I was able to get the breather tube and filter from the previous owner. IDK why but I put some red loctite on this too. You don't need to sink in all the way, just make sure it's secure. Start it in by hand and tap it the rest of the way with a hammer. This will help with routing your breather assembly later. line it up so it points near the center line of the carb. Now you can re-use the 90 you pulled out of the other hole. Line up your drill bit the best you can and keep a clean hole. Easily found in most hardware stores or possibly where you bought the 1/4" plug for the previous step. The correct drill bit needed is a 15/32". You will need to be accurate with your drilling here. Tighten up the plug and move on to drilling out the new hole. I Used a big glob of red loctite because I never plan on taking it out again. Now that we have a nice tapped hole you can use either pipe thread sealer or a generous amount of loctite. Run the tap in far enough that the plug will mount flush when installed. You will NOT need to re-drill the hole you just opened up for the tapping. To plug this hole you need a 1/4" pipe thread tap and a 1/4" allen head plug. Tape off anything you don't want shavings in unless you're doing a full teardown and cleaning later. Comes out easy once you get it moving and it won't hurt anything for our next step. The 90 has little barbs on is and you're basically ripping the aluminum up getting it out. The KTMs use the hole we need but I have a DR650 carb here.įirst thing you do is remove the top, spring, slide and needle/ Then stick something big and solid in the 90 and twist it out. The good thing is the place it needed to go was already casted in the housing (blue arrow) and just needs to be drilled out. All the credit goes to him.įirst thing we need to do is move this big 90 degree elbow (red arrow) that feeds a breather for the slide. The following intructions and pictures have been copied (and some edited slightly) from ATJ_Number_1's original thread and Facebook page. The original thread where all of this information came from (and where the performance results can be found) is located HERE. I suggest reading the original THREAD, as there is more info in there pertaining to the KTM version of the BST40 and various jetting recommendations. If using one from a KTM, the vent line modifications aren't needed so you may want to research exactly what needs to be done, in that case.
These pictures and instructions apply if you are using a BST40 from a DR650. I thought I'd take the time to try to put it all together for anyone wanting to do this in the future. Luckily they are all available on his Facebook page, but do not have all the captions with instructions. Since his original post, most of the pictures aren't showing up. First of all, I would like to thank ATJ_Number_1 for taking the time to figure all of this out.
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