Who has a surplus AS2?

[poelinca]

My inlet rubber is roughly 33mm long (eyeballed it as i can't fit the calipers in without taking the carb or the tank off).

I don't quite understand where should a take the second measurement, can you post a pick ?

[(F5)]

That pretty much answers it thanks. The new frame will just have everything mounted closer and/or has new airbox anyway.

I've had a sleep and decided to go for my higher risk most benefit option. Welding extension on airbox side. This is away from venturi so will just look like a longer airbox inlet to the carb in the slow airflow area.
Risk is overheating carb, melting rubber seals and deforming slide area.

So I'll talk with my tool maker/welder/ all round clever guy, to lessen this. Only have to make it strong enough not to crack. Sealing can be done with epoxy devcon. About 8 tacks should be enough on outside. Just going to vet out of bed to look at a sacrificial KX carb to use for the mounting area.

[(F5)]

Hmm, sacrificial carb mount isn't long enough to saw off. Will see if weldy guy has stock big enough to turn something off, I don't. Also if he is game to weld carb metal.

[(F5)]

Ha. Love this guy. Always has a better plan.
He's just going to take a lick off carb so it's uniform. Then make up a stepped extension size for size and Loctite retaining it on. Won't leak won't move.

[(F5)]

Well here it is ready to press on once I've carved some grooves to match internal air feeds.

[poelinca]

Nice job!

The weekend is near, let us know how it runs.

[(F5)]

Cheers yes hes done a great job. If the kids go to sleep ok (wife is away on girls weekend) I'll try sort it and heat/slide it on, maybe even fit to the bike.

He's licked the end of the carb to remove the lip and make it actually round so could then size extension to suit. I have a lathe but can't do this level of work. Well he also had ally tube the right size.

Will only be driveway tuning on Sunday. Next ride is week after.

Have NEDJ needle already fitted to slide.

[(F5)]

Well that was a tight fit but some Loctite 601 some heat the vice and blocks of wood. It ain't ever coming off or leaking.

Compared with KX carb which is largely the same as my AS1 GG.

[(F5)]

Both exactly the same length and air box mount size.

Now to set float levels. But I hear kids upstairs that need getting back to bed.


Ok again.
Well float height was super low fuel level. Adjusted to 7mm with cardboard template.
Roughly in there. Needs more wiggling and maybe heat to get airboot 100% on. My motionpro cable fits and doesn't leak when on sidestand unless pulled over with rear off ground.

Not so keen that float drain plug bears on the cases. Might tickle a corner off it, have a spare it it goes through.

Rest can wait till later, going to bed.

[motopsycho87]

I did that many years ago to make a pwm 39 fit a kdx200 . Threaded the carb and adaptor, I'll see if I can find the images on the kdxrider forum