NCY Teflon intake and Mikuni fuel pump installed

[ltdHPP]

As I was about to replace the factory intake manifold again, I noticed the Teflon intake costs almost the same as two OE ones... and that it and the Mikuni fuel pump are like a match made in heaven. Its got two vacuum ports, one fat one for the fuel pump and a smaller one for the valve on the carb. The OE pumps are known to be barley able to do the job, and if it were ever to quit on me I'd sure wish I had paid $30 for a better fuel pump... so I did.

I kept reading threads on installation issues for these, so I thought I would share my efforts and results.

I should start by mentioning this scooter is a less common engine and frame style - its a 1P57QMJ on the larger touring frame you usually see 250cc motors in.

First, from reading on here I knew the intake was slightly big for a factory size 24mm carb, but I'm a crafty individual so I wasn't worried. Luckily I found a perfect thing to use for a sleeve in a box-o-junk at my work full of 'might use that for something' stuff we save.
I really wish I could tell you where to find one, but I can't. I can tell you what it is though....
When we get new radiators to install in cars, they come with caps over the hose and line hookups. Sometimes plastic, sometimes rubber, and I found a rubber one to trim up and use for this. My other plan was going to be to layer up some 35mm shrink tubing on the carb, if that exists. It looked like you could just crank down on the thing enough to hold it, but I didn't want to risk an inferior seal.





BY THE WAY

The 30mm designation for this intake I can only assume refers to the size of the carb butterfly it is made for, NOT the inner diameter of the intake manifold inlet, or outer diameter of the carb its made for. This made the quest for a sleeve even more difficult, at first, lol.

[ltdHPP]

As far as actually installing the intake to the head, it fits like a glove, but I was not able to reach in and stick the carb right in or scoop it out like with the original one. There are definitely clearance issues with the frame and cross-member (this is a stock carb) trying to install the carb with the intake in place, BUT I was able to install the carb into the intake first, then install them together, and it went fine. this is mildly inconvenient now to remove the carb later... but I can deal with it. I used a little silicon grease to keep the very thin O-ring for the intake in place... don't loose it!
Depending where it is to begin, you may have to re-position the angle of your throttle cable too.

Now... will this still work with the factory airbox? I dunno. I have a tube and pod filter on mine...

The fuel pump install was easy... it almost lined up with both holes...
You could widen the holes out some if you want, or use one bolt and a quality zip tie. Don't buy cheap zip ties...

Here are some pics of everything installed: