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Old 10-07-2007, 08:27 PM   #1
mar45 OP
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KTM 950SM Custom Aircleaner

Experinmenting with the 950 headers and aircleaner has netted some large horsepower and fuel mileage gains. The headers are equal lenght 2 into 2, 37.5" by 1.5" thin wall 304 stainless. This length brings the engine onto the pipe at about 4000 rpm, or right in the center of my use range. For the best HP readings on the Dyno 2.5" core cans where used, but are also very loud. Best sound and quiet enough for use in town was with 1.75" cores.
The air cleaner was where the largest gains where seen, these LC-8 motors are large air pumps and need a lot of cold free flowing air supply to make good power and response.
I was holding off on sharing this info to make sure it was right. The carb jetting took the most time and my thanks goes out to all the guys that had jetting input as that was a great help.
The engine was run on the dyno in a stock condition right after break-in so I would have good documentation of before and after the mods. I also have photos of the work as it was done.
The best fuel mileage to date was 51.4 mpg with normal around town at about 46 mpg. The last dyno run was a little over 100 HP at the rear wheel.
The throttle response and exhaust sound is great, and with this air cleaner you can hear the air flow and it sounds like a large V-8.
This is all low cost stuff that can be done in any normal shop, like the air cleaner is two sheets of aircraft Alum and a $5 Fran air filter.
This engine also runs very cool and I now have the fans removed as they are not needed.
My test conditions where from low desert to high mountain passes, 35 to 105F and elevation from 400 to 5800 MSL.
Carb Jetting:
MJ = 175 (both)
MAJ = 40
LJ = 42
ACVJ = not used and plugged
IAJ = 90
Needles = Stock NDFB 3rd clip
IMS = 1.5 turns (about) Set using a F/A meter
Filter = Fran # CA351
TPS = full CW
Carb Vents = inside the air cleaner
Floats = stock setting.

For more photos, e-mail me at mar45@bentonrea.com

c/u mar45
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Old 10-07-2007, 08:38 PM   #2
overlander
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very interesting

Lets see more pics! Howzit look from the top side? Sure looks simple from this angle! We must see the exhaust, too.
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Old 10-07-2007, 09:01 PM   #3
Keith
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oh hell yeah!
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Old 10-07-2007, 09:19 PM   #4
J.W.Mudd
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Thumb Hot Set-Up

Outstanding

Please post additional photos, we all want to see this
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Old 10-07-2007, 09:22 PM   #5
idahoskiguy
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More pics and details please. Looks very promissing and your mileage figures would put the 950 in the realm of the Rotax V-Twin Aprilia uses. Always suspected the KTM could get much better mileage. My 1000cc V-Twin Aprilias deliver near 50 mpg in normal use and 50+ if you ride easy.
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Old 10-07-2007, 10:58 PM   #6
jsrider
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Quote:
Originally Posted by idahoskiguy
My 1000cc V-Twin Aprilias deliver near 50 mpg in normal use and 50+ if you ride easy.
My '01 Aprilia Mille was hard-pressed to get over 35 mpg no matter how I rode. My Ducati 916, on the other hand, got mid 40's even when flogged. The last time I saw 50 mpg on a motorcyle was a 1989 BMW K75S.
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Old 10-07-2007, 11:00 PM   #7
moparmiller
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Parks I assume?

The SM is looking sweet- I may have to get a better look at your set up one of these days when I get back into town. Your set up looks to be the best combination of tons o' power and killer milage. Do you think there would be any way to fit some type of snorkel for dust reduction at the filter (the SE throughs an atomic dust cloud at Juniper Dunes). But at $5 a filter that could be a negligable issue.

Erik- From TCCS
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Old 10-08-2007, 01:51 AM   #8
mar45 OP
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Running in heavy dust

I have been running for the most part on the street and the dirt I get on is offen hardpack so I would not see the dust that you get riding 3rd in trail, like at Juniper Dunes. For that you may want to run a Pre Filter over a stock airbox.
Check on Head2wind (Ken,s) work down the page, he and some of the guys have done a lot of work and study on jetting with the pre-filters.
I find that riding off road that I do not need much of the LC-8s power and use low RPM most of the time. At low rpm the pre-filter may be the best way to go.

Now for Erik, good to hear from you, and miss you at the shop. Running paddle tires and climbing steep sand hills is different and you may want the extra HP. In sand the only thing better than HP is more HP and lots of RPM.

c/u, mar45
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Old 10-08-2007, 08:37 AM   #9
youngblood
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Please post these pics!

Quote:
Originally Posted by cmwoodys
Hey Mar45,

Got your pictures, Thanks! Very nice work. I could host them on my photo site if you like.

I'm still gooning at what you did and will get back to ya with a few questions. Really like the way you used the plate to deflect hot air off the radiator and the reuse of that SAS port. Very cool looking heat shield?? at the bottom of the carbs too.

Chris
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Old 10-08-2007, 03:27 PM   #10
wsdbikes
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what were the stock dyno results?

" The last dyno run was a little over 100 HP at the rear wheel.

Also not clear on all the abv below.

Carb Jetting:
MJ = 175 (both)
MAJ = 40
LJ = 42
ACVJ = not used and plugged
IAJ = 90
Needles = Stock NDFB 3rd clip
IMS = 1.5 turns (about) Set using a F/A meter
Filter = Fran # CA351
TPS = full CW
Carb Vents = inside the air cleaner
Floats = stock setting.
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Old 10-08-2007, 03:31 PM   #11
youngblood
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Thanks for the pics man! That air cleaner setup looks sweet. Tempted...
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Old 10-08-2007, 04:20 PM   #12
moparmiller
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So how is your power delivery compared to stock? Is the extra power coming on early, mid, or at the top end?
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Old 10-08-2007, 09:32 PM   #13
brents347
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cmwoody, with proper permission of course, please do post up those pictures so we can all see and discuss. This is exciting stuff!
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Old 10-08-2007, 10:47 PM   #14
Nowwhat
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Did I miss how you put what looks like a SE header on a SM...?
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Old 10-08-2007, 10:58 PM   #15
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Quote:
Originally Posted by Nowwhat
Did I miss how you put what looks like a SE header on a SM...?

Those headers are his own design and one-off build-
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