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General Category >> Rubber Side Down! >> Exhaust Port Widening
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Message started by Dan P on 03/10/22 at 15:38:59

Title: Exhaust Port Widening
Post by Dan P on 03/10/22 at 15:38:59

Hello, I'm a newbee and have been building my 06 S40 for about 2 months. The forum has helped out a lot and I have met some good people through it.
I have searched but as you all know a lot of the old posts no longer have pictures available. I also tried the Search engine, but haven't had much luck with it. My bike only has 4K miles so i'm on the fence when it comes to how far I want to take the motor? I plan on going with Lancer's Carb Kit, and I'm trying to fine a Mac Header. So the question is : How has opened up the Exhaust port on their motor without pulling the motor apart ? What techniques have been used to do it with the motor together ? I did see something about paper towels and shaving cream. I wasn't able to find much else, or pictures. I would like to do it but don't want to get something into the motor that will cause damage later. If you have experience with this procedure please let me know. Thank you for your time and sorry this is so long. Dan P

Title: Re: Exhaust Port Widening
Post by Dave on 03/10/22 at 17:42:39

Look through DragBikeMikes porting thread. You don't have to go as far as he did - but the exhaust port should be "D" shaped.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1615569533

You can do it without removing the head by ensuring the exhaust valves are closed, then jamming toilet paper or paper towels to shield the valves and guides from the grinding mess.

Title: Re: Exhaust Port Widening
Post by Dan P on 03/11/22 at 06:16:35

Thanks Dave I will check that one out.

Title: Re: Exhaust Port Widening
Post by Yoshi on 03/13/22 at 05:28:35

Why would you want to widen your exhaust port? There wont be any major improvements from doing this modification alone.

Title: Re: Exhaust Port Widening
Post by Dan P on 03/13/22 at 07:58:24

Well from what I've read on the forum it does help. I also plan on replacing the stock header and muffler with something more free flowing.

Title: Re: Exhaust Port Widening
Post by Fast 650 on 03/13/22 at 09:03:20

The exhaust port is so bad on these that nearly anything that you do to the exhaust side of things gives an improvement in flow. Even a fairly conservative first time attempt at porting combined with a better exhaust system is a considerable performance improvement.