Mod an FCR carb to fit onto the Z400

The YFZ carb has the tors and tps on the choke side of the carb making it HUGE! I found two ways to get around this so I thought I would share them. Common sense applys, you dont want metal shavings in your carb so take the proper precautions. Work slow, smart, and clean.

1. Pic of carb with all the YFZ junk on it.

2. Remove the black tps housing with a phillips screw driver. Next use a hack saw or cut-off wheel to make a slot in the cover screws, then use a slotted screw dirver to remove them. Remove the tors cover plate, 11mm nut on the throttle shaft, two phillips screws, and lower tors housing.

3. Next, use a hack saw or air recipro saw to cut the throttle shaft off leaving aprox. 3/16 hanging out of the carb body. Use a flap wheel on a die grinder or dremel to smooth and round shaft.



4. Now to make the cap, start with the lower tors housing.



5. Put it into a vise and use the same hack or air recipro to ROUGHLY cut out the wanted piece. Cut wide and use a bench grinder and flap wheel on a die grinder or dremel to make the finished size.



6. Check new cap for fit, open the throttle many times feeling/looking for snags, rubbing etc... Correct any that you find.



7. To finish the cap you need to use a hot glue gun, fill the screw and throttle shaft holes to create the void needed for propper operation.



8. Once glue is dry fill the cap with Devcon metal epoxy (jb weld should also work) Let it dry and sand smooth. (pic is of mine not dried or sanded smooth yet)



There you have it. Also, if you are inexperienced working with metal be very careful, work slow and smart. The metal carbs are made of is very soft and you could quickly damage something. As careful as I am to keep stuff out of my carbs when working on them I will still take them apart and do a good interior cleaning once finshed with this.

I said I had two ways, here is the second. It is a little less work but I dont think it is as good of a fix either. If you are tool challenged it could be the way to go I guess. Follow the first steps then when you are ready for the cap take the TPS housing and drill out the middle, about half way deep then screw it into place and check for snags, rubbing etc... Use a pair of dykes to cut off wires.

Here it is all done!