SuzukiSavage.com - Exhaust port

klx650sm2002 Serious Thumper Offline The more I learn the less I know. Posts: 2041 Cumbria,England Gender:	Exhaust port 03/12/05 at 06:21:48 There have been a lot of new members since the last time I asked this question so I'll ask it again, have any of You modded that horrible Savage exhaust port and with what results ? Thanks a lot, Clive W
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Exhaust port Reply #1 - 03/12/05 at 07:00:14 Ah, but I haven't forgotten. It's on my "to-do" list
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woodworker

Ex Member

Re: Exhaust port
Reply #2 - 03/12/05 at 10:05:55

klx650sm2002 wrote on 12/31/69 at 16:00:03:

There have been a lot of new members since the last time I asked this question so I'll ask it again, have any of You modded that horrible Savage exhaust port and with what results ?
Thanks a lot,

Clive W Cheesy

I've ground the "V" section down about a 1/4" in the exhaust port and beveled the outlet opening as much as possible so that the bevelled edge just meets with the inside diameter of the exhaust gasket. The following pic at this link[url]http://members.shaw.ca/kenerechook/exhaustport.htm [/url] shows the ground out "V" section but not the additional bevelling, which I did after the head had been reconditioned in the machine shop and neglected to take a pic at that time. You must be careful when removing the "V" section, you have only so much meat between the port and the valve side of the head, (MEASURE CAREFULLY!) and remove as much material as you deem safe.
As for results: The final results will only be realized when I get the opportunity to break the new engine in properly(see "86 REBUILD" on page 3 of this forum for more info) and consequently dial in the carb (which must be done at full throttle for main jet sizing)

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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Exhaust port Reply #3 - 03/12/05 at 12:48:30 How much bigger is the opening than this stock picture?
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woodworker Ex Member	Re: Exhaust port Reply #4 - 03/12/05 at 14:22:44 Savage_Greg wrote on 12/31/69 at 16:00:03: How much bigger is the opening than this stock picture? http://home.comcast.net/~gmdinusa/ExPort01web.jpg 1.499" plus or minus .005"
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PRH111

Ex Member

Re: Exhaust port
Reply #5 - 03/12/05 at 16:17:24

Opening that exhaust port exit will increase reversion based low rpm performance issues (even with our low rpm biased camshaft). How much difference in size is left between the size of the header tubing and the exhaust port expansion you did? (Then again actual performance loss and gains from your work would be hard to quantify since you changed multiple things at once).

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klx650sm2002

Serious Thumper

Offline

The more I learn the
less I know.

Posts: 2041
Cumbria,England
Gender: male

Re: Exhaust port
Reply #6 - 03/13/05 at 01:42:19

Hey Woodworker,
I am so pleased to hear that someone has finally done it and opened up that port, well done and thanks a lot.
I would have been happy to open the circular part but I had no idea about the "V" section and am pleased You put a number on it.1/4" is more than I expected and should make a big difference.
Sorry I missed Your link on feb 25 but have read it now.

Clive W Cheesy

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klx650sm2002 Serious Thumper Offline The more I learn the less I know. Posts: 2041 Cumbria,England Gender:	Re: Exhaust port Reply #7 - 03/13/05 at 01:57:21 Hey Greg, This is good news for You too, that port being opened up to 1.5" is a perfect match for Your Raask pipe. The increase of a quarter of an inch is a big percentage. You have this to look foreward to. Clive W
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woodworker

Ex Member

Re: Exhaust port
Reply #8 - 03/13/05 at 03:12:22

klx650sm2002 wrote on 12/31/69 at 16:00:03:

Hey Woodworker,
I am so pleased to hear that someone has finally done it and opened up that port, well done and thanks a lot.
I would have been happy to open the circular part but I had no idea about the "V" section and am pleased You put a number on it.1/4" is more than I expected and should make a big difference.
Sorry I missed Your link on feb 25 but have read it now.

Clive W Cheesy

That 1/4" removed from the "V" section is an estimate!As mentioned previously, be very careful as to how much you remove. It is difficult to measure the thickness of material left from the interior of the head to the top of that "V" section!

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woodworker

Ex Member

Re: Exhaust port
Reply #9 - 03/13/05 at 03:17:01

PRH111 wrote on 12/31/69 at 16:00:03:

Opening that exhaust port exit will increase reversion based low rpm performance issues (even with our low rpm biased camshaft). How much difference in size is left between the size of the header tubing and the exhaust port expansion you did? (Then again actual performance loss and gains from your work would be hard to quantify since you changed multiple things at once).

If reversion becomes a major issue and there is no way to correct it with header sizing, I plan to TIG weld and regrind the opening back to original size.

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klx650sm2002 Serious Thumper Offline The more I learn the less I know. Posts: 2041 Cumbria,England Gender:	Re: Exhaust port Reply #10 - 03/13/05 at 04:33:48 I don't think You'll have to weld anything, KLX is 39.6mm and drives from tickover. Clive W
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Exhaust port Reply #11 - 03/13/05 at 05:33:25 woodworker wrote on 12/31/69 at 16:00:03: 1.499" plus or minus .005" How about this part? how much did you grind here? (image gone)
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woodworker

Ex Member

Re: Exhaust port
Reply #12 - 03/13/05 at 06:39:57

Savage_Greg wrote on 12/31/69 at 16:00:03:

How about this part? how much did you grind here?
http://home.comcast.net/~gmdinusa/ExPort02web.jpg

Greg; If you have another look at my head (which is inverted from the picture of your head) you will see the "V" section with a flat spot on it about 1/2" wide after grinding. As previously mentioned, it is difficult to measure how much meat you have between the valve side of the head and the exhaust port side. Extra caution is required! I never did take a measurement of the dimension you are looking for.

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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10661 Oklahoma Gender:	Re: Exhaust port Reply #13 - 03/13/05 at 07:01:02 So, after your porting work, what kind of performance difference did you realize from it? Was this done by itself or did you do other upgrades at the same time?
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woodworker Ex Member	Re: Exhaust port Reply #14 - 03/13/05 at 07:04:21 LANCER wrote on 12/31/69 at 16:00:03: So, after your porting work, what kind of performance difference did you realize from it? Was this done by itself or did you do other upgrades at the same time? Check above for more info and this link[url] http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;n... [/url]
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