Making a great bike even better

So here I am, having just bought myself a SD from 2005, 28.000 km down, running like a charm, but, I need more.
I've been reading here for quite some time now and I want to do some good for my little duchess.
I would like to do the following conversions, mind not in this particularly in this order but sooner or later all of them should be done.

- Exhaust upgrade, likely a Remus Hexacone, I'd prefer an Akra but those cost twice as much here in Switzerland, maybe if I find a good used one but I prefer new
- Motobox if I can get one of the last batch that has yet to be made, otherwise a DNA or some other Airbox + filter
- custom mapping
- Gear sensor removal (if I don't get a mapping beforehand)
- SAS removal (not really sure what that does but I heard it will improve the bike, input from your side would be much appreciated)
- maybe a switch to a lower front sprocket, but not sure about that

My questions are,
- can I just do the SAS valve and the gear sensor removal without any of the other conversions ? I know that I can remove the gear sensor but what about the SAS and what exactly does it do ?
- Can I fit the Motobox (or any other aftermarket Airbox) without a remap ?
- What other things would you recommend ? Not in regards to optics but pure performance (more power or better riding experience)

Thanks a lot for your kind help in advance,
Have a great evening !

Jens

Question 1
Don't without removal of catalytic exhaust. SAS is a secondary or supplemental air system that oxygenates the unspent gasses entering a hot converter therefore reducing VOC's into the environment. Change your exhaust system first.
#2
Yes you can exchange your air box at any time. That said correct mapping is where the performance upgrades are taken to the highest level.
#3
Tyres, gas, Tyres, gas Tyres, gas, a diet and exorcize.

Your better with more teeth at the rear than less at the front. The 05 ran a sixteen front and you will not be interested in running a fifteen.

Get exhaust and intake, turn off everything with tuneecu and you're done! Although the 05/06 has a 17 front IIRC, my 06 did at least and switching to a 16 woke it up. The "second" generation SD's came with 16 stock.

Not sure what training or experience you have, but anything from reading a performance based motorcycle riding book to taking an advanced riding class, a dirt bike class, or some track days would greatly propel your motorcycling career in a safer, more skilled direction.

Jens,
Hertzlich willkomen!

You sound like you're heading down a similar path to mine last year. I did the same mods and came away impressed. The airbox, tune ecu and exhaust being the biggest impression.

You can download a document from the Motohooligan website which has information on the removal of the SAS system and air box fitment.

So what would you recommend doing first ?

Exhaust.
SAS Removal.
TB Synk.
Clean air filter.
Remap.
Ride it this year.
Air box next year if needed.

I belive I have found something I need to do, an upgrade to 1200ccm
The page below is in german but you should check it out!

Okay getting this thread back up.

I was just offered a Motohooligan Airbox, price id allright, I'm just worried about it beeing usefull without an aftermarket exhaust ? My dealer offered me to install it and add a new mapping. The thing is, they can only use the mappings KTM provides so I'm not sure if that's even a good option. I'll probbably buy it anyway but I'm not sure if I'll install it before I get another exhaust.

Any suggestions ?

Before I forget, I no longer got the 05 Superduke but a 2010 SD-R with the Acra headers.

Because Motohooligan parts are no longer available this item will be always in limited numbers now as a second hand part. I'd snap it up without a moments hesitation. It is, in my opinion, the best of the aftermarket air-filter replacements and even if the Rottveiller and other options are as good they will not be viewed with as much reverence or value in the future. MH parts for the SD will become classic collectors parts like Moriwaki exhausts for 1990's Kawasaki's and Swarbrick expansion chambers for 1980 Yamaha lC's.

It's the most useful thing you can do to mod your SD but it is of course better to also get rid of the standard exhaust and CAT system which weighs a ton and is very restrictive. You then need to get a custom map done - either with the addition of a PC and dyno set up or a Tune ecu set up. there are loads of threads on here about the options.

With the airbox, secondary butterflies removed, exhaust and proper tune including ignition advance... there is no reason why a 990sd wont make over 130hp at the wheel. Mine is up around 133 which is around 150 at the fly wheel.

those arent bad numbers.. we are talking older r1 numbers here... plenty quick enough on a mountain pass and enough to keep up with a 600 on the straight (if using a quickshifter... something that the new ones dont get to use which is a big shame and the only thing putting me off the new SD atm).

on that note... does anyone know if ktm plans to fix the qs issue on the 1290 SD's?