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Discussion Starter #1 (Edited)
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
 

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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.
 

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I had the same results with viewing the attachments. Nice work Ken. I hope it works very well for you.
 

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Discussion Starter #5 (Edited)
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. I IMG_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.
 

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Discussion Starter #9
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.
 

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Discussion Starter #12
Here are a couple more pics from today. I encountered a couple of issues. One was that the air tube from the air box was too close. I adjusted the length with a reciprocating saw. Cornelis addressed this so I already knew about it. He used duct tape around it and secured with tie wraps. I have done this before. I have also used a piece of rubber hose and pipe clamped it which worked really well last time. If I can find 1 3/4" hose of some sort I am going to try that first.
View attachment 144194

The next issue was the crankcase vent tube is too close to the bottom of the carb. I had to remove it, chip it off since it is from 1993. Hopefully a new piece of rubber tube will bend good enough.
View attachment 144210

The other issue is that the choke lever slightly hit the cam tensioner adjuster. This is with the cable linkage adapter on it. It is only the plastic edge which could be trimmed off. Since I am going to convert it as most TWs are with a manual choke this should make this a non-issue. I don't think this shows up in the pic below but here is a pic of the carb on the bike. I still have to connect the air box hose, run the cable to the throttle. I may see if there is a way to use the stock throttle tube with the cable. If not I'll use the one that came with the kit.

View attachment 144202
Not much longer but it will be up and running.
 

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Yes, that's right, the carb has a built in acceleration pump that squirts a bit of extra fuel into the combustion chamber during acceleration which gives the bike that extra bit more grunt. Since I installed it I'm having a lot more fun on my bike than before

Its a good quality carb also, it comes out standard on the Honda bikes with carburetors and also all the Chinese dual sport bikes with 200-250cc engines.

Ken, the crankcase vent tube can touch the carb, its not a problem at all, the pipe bends a bit underneath the carb also but that is also fine

 

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Yes, that's right, the carb has a built in acceleration pump that squirts a bit of extra fuel into the combustion chamber during acceleration which gives the bike that extra bit more grunt. Since I installed it I'm having a lot more fun on my bike than before

Its a good quality carb also, it comes out standard on the Honda bikes with carburetors and also all the Chinese dual sport bikes with 200-250cc engines.

Ken, the crankcase vent tube can touch the carb, its not a problem at ll, I will try to post a photo of this later today or tomorrow
Have you been able to compare fuel mileage between the old and new carbs?
 

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Have you been able to compare fuel mileage between the old and new carbs?
Fuel consumption is only a fraction higher than the stock carb, less than 5%, the acceleration pump uses very little extra fuel
 
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