Fcr 39 Set Up From 04 Yfz

[mmikulak]

Well I had a beotch of a time setting up my FCR39 from an 04 YFZ. I am posting this to possibly help out a Z brother that may contemplate a FCR install. Let me tell you the pain in the arse is worth it!!

Maybe this can be made a sticky.. First do a search and learn how the thing works and what to expect. Search Thumpertalk.com and this site. Then maybe use this as a guide.

First of all. Take it apart and make sure it is clean. If you look in the mouth of the carb it has a hole in the bottom center of the carb that is the Main-Air-Jet hole. It is not adjustable. It is drilled at 200(info from Sudco). The other carbs(not yamaha I am unsure of honda) have a jet there. When the carb is apart and the main and holder is out you can put a piece of wire or thick fishing line through there and it will end up coming through the main holder brass straw belongs. Mine was pretty much clogged. Clean the pilot passage with a smaller wire. By the way- the Yamaha pilot jets are a type 21.

Make sure the AP diaphragm is installed correctly. Not upside down lke mine was!!!! The larger part of the rivet goes downward. I had a TERRIBLE bog and this was the main culprit .

Adjsuting the AP linkage. The best source for this was Thumpertalk's Honda 450 discussion. link-- http://www.thumpertalk.com/forum/showthrea...4181&page=1 It is a big thread but you should get the idea by the first 20 pages. I read until they talked about the 3 types of mods they were using.

I adjusted the linkage by holding the throttle wide open and adjsuting the screw til it "just touched" the AP black lever after that I did the O-ring mod to the linkage. I made sure nothing would bind.

UPDATE- I DON'T RECOMMEND USING AN O-RING. READ ON FIND OUT WHY

I am not dialed in 100% but I am real close. Check my signature for my jetting.

Also thanks to Normal, RRGUY, NJC, and Jasontallica and I am sure there are others I am forgetting .

Mike

[PeeWee]

Man...there ain't none of those guys you mentioned that knows what they're doing!!!! LOL j/k You had some damn fine people helping you out....that includes you too Normalz!!!!

[kcsteck]

QUOTE (mmikulak @ Oct 20 2006, 10:02 AM)

Well I had a beotch of a time setting up my FCR39 from an 04 YFZ. I am posting this to possibly help out a Z brother that may contemplate a FCR install. Let me tell you the pain in the arse is worth it!!

Maybe this can be made a sticky.. First do a search and learn how the thing works and what to expect. Search Thumpertalk.com and this site. Then maybe use this as a guide.

First of all. Take it apart and make sure it is clean. If you look in the mouth of the carb it has a hole in the bottom center of the carb that is the Main-Air-Jet hole. It is not adjustable. It is drilled at 200(info from Sudco). The other carbs(not yamaha I am unsure of honda) have a jet there. When the carb is apart and the main and holder is out you can put a piece of wire or thick fishing line through there and it will end up coming through the main holder brass straw belongs. Mine was pretty much clogged. Clean the pilot passage with a smaller wire. By the way- the Yamaha pilot jets are a type 21.

Make sure the AP diaphragm is installed correctly. Not upside down lke mine was!!!! The larger part of the rivet goes downward. I had a TERRIBLE bog and this was the main culprit .

Adjsuting the AP linkage. The best source for this was Thumpertalk's Honda 450 discussion. link-- http://www.thumpertalk.com/forum/showthrea...4181&page=1 It is a big thread but you should get the idea by the first 20 pages. I read until they talked about the 3 types of mods they were using.

I adjusted the linkage by holding the throttle wide open and adjsuting the screw til it "just touched" the AP black lever after that I did the O-ring mod to the linkage. I made sure nothing would bind.

I am not dialed in 100% but I am real close. Check my signature for my jetting.

Also thanks to Normal, RRGUY, NJC, and Jasontallica and I am sure there are others I am forgetting .

Mike[/b]

just got a 05YFZ carb and am tryin to install on my KFX400 its diff from the FCR thats on my CRF450 thats for sure.well anyways the bottom throtte cable and bracket is hitting the cross memeber and not letting me put carb on all the way. How did you get yours to fit ?
Casey

[mmikulak]

QUOTE (kcsteck @ Oct 20 2006, 08:24 PM)

just got a 05YFZ carb and am tryin to install on my KFX400 its diff from the FCR thats on my CRF450 thats for sure.well anyways the bottom throtte cable and bracket is hitting the cross memeber and not letting me put carb on all the way. How did you get yours to fit ?
Casey[/b]

Bottom Throttle cable? There was only 1 on mine and it barely missed the cross member.. There was not cutout in the carb body for a 2nd cable.

I am no expert but I have never seen a carb from an ATV with more than 1 cable. That is usually from a twist(bike) throttle.

If your slide returns by itself you probably don't need the return cable and can take it off.

If you'd like some pics send me a PM with your e-mail address.

Mike

[Black Z400]

QUOTE (PeeWee @ Oct 20 2006, 10:19 AM)

Man...there ain't none of those guys you mentioned that knows what they're doing!!!! LOL j/k You had some damn fine people helping you out....that includes you too Normalz!!!! [/b]

I disagree... Normalz is a moron... he probably just got a lucky guess. j/k we all know that Normalz knows more than most of us about the z, and that most definately includes me.

[slvrblt00]

My fcr39 is on the way and am needing some jetting tips to start with. Mods are in my sig and since I don't have cams and drz kit will this effect my jetting? Also did you use the drz and 400 ex boots. Just reading up on the fcr until it arrives. I see most people use the drz boot, but don't see everyone using the 400ex also. Does the 400ex boot need modifying to work. I looked at the fcr tips from normal ( http://www.ttbomb.com/z400/fcr/ ) and didn't see anything about the 400ex boot. Thanks

What exactly does the Boyesen Quick Shot do and if you adjust and mod the ap is it still necesary. thanks

[NormalZ]

QUOTE (PeeWee @ Oct 20 2006, 11:19 AM)

Man...there ain't none of those guys you mentioned that knows what they're doing!!!! LOL j/k You had some damn fine people helping you out....that includes you too Normalz!!!! [/b]

Very rarely am I included in the "damn fine people" club - thanks for ruining it for me, PeeWee, ya bastage.

QUOTE (Black Z400 @ Oct 20 2006, 10:55 PM)

I disagree... Normalz is a moron... he probably just got a lucky guess. j/k we all know that Normalz knows more than most of us about the z, and that most definately includes me.[/b]

Black Z400, I don't know you, but you're damn lucky you decided to toss in some smilies with that comment, because you just about earned a serious ass-whoopin'.

[kcsteck]

QUOTE (mmikulak @ Oct 20 2006, 10:26 PM)

Bottom Throttle cable? There was only 1 on mine and it barely missed the cross member.. There was not cutout in the carb body for a 2nd cable.

I am no expert but I have never seen a carb from an ATV with more than 1 cable. That is usually from a twist(bike) throttle.

If your slide returns by itself you probably don't need the return cable and can take it off.

If you'd like some pics send me a PM with your e-mail address.

Mike[/b]

Ok well I was told it was a YFZ carb and now after you said that I went on internet and looked for YFZ carb and I clearley see that it wasnt. Dam ebay people! Looks like one that comes off a KTM dirtbike or somethin. yes it came with twist throttle as well. yes it does return by itself. this carb unlike the one on my CRF 450 has like mechanical arms on side of carb that move when you do the throttle and link down to accelertor pump etc.looks exactly like this one
carb like mine on ebay

what I need to know is what do i do to make this work?do I cut crossmber notch for throttle cable to fall into and not hit.do I cut that part of throttle bracket off carb and loose the cable since it returns on its own?I really want to do the thumb throttle anyways once i figure out how I do that wit this carb , where do I get the correct cable? do I sell carb and get dif one?Let me know .
Casey
I appreciate the help .

[mmikulak]

Casey,

I don't feel right telling you what to do because I don't want the throttle to get stuck open under my directions. But this is what I would do:
I would make sure the carb slide will close and close fast on its own. The stock thumb trhottle has a return spring in it so it makes it a little easier on the slide closing. Mine(YFZ) has enough spring to close the slide and pull the thumber back and back fast. Mine is supposed to have the "softer" return spring too.

If that one closed like the one I am using I would cut the bracket and lose the return cable.

Right now I am using the YFZ thumber and cable. I may want to get the correct cable so I can use my stock thumber. You an get them from the place in this link http://www.ttbomb.com/z400/fcr/

Unlike the YFZ carb, the intake bell on that carb is removable. Not a bad thing. There is no way for me to know if it will fit. I don't have an EX boot.

I would also do the "wire mod" that they talk about in Thumpertalk.com use the link I posted in the first post. Make sure it doesn't bind and set the screw with the throttle WIDE OPEN. Check for binding or possible binding again.

[mmikulak]

Silver,

I didn't use the DRZ boot. I do have one on order cause I dont' trust the stock boot. Carb is not in it enought IMO.

I don't think the QS is necessary. I heard it does improve the way the AP ressy fills. It is supposed to ensure there is no air bubbles in the ressy too. Air compresses and fuel doesn't so it is supposed to give a better squirt. It is also 80 bucks so I would try it without first.

To get the EX boot go to a honda parts site like www.ronayers.com and order a new one. I am using stock boot. Jetting should be similar the EX boot flows a bit better.

Mike

[kcsteck]

QUOTE (mmikulak @ Oct 21 2006, 12:30 PM)

Casey,

I don't feel right telling you what to do because I don't want the throttle to get stuck open under my directions. But this is what I would do:
I would make sure the carb slide will close and close fast on its own. The stock thumb trhottle has a return spring in it so it makes it a little easier on the slide closing. Mine(YFZ) has enough spring to close the slide and pull the thumber back and back fast. Mine is supposed to have the "softer" return spring too.

If that one closed like the one I am using I would cut the bracket and lose the return cable.

Right now I am using the YFZ thumber and cable. I may want to get the correct cable so I can use my stock thumber. You an get them from the place in this link http://www.ttbomb.com/z400/fcr/

Unlike the YFZ carb, the intake bell on that carb is removable. Not a bad thing. There is no way for me to know if it will fit. I don't have an EX boot.

I would also do the "wire mod" that they talk about in Thumpertalk.com use the link I posted in the first post. Make sure it doesn't bind and set the screw with the throttle WIDE OPEN. Check for binding or possible binding again.[/b]

Thanks mmikulak!
I removed return cable and it returns fine. Only thing I have slop in the twist now like 1 inch worth before it actuates carb open.I tried adjusting cable as far as it would go.still there. Quad runs good just need to fine tune it. Will thumb throttle cable for any FCR work on my stock z thumb throttle? I bought one on here from Avalancheharpo
but have yet to hear from him on sending it out yet. will thumb throttle cable just hook up to top cable guide mount on carb like I have now with the twist throttle cable, so I can cut that part of bracket so it wont hit crossmember?

Im runnin 170 main OBDV needel clip in middle 4th clip,45 pilot 65 leakjet 2 1/2 turns on air let me know what ya think

Casey

[slvrblt00]

Thanks mmikulak for the info. I will order both boots, ncvq needle, fuel screw, and jets. Anyone deal with a good and quick place to order jets. My local shops might have some main jets but i don't think they will have many pilots or leak jets. Anyone have a suggestion on jets to start with like 155-160-165-170 and 48-50 pilots and 50 leak and any others or is this to much. I see some have plugged there leak jets wouldn't this give you way to much fuel on a z and also wouldn't this make the ap shoot gas no matter how the throttle is pressed?? thanks everyone.

[mmikulak]

QUOTE (kcsteck @ Oct 21 2006, 02:03 PM)

Thanks mmikulak!
I removed return cable and it returns fine. Only thing I have slop in the twist now like 1 inch worth before it actuates carb open.I tried adjusting cable as far as it would go.still there. Quad runs good just need to fine tune it. Will thumb throttle cable for any FCR work on my stock z thumb throttle? I bought one on here from Avalancheharpo
but have yet to hear from him on sending it out yet. will thumb throttle cable just hook up to top cable guide mount on carb like I have now with the twist throttle cable, so I can cut that part of bracket so it wont hit crossmember?

Im runnin 170 main OBDV needel clip in middle 4th clip,45 pilot 65 leakjet 2 1/2 turns on air let me know what ya think

Casey[/b]

No, the YFZ cable will not work unless you drill and tap the Z thumber. I can't say for sure if it will hook up the same way. Get that motionpro cable for the stock thumber.

I think that if it is runnig good than you must be pretty close.

Did you get more power???
Mike

QUOTE (slvrblt00 @ Oct 21 2006, 02:55 PM)

Thanks mmikulak for the info. I will order both boots, ncvq needle, fuel screw, and jets. Anyone deal with a good and quick place to order jets. My local shops might have some main jets but i don't think they will have many pilots or leak jets. Anyone have a suggestion on jets to start with like 155-160-165-170 and 48-50 pilots and 50 leak and any others or is this to much. I see some have plugged there leak jets wouldn't this give you way to much fuel on a z and also wouldn't this make the ap shoot gas no matter how the throttle is pressed?? thanks everyone.[/b]

I got my jets from the Honda dealer. The main jets were large hex and the pilots are Kehein type 21. Mains as you suggested and piots 45-48-50

Blocked AP will do just as you decscribed.

[kcsteck]

QUOTE (mmikulak @ Oct 21 2006, 04:26 PM)

No, the YFZ cable will not work unless you drill and tap the Z thumber. I can't say for sure if it will hook up the same way. Get that motionpro cable for the stock thumber.

I think that if it is runnig good than you must be pretty close.

Did you get more power???
Mike
I got my jets from the Honda dealer. The main jets were large hex and the pilots are Kehein type 21. Mains as you suggested and piots 45-48-50

Blocked AP will do just as you decscribed.[/b]

which way on leak jet makes for shorter squirt going up or down in numbers ?I have a little bog if i stab it real hard. leakjet does what? I dont want to have to buy one of those boysen AP covers if not needed is what I am trying to do.
Casey

[mmikulak]

QUOTE (kcsteck @ Oct 21 2006, 07:59 PM)

which way on leak jet makes for shorter squirt going up or down in numbers ?I have a little bog if i stab it real hard. leakjet does what? I dont want to have to buy one of those boysen AP covers if not needed is what I am trying to do.
Casey[/b]

Down or lower makes longer squirt. Larger make shorter quirt. Did you adjust the AP like I suggested?

Hold the throttle wide open (til the slide disappears) then screw in the AP screw til it hits. Then wire or O-ring that linkage together.