Hi guys, just a quick update, I was lucky enough to find an intake manifold for a 2001+ TW200 in the $25 (shipped) range from eBay. There is definitely a difference between the 87-00 and 01+ manifolds boot where it joins the carb, but the difference is manageable by using a wider clamp (Home depot generic clamp). I am also using a pod filter which gives me some flexibility in the mounting positions. I believe there is a thread floating around that compares the carb differences between the generations, but it also shows the manifold differences. The main difference is that the 01+ manifold has a vacuum port for the evap/emissions related pipework and the groove inside the manifold that holds the carb in place is slightly different.
Prior to putting on the new manifold, I was having a really hard time mending the ripped rubber. The rubber portion of the manifold was simply too short to clamp or glue on any support for a silicon or replacement rubber hose. Furthermore, it is inherently difficult to glue rubber... I had a hard time finding a glue that was strong enough to hold the rubber manifold together yet flexible enough to not tear again once the band clamp was tightened. I tried all types of glues with rubber fillers without much luck. I was only able to get about 5 miles into a ride before the repair (bandaid) would rip.
Randucci, thank you for offering to help! I've had the new manifold on for about 10 miles so far and despite the mismatch, it is holding well. I'll check back in a few weeks to let you guys know how it is holding up in the long run. Thanks again!
