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General Category >> Rubber Side Down! >> Exhaust port mod
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Message started by klx650sm2002 on 01/05/06 at 03:12:47

Title: Exhaust port mod
Post by klx650sm2002 on 01/05/06 at 03:12:47

Has anyone taken advantage of the cold weather down time to derestrict the Savage exhaust port? I'm interested to know how far you can go.

Clive W :D

Title: Re: Exhaust port mod
Post by lancer on 01/05/06 at 08:36:34

I did mine a couple of months ago, but no head work since before Thanksgiving.

Title: Re: Exhaust port mod
Post by Reelthing on 01/05/06 at 20:06:03

lancer wrote:

I did mine a couple of months ago, but no head work since before Thanksgiving.

did you take any metal out on the "roof" of the port or stick with expanding the outside at the pipe connection?

Title: Re: Exhaust port mod
Post by klx650sm2002 on 01/06/06 at 02:31:54

Hey Lancer

How far did You go with the port mods ? From what I've heard you can open the circular part out to 38mm no problem, But what about that flat bit in the top of the port, how much did you take off that ?

Clive W

Title: Re: Exhaust port mod
Post by lancer on 01/06/06 at 09:16:39

I do not recall exactly how much was removed, but I would estimate about 2 mm all around and with the bottom of the port being flat...making a D shape. I went inside the port 25-40mm and removed some material to widen the inside of the port. When the 2 ports coming from the exhaust valves combine into 1 port there is a good amount of room initially, but then quickly gets smaller. I just tried to make the transition more even and smooth and a little straighter.
The header I made is 1.75" OD/1.66"ID, which should be about the best overall size for this size engine/power output and useable rpm range. The port work was designed to try to match the pipe as well.

I did not spend a lot of time on it, at least one..,maybe two hours. But the engine runs really well and does not like hardly any restrictions on the exhaust at all. Too much restriction and it really shows up with rejetting required.

Title: Re: Exhaust port mod
Post by klx650sm2002 on 01/07/06 at 01:20:28

Hey Lancer

I'm lucky with KLX, the ports are good as std. I too run a 1.75 o.d. 1.625 i.d. header which fits the exhaust port perfectly.

Clive W :D

Title: Re: Exhaust port mod
Post by lancer on 01/07/06 at 05:27:07

What can we say...GREAT MINDS !? ;D

Title: Re: Exhaust port mod
Post by Greg_650 on 01/07/06 at 07:45:03

Lancer,

Small favor....Would you mind removing your header and taking some photos?

Doesn't hurt to ask :)

Title: Re: Exhaust port mod
Post by lancer on 01/07/06 at 11:50:56

Greg_650 wrote:

Lancer,

Small favor....Would you mind removing your header and taking some photos?

Doesn't hurt to ask :)

I do not mind at all. I do, however have some photo's of the port on this site somewhere. I was looking for them last night but could not find them. I will try again, and if not successful I will get some more to put up.

Title: Re: Exhaust port mod
Post by theikeman on 01/07/06 at 12:16:37

Here is where the pics of lancers porting job are:

General / Technical Documents/Reference / Re: Lancer Upgrade

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1126030690;start=2#2

FYI

Ike

Title: Re: Exhaust port mod
Post by Greg_650 on 01/07/06 at 12:35:27

Thanks for finding the photos. That's all that I need.

What about that flat casting on the inside top of the port? Any reason not to reduce that area too?