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Discussion Starter · #1 · (Edited)
Hey guys, me again with another couple of questions. Its a totally different install, so i figured I'd make a new thread.

I just got the WT603 in the mail today, and as MathieuOuellette stated, i was going to need a new manifold. However, every manifold i found online looked exactly the same as i have now.

I went ahead and lined up the carb to the manifold, and i cant see how im going to need a new one. The vacuum port isnt 100% lined up, but with a slight opening of the hole on the manifold, it should make a 100% tight seal.

What is your input on that? I kinda want a metal manifold, and will order one if need be, but i really dont think its 100% necessary.

The choke lever is kinda tight up against the vstack, but it still moves pretty freely, so i dont see the need to cut the red handle up too much just yet

Heres some quick pictures i snapped of the install.







Any input is greatly appreciated. Good day to you guys!

EDIT:::::: Or is this the intake manifold that is needed for the wt603?

Code:
http://www.pocketbikeparts.com/Intake_Manifold_HP_Cag_p/cgim301644.htm
 

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Discussion Starter · #2 ·
Also, if a new manifold is absolutely required, does this magical juice box i hear of actually work? If so I'd be interested in that, and here is a link for those who want to see what i mean.

Code:
http://www.adaracing.com/all/juice-box-49cc-pocket-bike/pbjb-49
 

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Discussion Starter · #4 ·
The choke will be modified once i take it back off for final fitting, however back to the 'vacuum' port..

Do you think i should remove my manifold and make the hole a little bit more to the right, to accommodate the hole on the carb/gasket perfectly?

I dont wanna break the gasket seal from my manifold if i dont need to though.

Also, mathieu, any input on the 'juice box'?
 

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PBP SENIOR M!LKER
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I had to do it with a Copy carb but pretty much the same thing.. You dont need that thin adapter and extra gasket if you modify the intake adapter..

http://www.pocketbikeplanet.com/showthread.php?t=78554 again all credit goes to EPR, CAM2...

Yours will work as long as they are really aligned well.. The extra piece and gasket just add more places to leak...

Good luck!
 

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PBP SENIOR M!LKER
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The juice box is the same as a boost tube... Make your own.. Tons of info on here about them.

Oh ya, I had to grind down half that choke lever before I got a good seal...
 

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The addaptor plate should line up the slotted hole on the stock one w/ the 603 hole. I just fill in the bottom part of the pulse channel and leave just the upper part open to match the new carb. Scooterpartsrus has the metal ones for $12.99 and $3 S/H PB Intake Manifold. Drill and tap a 1/8" NPT in the top and add a barbed fitting for a boost bottle you can make yourself.
 

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Discussion Starter · #8 ·
Let me get this straight. I need to JB weld the entire port closed then redrill it using the gasket as a template? Shouldn't it still get a good seal with with the gasket regardless?

Thanks for all your help guys, I really appreciate it.

Also, the metal one will need to be modded in the same fashion, correct?

I have a crack in my gas tank that I read JB weld will fix aswell, so I might as well kill 2 birds with one stone.

One more question, any performance gain from a metal manifold to a plastic one? If not I'll just mod the plastic one.

thanks again guys, im posting from my phone so my apologies for any spelling mistakes
 

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Hey I was thinkin bout gettin the same carb and stack as u, what PB did u put it on and did it really make a difference?
 

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Let me get this straight. I need to JB weld the entire port closed then redrill it using the gasket as a template? Shouldn't it still get a good seal with with the gasket regardless?

Thanks for all your help guys, I really appreciate it.

Also, the metal one will need to be modded in the same fashion, correct?

I have a crack in my gas tank that I read JB weld will fix aswell, so I might as well kill 2 birds with one stone.

One more question, any performance gain from a metal manifold to a plastic one? If not I'll just mod the plastic one.

thanks again guys, im posting from my phone so my apologies for any spelling mistakes
You just want the holes lined up as strait as possible.. I drilled mine at an angle on a press so I wouldnt need that extra metal adapter.. All those pieces are an airleak waiting to happen. It will work as long as all your holes line up, the smoother the flow the better.. Shoulda got the 813 Pumper and you would have just sealed the hole..

Metal Intake just lasts longer... They both work!
 

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Discussion Starter · #11 ·
Ahh, if i only knew the 813 was a better carb at the time.. ill seal the hole and make it straight through tomorrow, and will report back.

Have the rest of my parts coming tomorrow, well the immediate ones atleast. Hopefully I'll have a running bike by tomorrow and i can post some pics / a video.

Kinda wanna finish this bad boy up and keep or sell it for an x18 or x19.

Just NEEEEED a bigger engine hehehe
 

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Discussion Starter · #12 ·
Hey I was thinkin bout gettin the same carb and stack as u, what PB did u put it on and did it really make a difference?
Its going onto my x7 gOwner, but its kinda a mini build that i have going on. I have not test fired the engine yet with it on, but when i do ill let you know how it works. (Hopefully tomorrow)

By the way, Thank you, Nips
 

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Discussion Starter · #14 ·

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That thin addapter plate if installed right, should cover up the long channel and line up the pulse hole on the 603 or 813. I carefully drill the carb pulse hole out to 1/8", the manifold and the head hole too. The 813 is almost the same but has a accell pump like a car, and no choke plate in the carb so it cost $9.50 for a choke plate and $8 for a nice 19mm V-stack. 2 months ago I got a Walbro WT-813 for $29.99 at Dave's in Utah and they have great shipping. Dave's has a weekly Go-Ped sale of carbs & alot of stuff you can use on these bikes too.
 

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I forgot, there are all kinds of ways to mod the Cag or piston port engines. Here is a cut stock cylinder w/ Cag alloy head modded to fit the cylinder, did all of it with a bench grinder and hand tools, hacksawed the cylinder, 5th fin from the top. The piston clears the head piece by .023", its a radical engine Now,lol.
 

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Nothing right now, could put it on my scooter, but to much HP for it, it's squirrelly enough already w/ the special cylinder Sam, Boosted306 made for me, it has the 813 w/ boost bottle intake and the Jet Pro exhaust.
 
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