CVK40 Pumper install - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 54 Old 03-29-2013, 06:09 AM Thread Starter
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Arrow CVK40 Pumper install

After doing some research I found that some of the Vulcan 1500 cruisers around the year 2000 had a CVK40 carb with an accelerator pump. I couldn’t find any information on installing one on a KLR but thought it was worth a try. I located one on ebay that was listed as coming from a 2000 model Vulcan Classic. I looked at a microfiche for that year and model and it showed a pumper carb listed as stock . The carburetor looked rough but functional so I decided to take a chance on it working. I ended up buying the carb for around $70.
This thread is to show how I installed the carb on my KLR and some issues I encountered and how I dealt with them. I make no claims of massive horsepower gains, cures for erectile dysfunction, etc. This is simply to show what the carburetor is and give ideas as to installing it on the KLR. I’ve had the carb installed for about 600 miles so the fitment situation seems to be done with the exception of a few minor details. The only thing that may be an issue with some people is re-routing the header pipe. This may or may not need to be done and I will mention the reasons and a possible option. If the header pipe modification is needed or desired, I will post pics and info that a welder or person with shop skills can use as a guideline to make the mod.


When the carb arrived it did indeed look rough but I checked it over and everything seemed to be ok so I dis-assembled it to clean it in PineSol.


As it arrived


After cleaning I took a few pics of the pumper(left) and non-pumper(right) for comparison.








Some things were different but it looked like the the carbs were similar enough to try.
No wiring needed on the KLR so the connection was removed.


This view is after the connector is removed. I made a simple plate out of lexan and covered it.






More to come later

Last edited by Tom Schmitz; 04-23-2013 at 10:33 AM. Reason: wording
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post #2 of 54 Old 03-29-2013, 07:48 AM
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Wow, MacG! Terrific contribution to KLRiana! The very best potential of a motorcycle website to share and inform, with the primary evidence of direct, hands-on experience!

You answer, "All I ever wanted to know about CVK pumper carbs, but was afraid to ask!"

Looking forward to more images and text on the pumper implant.
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post #3 of 54 Old 03-29-2013, 09:36 AM
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I stickied this thread. Looks like it's going to be great. Thanks for the input.

And I added it to the "Common Mods and Issues" thread - Tom

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Last edited by Tom Schmitz; 03-29-2013 at 11:32 AM.
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post #4 of 54 Old 03-29-2013, 10:42 AM
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I have a ton of questions! Can't wait to see the rest!

T

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“The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

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Last edited by Tom Schmitz; 04-15-2013 at 10:51 PM. Reason: 1998-2004 Vulcan 1500 Classic
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post #5 of 54 Old 03-29-2013, 08:38 PM Thread Starter
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The idle adjustment on the pumper is a cable.



The cable adjustment option could be used if desired. The KLR throttle cables attach to the mounting locations on the carb without issue.


I decided not to use this set up and went with a simple machine screw. I used a 4mm socket head screw that can be adjusted with a hex wrench or pliers.






In this pic you can see how the idle adjustment is on the KLR carb. This is why I went with the cable mounting plate from the pumper carb which includes the idle screw mount.




This is the carb in place. It’s a tight fit but there is ample clearance




more
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post #6 of 54 Old 03-29-2013, 08:41 PM Thread Starter
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With the header pipe mounted, the clearance between it and the acc. pump was about 5/16”.





I didn’t like the pipe being this close due to the heat getting to the fuel pump. Riding at highway speeds a lot may not cause problems due to good air flow but I ride in slow, technical areas often where the air flow would be limited. In order to test the carb out and not be affected by the heat, I decided to offset the header a bit to get it away from the pump. Another possible option that may work is header wrap. I bought a roll of 1” wide titanium header wrap to try in the future.

The closest diameter tubing and elbows I could find to fit the header pipe were 1¾” O.D. thin wall stainless I bought a variety of 45s and 90s to get the offset clearance I wanted. When I received the elbows, the wall thickness on the 45s was different from the 90s. The 90s fit nicely over the outside of the header pipe so this was the best option to use.

The 90 deg. elbow as it came



After trying different routes with the elbows , the angles needed came out very simple. In the end I used three 45deg elbows and one about half that size. These can all be cut from two of the 90 deg. elbows. The only other piece needed was a piece of straight tubing about 2 5/8” long.




This is the offset after tacking




After welding, everything was smoothed out


Even though the fit is close, the carb can be tilted to change jets or access the bottom of the carb.





Even with the offset, the KLR header pipe heat shield can be modified to fit. This pic shows the shield attached with the front mounting screw. I’ve been running the bike without the shield but will mount one later as time allows.



( I usually wash the bike off to work on it but weather didn’t allow a bath before the work started.)

That’s basically how I mounted the carb to fit the KLR and re-routed the pipe for clearance
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post #7 of 54 Old 03-29-2013, 09:12 PM
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Wow! Nice work on the header pipe MacG! Did you TIG it?
Regards....justjeff

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post #8 of 54 Old 03-29-2013, 09:24 PM
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Wow. Just wow.

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“The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 03-29-2013 at 09:31 PM.
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post #9 of 54 Old 03-29-2013, 09:31 PM
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MacG -

I could see a use for the TPS with my LM-2 wide band O2 meter.

Really nice work, man. Really nice.

T

Tom [email protected]

“The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #10 of 54 Old 03-29-2013, 09:38 PM
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Ditto on the header pipe....very nice!
I wrapped my header with two layers of wrapping to help with the heat as I too have maybe 1/4" space away from the pump section. So far no issues at all. But you have solved it for sure with that nice pipe.

Willys
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