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Offline Louis Photo

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FCR carb
« on: April 24, 2014, 10:46:04 am »
I bought a workshop e-manual on Bid or Buy for a DZR, but unfortunately it features the 36mm Mikuni carb only. Does anybody know where I can download a manual with the Keihin FCR carb?
It's time that I learn how to remove and clean this thing myself.
 

Offline Louis Photo

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Re: FCR carb
« Reply #1 on: April 24, 2014, 12:23:39 pm »
just wasted another 130mb data, downloading the wrong manual from drz400e.com  >:(  I dont think the manual with the FCR carb exist on the internet.
 

Offline Louis Photo

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Re: FCR carb
« Reply #2 on: April 24, 2014, 01:10:49 pm »
I found a badly photostatted copy of a KLX400 Clymer manual, will have to do.
 

Offline spankme

Re: FCR carb
« Reply #3 on: April 24, 2014, 01:13:55 pm »
Wr 450 , yz426
 

Offline Louis Photo

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Re: FCR carb
« Reply #4 on: April 24, 2014, 01:30:56 pm »
 

Offline Torque Curve

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Re: FCR carb
« Reply #5 on: April 24, 2014, 07:58:03 pm »
I bought a workshop e-manual on Bid or Buy for a DZR, but unfortunately it features the 36mm Mikuni carb only. Does anybody know where I can download a manual with the Keihin FCR carb?
It's time that I learn how to remove and clean this thing myself.

No manual teaches you how to remove, but more importantly how to re-install a FCR carb on the DRZ - pinched fingers and a decent vocabulary will conclude the lesson well. Its a bit like figuring our a Chinese puzzle. For starters you have to loosen the lower bolts on the sub-frame, remove the 2 bolts that hold the exhaust pipe and remove the upper subframe bolt. This is done to pull the airbox boot back and to get the coolent overflow bottle out of the way. You also have to remove the rectifier from the frame.
Once the airbox boot is pulled off the carb, also undo its clamp on the airbox and pull the whole boot out of the frame for space to work.
You can now pull the carb out of the inlet manifold and take on the challenge of getting it out of the frame. It helps if you also remove the rubber inlet manifold.
If you still struggle to get it out, or back in then remove the engine mountings to tilt the motor forward for more space. I never did this - I'm to stubborn.
Good luck. I started on over an hour at first, but later got it down to 20 minutes in and out when I did jetting runs for the 462 big bore build.
“Sometimes it's a little better to travel than to arrive”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
 

Offline Louis Photo

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Re: FCR carb
« Reply #6 on: April 24, 2014, 08:14:38 pm »
I bought a workshop e-manual on Bid or Buy for a DZR, but unfortunately it features the 36mm Mikuni carb only. Does anybody know where I can download a manual with the Keihin FCR carb?
It's time that I learn how to remove and clean this thing myself.

No manual teaches you how to remove, but more importantly how to re-install a FCR carb on the DRZ - pinched fingers and a decent vocabulary will conclude the lesson well. Its a bit like figuring our a Chinese puzzle. For starters you have to loosen the lower bolts on the sub-frame, remove the 2 bolts that hold the exhaust pipe and remove the upper subframe bolt. This is done to pull the airbox boot back and to get the coolent overflow bottle out of the way. You also have to remove the rectifier from the frame.
Once the airbox boot is pulled off the carb, also undo its clamp on the airbox and pull the whole boot out of the frame for space to work.
You can now pull the carb out of the inlet manifold and take on the challenge of getting it out of the frame. It helps if you also remove the rubber inlet manifold.
If you still struggle to get it out, or back in then remove the engine mountings to tilt the motor forward for more space. I never did this - I'm to stubborn.
Good luck. I started on over an hour at first, but later got it down to 20 minutes in and out when I did jetting runs for the 462 big bore build.

I got it out surprisingly easy, without loosening the sub-frame. There's a thread on Thumpertalk with two opinions...  http://www.thumpertalk.com/topic/675512-carb-removal-drz-400-e/

I'll let you know how the putting back in went  ???
 

Offline Torque Curve

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Re: FCR carb
« Reply #7 on: April 24, 2014, 08:20:59 pm »


I got it out surprisingly easy, without loosening the sub-frame. There's a thread on Thumpertalk with two opinions...



Bastaaaaad. Maybe your's is the big-frame DRZ ;)
“Sometimes it's a little better to travel than to arrive”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
 

Offline Louis Photo

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Re: FCR carb
« Reply #8 on: April 25, 2014, 02:34:10 pm »
I hoped it will be a simple cleaning job, but it looks like the carb is leaking from a damaged rubber gasket. Where do I start looking for parts for this carb? I know the FCR 39 is used in Suzukis, Yamahas and Kawasaki. Do I just start phoning the agents or are the a carb specialist I can contact?
 

Offline Tiger Shark

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Re: FCR carb
« Reply #9 on: April 25, 2014, 03:02:40 pm »
YOU TUBE is a wonderful thing..................... :3some:
XT550 - sold
CRF 450X - sold
WR450F  ............braaap of prefferance
 

Offline grego

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Re: FCR carb
« Reply #10 on: May 24, 2014, 10:39:12 am »
i think its the the Clymer manual for the DRZ that covers the FCR carb.
you can order parts from andrew at mcomp.co.za
 

Offline Louis Photo

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Re: FCR carb
« Reply #11 on: May 24, 2014, 03:15:54 pm »
i think its the the Clymer manual for the DRZ that covers the FCR carb.
you can order parts from andrew at mcomp.co.za

Thanks  :thumleft: I'm getting the little gasket from Mcomp, used Hylomar universal blue in the interim, seems to do the job.
 

Offline Grumpleton

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Re: FCR carb
« Reply #12 on: May 25, 2014, 08:23:22 pm »
Ive got the manual in a PDF format if you want a copy, I will put it in my drop box and send you the link and passwords. just let me know , by the way the file is 113 megs
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Offline Louis Photo

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Re: FCR carb
« Reply #13 on: May 25, 2014, 08:46:49 pm »
Ive got the manual in a PDF format if you want a copy, I will put it in my drop box and send you the link and passwords. just let me know , by the way the file is 113 megs

Thanks  :thumleft: I'll PM you my email.
 

Offline Grumpleton

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Re: FCR carb
« Reply #14 on: May 26, 2014, 07:45:26 am »
I see the manual that i had also dous not have the FCR carb  >:(
« Last Edit: May 26, 2014, 07:46:12 am by Grumpleton »
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Offline Louis Photo

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Re: FCR carb
« Reply #15 on: May 26, 2014, 08:21:42 am »
Nope, it's also the one with the Mikuni carb. I'll let you know if I find the right manual.
 

Online Metaljockey

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Re: FCR carb
« Reply #16 on: May 26, 2014, 09:30:28 am »
I just received a gasket kit from the Netherlands for the FCR that I am not going to need.

If you still need one.

Offline pielas

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Re: FCR carb
« Reply #17 on: June 10, 2014, 11:51:41 am »
I just received a gasket kit from the Netherlands for the FCR that I am not going to need.

If you still need one.

Hi Metaljockey, if Louis doesn't take it and it is still available, I will put it to good use. PM sent
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual