How to Install a Pumper Carb on Your TW 2
Close
    
    
Page 1 of 9 123 ... LastLast
Results 1 to 10 of 86
Like Tree365Likes

Thread: How to Install a Pumper Carb on Your TW 2

  1. #1
    Senior Member Ken's Avatar
    Join Date
    Aug 2016
    Location
    Houston, Texas
    Posts
    1,983

    How to Install a Pumper Carb on Your TW 2 #1

    Ken's copy cat pumper carb installation.
    My TW has been running perfect. I think Cornelis was onto something with the pumper carb so I decided to do it. I bought the same carb kit and intake as he did.

    Note the intake mounting holes to the stud holes out of the box. That is why this isn't exactly a bolt up.

    IMG_20171207_182337.jpg

    I started out with the intake and cut it in half with a band saw. If you get it just right you cut the plastic right between the metal which I managed to do.

    IMG_20171207_182420.jpg

    IMG_20171207_182438.jpg

    I made a template of the original angle of the studs and the modified angle needed. I am thinking about submitting it to Allied Express and see if they could make a TW intake. These are 2 pieces of metal molded with rubber, plastic material which only needs to be rotated for the correct TW angle. Of course this one would be a tad longer than stock.

    diag.jpg

    To find the correct angle needed I mounted the intake side to the bike. This is the original bolt pattern but the bolts need to be horizontal to mount the new carb.

    IMG_20171208_170702_0.jpg

    I then turned the intake to the correct angle needed. I got the bike to the balance point and then used a level across the mounting studs to find the correct position.
    IMG_20171208_170727_1.jpg
    That is my level not a piece of wood. I used a hose clamp to hold the intake into position at this point. Then I removed the intake from the bike.
    IMG_20171208_173604.jpg
    I actually made the template at this point for future reference or for others to have the correct angle on the intake. I didn't feel like waiting for Loctite that Cornelis used to come in. I also didn't see that it was fuel resistant. I chose Permatex 1 to glue the intake together. I put the band around the part once glued and then c-clamped to press it firmer. Hind site is applying the permatex is to put it on one side with your finger and keep going in circles around the surface until it becomes tacky then press both parts together before clamping.
    IMG_20171208_193721.jpg
    Here are the tools I used.
    IMG_20171210_061618.jpg
    Attached Images Attached Images
    Last edited by Ken; 12-11-2017 at 07:38 PM.

  2. #2
    Senior Member Fred's Avatar
    Join Date
    Dec 2011
    Location
    Turtle Wrangling the Sierras
    Posts
    19,175
    Nicely done Ken and rather well explained.
    However for me all your pics after post #1 are coming up “INVALID” and the not viewable. I can imagine what I am not seeing though.
    I was curious as to outer diameter of AliiExpress intake manifold as I envisioned looking for a possible rubber no-hub plumbing coupler that could slip over your assembly.....Not that it might be any better or stronger, just possibly look a little cleaner.
    2003 TW200 "Betty Boop"
    2006 TW200 "Nibbler", a.k.a. “Mr.Gizmo"
    Hidden Content All Things Considered I’ld Rather Be Motorcycling

  3. #3
    Senior Member jtomelliott49's Avatar
    Join Date
    Sep 2012
    Location
    Wichita, KS
    Posts
    1,871
    I had the same results with viewing the attachments. Nice work Ken. I hope it works very well for you.
    littletommy and Badgerflorida like this.
    Tom in Wichita

    78 Moto Guzzi SP1000
    87 Yamaha TW200
    99 Yamaha TW200
    03 Honda Shadow Spirit (girlfriend's ride)
    74 Moto Guzzi Eldorado Police model (in many pieces)

  4. Remove Advertisements
    TW200Forum.com
    Advertisements
     

  5. #4
    Senior Member Badgerflorida's Avatar
    Join Date
    Jun 2017
    Location
    Milwaukee, WI
    Posts
    1,324
    Good stuff Ken. Thanks for sharing. Cheers
    01 SOLD
    96 SOLD
    89 restored SOLD
    89 (restoration in process)
    05 (restoration in process)
    03 SOLD
    04 in great condition

  6. #5
    Senior Member Ken's Avatar
    Join Date
    Aug 2016
    Location
    Houston, Texas
    Posts
    1,983

    How to Install a Pumper Carb on Your TW 2 #2

    Here is my setup for my Permatex 1.

    IMG_20171209_095540.jpg
    I had to wait for this to dry, bummer.
    After drying I unclamped it leaving my paper towel stuck to it. IIMG_20171210_054328.jpg
    soaked it in water to get the rest of the paper towel off of it.
    IMG_20171210_054340.jpg

    Paper towel removed.
    IMG_20171210_061545.jpg

    Now I used Permatex Ultra Grey which is
    very similar to what Cornelis used. I applied this all around outside
    and over the Permatex 1.

    IMG_20171210_085823.jpg



    For clamping I used another pipe clamp
    and cut to length with a dremel tool. It was too strong for cutters
    to go through. I then placed this around the intake and then put the
    clamp over it and tightened it up.

    IMG_20171210_090057.jpg

    Here are the final pics of the intake,
    not pretty but hopefully it will work. Waiting for it to dry again.

    IMG_20171210_093932.jpg
    I used only the new intake the old one
    is still totally intact. Here are some comparisons. High rise
    performance intake?

    IMG_20171210_064240.jpg

    Here is a picture of the prototype
    installed before I had the final sealant and pipe clamps on it.
    IMG_20171210_062922.jpg

    I started this on Friday so it wasn't
    too time consuming. The sealant curing is frustrating waiting for it
    to dry. 24Hrs and I used 2 sealants.
    Attached Images Attached Images
    Last edited by Ken; 12-11-2017 at 07:41 PM.
    littletommy, Fred, ejfranz and 5 others like this.

  7. #6
    Senior Member Donzo's Avatar
    Join Date
    Oct 2016
    Location
    NorCal
    Posts
    809
    Nice job. I love projects like this - fabricating/modifying is strangely satisfying for me. Keep us posted on how the install and more important - what kind of performance you find.
    littletommy, Ken, SanDue and 2 others like this.

  8. #7
    Senior Member Ken's Avatar
    Join Date
    Aug 2016
    Location
    Houston, Texas
    Posts
    1,983

    How to Install a Pumper Carb on Your TW 2 #3

    Here are some more pics for comparison of the original and the modified intake.
    IMG_20171210_063912.jpgIMG_20171210_064106.jpgIMG_20171210_064131.jpg

    Here is the final intake picture before the installation.
    IMG_20171211_09.3945.jpg
    Last edited by Ken; 12-11-2017 at 07:43 PM.

  9. #8
    Senior Member Fred's Avatar
    Join Date
    Dec 2011
    Location
    Turtle Wrangling the Sierras
    Posts
    19,175
    Once painted the new manifold looks just fine. Well done Ken.
    2003 TW200 "Betty Boop"
    2006 TW200 "Nibbler", a.k.a. “Mr.Gizmo"
    Hidden Content All Things Considered I’ld Rather Be Motorcycling

  10. #9
    Senior Member Ken's Avatar
    Join Date
    Aug 2016
    Location
    Houston, Texas
    Posts
    1,983
    I looked at the plumbing couplers at Ace. My gap between intake pieces was only as wide as the pipe clamp. That is why I used another pipe clamp cut off instead of a solid strip like Cornelis under the final hose clamp. I'm sure the solid strip is better at sealing. I double sealed so I should be fine. The coupler would still need a hose clamp for rigid stability. That just seemed like extra work when I looked at the couplers.
    1993 TW200 just over 46,000 miles

  11. #10
    Senior Member Cornelis's Avatar
    Join Date
    Mar 2015
    Location
    Centurion, South Africa
    Posts
    589
    Looking good Ken, I'm sure that coupling is properly sealed, no air is ever going to leak into there at all
    1990 Yamaha TW200Hidden Content _____________ Come to Me, all you who are weary and burdened, and I will give you rest. - Matthew 11:28
    Hidden Content

Page 1 of 9 123 ... LastLast

Sponosred Links

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Similar Threads

  1. How To Install a Pumper Carb on Your TW
    By Cornelis in forum Sticky threads
    Replies: 22
    Last Post: 10-08-2017, 08:26 AM
  2. Carb tuning, Dr350 Tm33 pumper
    By rivershot in forum Other Bikes
    Replies: 7
    Last Post: 03-26-2017, 08:34 AM
  3. Replies: 5
    Last Post: 07-11-2016, 06:41 PM
  4. Carb install help on a 1989
    By a1parrothead in forum Technical Help
    Replies: 7
    Last Post: 05-15-2016, 11:39 PM
  5. Searching for a Mikuni TM28-1 pumper carb overseas
    By PalmStateCrawler in forum Performance and Customization
    Replies: 19
    Last Post: 06-24-2013, 04:19 PM

Search tags for this page

news

,
tw200 pumper carb
Click on a term to search for related topics.