How to Install the BPNW Intake Riser on the GY6 150cc Motor

Installing the Intake Riser on GY6 150cc

Introduction:

This guide will detail how to assemble and install the BPNW carburetor intake riser system on GY6 150cc based buggies.

This guide has instructions on how to install the intake riser, 30mm intake manifold, and 30mm carburetor found in the BPNW Air Performance Upgrade Level 2 package.. Individual parts also sold separately.

Please send any feedback on this guide to: webmaster@buggypartsnw.com

Tools:
– 5mm allen wrench.
– Flat-head screwdriver
– Philips screwdriver
– Blue Loc-tite

Safety Notice:

Before starting, allow the engine to cool completely. The cylinder head and body systems achieve very high temperatures from normal operation.

Part I: Accessing the intake.

1. If applicable, remove the stock air intake box. Turn off the fuel supply to the carburetor and disconnect the fuel line. Gasoline in the line may spill onto the ground. Open the carburetor bowl drain screw and drain the fuel from the bowl.

2. Disconnect and remove all hoses and the electric choke from the carburetor. Label all hoses before removing, if necessary.

3. Loosen the clamp on the stock intake manifold with a Philips screwdriver and remove the carburetor. Set aside.

Image 1: Cleaned cylinder head. (image taken with shroud removed and cylinder head disconnected from motor)
Image 1: Cleaned cylinder head. (image taken with shroud removed and cylinder head disconnected from motor)

4. Remove the nuts securing the stock intake manifold and take the manifold and gasket off (if there is a plastic spacer present, remove that, too). Remove the stock manifold bolts from the cylinder head. Clean away oil and grime from around the cylinder head intake, taking care to not allow any to fall into the intake!

Part II: Installing new intake riser

Image 2: Paper gasket.
Image 2: Paper gasket.
Image 3: Paper gasket placed.
Image 3: Paper gasket placed.

5. Place a paper gasket onto the cylinder head intake opening.

Image 4: Install o-ring into groove.
Image 4: Install o-ring into groove.

6. Place an o-ring into the groove on the bottom of the intake riser. You may need to use your fingernail to seat it properly.

Image 5: Insert bottom riser bolts.
Image 5: Insert bottom riser bolts.

7. Place the intake riser on top of the gasket, lining up the bolt holes (pay no attention to the plastic spacer in the photograph. It is no longer needed.) Insert the two shorter socket head bolts into the holes and tighten using an allen wrench.

– Note: Use of blue Loc-tite on these bolts is recommended. It is important that they do not come loose during operation.

Image 6: Riser bolts tightened.
Image 6: Riser bolts tightened.
Image 7: Intake Manifold O-ring.
Image 7: Intake Manifold O-ring.

8. Press the o-ring into the groove on the bottom of the 30mm intake manifold.

Image 8: Tighten the 30mm intake bolts.
Image 8: Tighten the 30mm intake bolts.

9. Set the new intake manifold on top of the intake riser and install the longer socket head bolts.

– Note: Use of blue Loc-tite on these bolts is recommended. It is important that they do not come loose during operation.

Image 9: Install the new carburetor.
Image 9: Install the new carburetor.

10. Loosen the bolt on the outer clamp of the new intake manifold and firmly press the exhaust of the carburetor into it. Make sure the carburetor is fully seated before tightening the clamp.

11. Install the velocity stack intake and UNI filter according the the tutorial found here.

12: Reconnect the fuel line to the fuel intake on the new carburetor. Restart the fuel supply from the gas tank. Reconnect any necessary breather tubes and electric choke, if applicable.

13. Ensure fuel is flowing to the carburetor and start the buggy to test.

14. Once the buggy starts, spray carb cleaner around the new intake manifold and intake riser to check for leaks. If the idle changes (for better or worse) then you have an air leak and need to check the gaskets and o-rings for proper seal. Do not spray carb cleaner on a UNI foam filter intake.

15. Run the buggy until warmed up and go for a drive, hitting wide open throttle (WOT) for a few minutes if possible.

16. Check the spark plug for color and rejet the carburetor accordingly by using this guide until the buggy is running at the optimal air/fuel mix.

17. Have fun with your newly upgraded air/fuel system!

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