FCR 40 Install Guide w/ Pics … Service Honda Route

[norcal.z400]

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!!!

[norcal.z400]

MODS: Any chance of getting this post made a sticky or adding it to the Z Tech for everyone to use????

The baseline jetting is just a baseline. Once installed on your quad you should check it and adjust for your temperature and elevation.

I hope this helps! Also ... other FCR40 owners please chime in if I have forgotten something!!!

[bulldogz400]

Excellent post! Yes this needs to be a sticky or in the Z tech spot. I have already printed this out and will be my guide for the installation of my carb when it gets here!! Thanx a ton!!

[Rooster]

Your petcock vacuum cover on the fuel valve is identical to mine right down to the color.

[bvstone]

What bike is this from? I didn't see it on the 02 or 03 CRF450. I did see the 16100-MEB-670. Is this the same thing?

And for jets, do you order them from the 2002 450?

[norcal.z400]

I just checked the service honda site and the 03 CRF450 Carb has a different part # ... 16100-MEB-771 and it has a cheaper price too. It also comes with a 42 pilot already, but a 170 main.

you can order the jets from service honda or also pick them up from a local honda dealer, just tell them you need them for a crf450

[Harkes2k]

I thought I saw someone post about the on/off switch, making it have on off and reserve for this carb...add that in to the tech section too if you can find it...

[Uncle Caleetro]

Will a Terrycable throttle work with that cable? Or the Mooseracing one.

[Zhvonte]

uncle, you wont want to have those other throttle cable.... because they are stiff as hell.... unless you like stiff thumb throttle, I would advise against them....

[popo35]

Originally posted by zhvonte@Aug 3 2003, 05:56 PM
uncle, you wont want to have those other throttle cable.... because they are stiff as hell.... unless you like stiff thumb throttle, I would advise against them....

Ya, what he said.

[Uncle Caleetro]

The Terrycable is stiff?

[norcal.z400]

Hey guys, DadsZ400 was able to convert his stock petcock to all for the selection of on/off/reserve!!! very good info!!!

http://z400central.com/invision/index.php?...showtopic=11761

[Uncle Caleetro]

So will the Terrycable throttle work with the cable from Service Honda? And are they really that stiff?

[popo35]

Originally posted by Uncle Caleetro@Aug 5 2003, 11:40 AM
So will the Terrycable throttle work with the cable from Service Honda? And are they really that stiff?

The Moose and Terry Cable are the same thing. Too stiff. Get a Honda 250R thumb throttle

[daversj]

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.