FCR 40 Install Guide w/ Pics … Service Honda Route

[z434RoosteR]

Yea i'd like to try this conversion but it's a really old thread and the bikes are newer along with all the pics are gone.

[drnez]

I just modified my stock throttle cable to fit, and picked up a used FCR40 off of a CRF450. I think I picked the carb up for around $250 or so.

[mash1up]

cfr or yfz fcr carbs any differences because i'm thinking of buying one 4 my z, and it seams like the crf450 carbs are a litle cheaper on ebay than the yfz450 carb. does anyone no. also how much do all the other litle parts that i will need coast so i can get a true price of all the mods needed 4 a complete carb change thanks peoples


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QUOTE (norcal.z400 @ Jul 29 2003, 10:35 PM)

I have been getting quite a few PM’s lately regarding the Keihin FCR 40mm carburetor and installing it on a Z400. I have taken a few pics and written a small guide to help others with the setup and install.

To run this carb you need a few Honda parts. Order them from the folks at servicehonda for a good deal. www.servicehonda.com

1. Carb: 16100-MEB-671
2. Throttle Cable: 17910-HC5-970
3. You may also want to pick up a variety of jets including 42 pilot, 178, 180 and 182 main jets.
4* Honda thumb throttle Housing and Assembly: 15+ parts (best to buy on eBay)

*You can also use your stock Suzuki thumb throttle assembly by tapping it to fit the 10mm x 1.25 Honda cable.

note - the throttle cable mentioned above will work but needs to be trimmed. You trim the Black Cover and the spiraled metal that supports the cover (NOT THE ACTUAL CABLE) just the cover!!!! You are just increasing the length the cable can travel. Trim it right where above the adjuster bolt! you see where my bolt is all mangled??? thats where!!!! Here is a pic:



Once you get your throttle cable trimmed and installed make sure it pulls freely from all the way closed to throttle stop

The carb comes with a few extra features for the CRF450 that we don’t need or use. I put a vacuum cap over the hot start cable inlet and there will be an electrical connection for the TPS (Throttle Position Sensor) Just leave it alone and unplugged. This picture shows the hot start capped.



You also need to cap the back side of the Fuel Petcock, the vacuum hose that connects to the stock carb is not needed anymore and you don’t want dirt or any foreign objects getting in there. Here is a pic


Once you have your throttle cable and thumb throttle assembly setup and re-jetted the carb for the Z400 you are ready to install it on the quad. A good baseline setup for the jetting is 1.25 turns out on the mixture screw, #42 Pilot, 2nd clip from the bottom (closer to taper) on the needle, and a #180 Main Jet.

1. Remove your tank cover and side plastics.
2. Remove the gas tank
3. Loosen the clamps on the stock carb and remove it and the throttle cable.
4. Remove the rubber head to carb air boot with clamps loosened.
5. Work the boot onto the carb and tighten clamp (I have found this to me much easier to install and leave it on permanently. If you need to remove the carb just loosen the front clamp on the head and remove it with the air boot attached to the carb.
6. Install the carb and tighten the clamp on the head.
7. Hook up the airbox to carb boot, it will be stretch but will work and also will not go anywhere when tightened.
8. Once everything is tightened up good work the carb back and forth and make sure it will not loosen up under hard riding.
9. Now hook up your throttle cable and route it to the assembly if you haven’t already.
10. Install the gas tank and hook up the gas line. The FCR with a stock petcock needs to run in the PRIME position so fuel will fill the carb bowl.
11. At this time I would start it up and make sure it runs good. If everything is well finish putting on the plastics and ride!!![/b]

[jlracing]

any links to see the 1st post with pic's, there not working for me.

[mrgixxer6]

QUOTE (KFX61 @ Feb 18 2004, 01:23 AM)

HA I'VE GOT THIS SAME SETUP BUT I WENT A DIFFERANT WAY
I USED THE STOCK CABLE & TOOK OFF THE END OF THE CABLE THATS ON THE CARB SIDE AND USE THE STOCK CABLE END OFF THE CRF450 CABLE, BUT TOOK A LITTLE FILE TO OPEN THE HOLE A LITTLE. SO, I GOT THE STOCK CABLE WITH THE END OFF OF THE CRF450 CARB AND THE BRASS RETAINER OFF THE STOCK Z CARB. THE BRASS RETAINER GOES ON THE CARB CAM. IT THREADS THE CABLE.
BUT THE TRICK THING I GOT WAS THE AIR BOOT OFF A 400EX.
JUST CUT THE AIR INLET OFF THE BOOT, & CUT OUT THE HOLE IN YOUR AIR BOX
IF YOU COMPARE THE TO AIR BOOT ( Z, 400EX) YOU WILL SEE THAT YOUR STOCK BOOT RESTRICK ALOT OF AIR.[/b]

FYI for anyone wondering.. The stock cable does work with the mods listed above.. i just did mine. Was gonna buy the Motion Pro cable, but i figured i'd try this.. And now i got stock cable to FCR.. You need to remove the Threaded part on the stock cable that threads onto the carb. and then u need to take the Threaded part off the cable that connects to the FCR. Drill it out to 9/64" and you are set!!! Make sure you get the old cable cap out of the FCR cable mount.. otherwise you can't recrimp that end on your cable. Any questions just PM me and save yourself $35.

dave

[daoust]

where can i find a direct fit cable for my fcr 40 to the stock thumb throttle

[hondareconred]

what main jet would yall recommend for a esr intake and a full system fmf t-4 exhaust

[motorhead_junkey]

QUOTE (daversj @ Aug 9 2003, 07:47 AM)

I modded the honda cable that norcal gave the part # for. I pulled the end off at the lever end and cut 5/16" to 3/8" of the sheathing off with dremmel tool. Be real careful not to nick the cable inside. Cut the black plastic cover back a 1/4" from the same end and reinsert into the adjusting end. You can use a coax crimper to re crimp the end on the cable. I tapped the stock throttle assemble with a 10mm x 1.25 cutter after predrilling with a 11/32 bit. Use grease on the tap to collect the metal filings. Make shure to get all the metal shavings out of the tapped throttle assemble so they don't end up inside the cable. Connect the cable at the carb end first, then screw the new cable into the thumb throttle assemble and adjust. This worked real well and I didn't have to buy a honda assembly.
The carb came with a 45 PJ and a 175 MJ. I installed a 42PJ and left the 175 main in. With my set up it the carb worked pretty good . No bogging good throttle response and pulls real hard on upper end. The main jet still needs to be determined and I am going try moving the needle in different directions to help the mid response.
FYO: I have both cams, port and polish head, full yosh sys, K&N filter, no lid, stock bore and ride at seal level.[/b]

does that go for the fcr 39mm carb too same steps

[Ricky Parsons]

ok so here it goes
parts list
070774 motion pro cable 34.95
drz intake to head boot
400 ex boot carb to box
bigger clamps idle screw

is this right

[eric.w.13]

i dont suggest using the drz boot. i used my stock boot and it cleared the head stay

[DirtMagnet]

Is the carb part number in the first post, still the best option?

This one: 16100-MEB-671???

Now that the 450R honda has this carb, is that a better option if you can find it used?

[chinoduca]

Does any one have the pictures of the installation?

[polorico]

Originally Posted by chinoduca

Does any one have the pictures of the installation?

I want to see the pics too!!!!

[chinoduca]

Originally Posted by polorico

I want to see the pics too!!!!

I did it and it was a piece of cake. Got an FCR 40 off a trx 450. I put stock carb to head boot on the carb (only losen it from the head to remove it because it's a tight fit on the carb and hard to put on) Then I bought a trx 450 throttle cable from Honda and drilled the stock throttle housing to fit the new cable and that's it. Oh and I have a velocity intake which bolted right up perfectly.

[Rbs13]

is the carb ment to sit flat or at a angle? surly sitting at the angle it does would effect the working opperation of the flot chamber?

any one care to post some pictures of the angle theres are?
also to help other people with there instalation?
all the pics through this topic are no longer avalible to view.

cheers

ps. i used the crf450 inlet to carb pipe, the ltz thumb throttle cable (fitted the crf450 fitting :carb side: to the ltz cable) and the ltz carb to airbox pipe. seems to work ok just worried about the angle........... going to figure the jetting out soon as im at sea leval and think the stock crf450 jetting will be close.