77036044000 2006 dirt bike boot, fitted all ktm dirt bikes in 06 except the SX450 and 450XC-G, and continues to 2012 in the 250 four stroke. this boot fits the 37/39mm carbs used on those models.

    again no guarantee this works ……. maybe some one will stump up with some photo's of one installed !

    Polaris

    Polaris part Number # 5413231 apparently all KTM powered Polaris sport quads 450/525, IRS and SRA, have the same part 2007 -2009. I've checked and this is the case.

    matching clamps, polaris part number # 7080511 , need two

    Supposed advantage the inner diameter is larger than the KTM's so perfect for bored carbs.

    No verification that it has the correct kink like the KTM to line up the air filter.

    again no guarantee this works ……. maybe some one will stump up with some photo's of one installed !
    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 !

  2. #2
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    I have one on the way from a seller on ebay. I hope it works. price was right. The O.E.M. is almost $70.

  3. #3
    Senior Member KTMATVHQ Guru
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    Holy shit is it really $70? I remember replacing mine somewhere along the line and it wasnt that bad. Maybe they jacked up the price on them
    99mm thumper cylinder 15:1 comp, Crankworks billet stroker, Custom Carrillo short rod, Racers edge +4ti head, 48mm hsr carb, Shortened and stretched trx fci intake, Custom programmed vortex

    296lbs ready to ride. This might be the fastest ktm duner in the world

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  5. #4
    Senior Member KTMATVHQ Guru
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    I just looked up the part kiwi reccomended above. It looks like ktm-parts.com has it for $41

    ktm-parts.com: INTAKE BOOT 450 SX
    99mm thumper cylinder 15:1 comp, Crankworks billet stroker, Custom Carrillo short rod, Racers edge +4ti head, 48mm hsr carb, Shortened and stretched trx fci intake, Custom programmed vortex

    296lbs ready to ride. This might be the fastest ktm duner in the world

  6. #5
    Senior Member KTMATVHQ Guru
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    Also the polaris boot does work in a pinch it just doesnt fit for shit. I ran one for a little while to avoid missing a trip.
    99mm thumper cylinder 15:1 comp, Crankworks billet stroker, Custom Carrillo short rod, Racers edge +4ti head, 48mm hsr carb, Shortened and stretched trx fci intake, Custom programmed vortex

    296lbs ready to ride. This might be the fastest ktm duner in the world

  7. #6
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    Yeah , local dealers are hungry I guess. Good price there. I found a 450 sx boot on ebay. I hope it works.
    Thanks for the link 5.0fox. I tried putting the part number in a different site it didn't work.
    Last edited by ibmorjamn; 07-17-2012 at 12:30 AM.

  8. #7
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    Is this new part suppose to help with fitment of carb and airbox lid tube to carb??

  9. #8
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    magic racing does not find that part number. they show this as the part number for the intake boot 83536044100
    Magic Racing's 2010 KTM ATV 450 SX ATV Parts List

    will this work?


    **Edit: Nevermind, found it in the 450 sx motorcycle section...
    Last edited by codytaylor; 11-20-2013 at 04:20 AM.

  10. #9
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    59436044200 at magic racing is $33.56. Bought one last week.
    2009 525XC, Custom made intake with K&N filter, Factory 540 kit, 8/06 cam, 41mm carb by Dave Hopkins, Bill's Pipe, Hi Flo water pump, Cool-Aide, Custom +6 Swing arm by Lance, Suspension by Rocket Ron.

  11. #10
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    Just curious if anyone knows from experience, if the updated boot from head to carb (59436044200) is a fix to the taring issue or the alignment issue from intake to carb on 08 XC's? The photo provided above seems to show more of an upward bend in the boot. My stock intake likes to slip off rather easily, and aligning it up is a chore. I understand now why so many people had new top ends on these bikes rather early when they first came out (sucking in dirt).

  12. #11
    Senior Member KTMATVHQ Addict
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    Quote Originally Posted by YenkoS/C View Post
    Just curious if anyone knows from experience, if the updated boot from head to carb (59436044200) is a fix to the taring issue or the alignment issue from intake to carb on 08 XC's? The photo provided above seems to show more of an upward bend in the boot. My stock intake likes to slip off rather easily, and aligning it up is a chore. I understand now why so many people had new top ends on these bikes rather early when they first came out (sucking in dirt).
    Yes. You may still want to rotate the boot to align if you think it needs it.

  13. #12
    Senior Member KTMATVHQ Guru
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    The new boot lines up well. Didn't really have any issues with my old one not lining up, but I usually loosen and rotate/align things the best I can the first time I have a carb off of a new machine. We had to put larger clamps on the carb side of the new boots. Just got another clamp the same as on the intake side of the carb since it has a large adjustment range and matches factory hardware.
    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

  14. #13
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    I noticed a flat spot on the bottom of the rubber coupler for the OEM air intake, I think it is wear from stress. When I go to re-seat the air intake to the carb, the top of the coupler will seat fully while the bottom of the coupler is at an angle and will not seat fully unless the bottom of the carb is lifted upward to correct the bad angle. Once the intake is on the carb and I let the carb rest, that bad angle puts stress on the lower portion of the rubber coupler causing it to want to back off if tightened too much. That is why I was asking about the newer intake boot from head to carb because the added upward bend in it appears to correct the poor angle of the carb to the air intake.


 

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