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TRANSCRIPT
04
.05
.10
07
:28
The K
eihin FCR
Carb
Reb
uild W
ith Zip-T
y Racing - D
r. Dirt - D
irt Rid
er Magazine
Seite 1 von 3
http://w
ww
.dirtrid
er.com/tech/1
41
_07
07
_keihin_fcr_carb_reb
uild/ind
ex.html
Ho
me
»Tech
»Th
e K
eih
in FC
R C
arb
Reb
uild
With
Zip
-Ty
Racin
g - D
r. Dirt
Th
e K
eih
in FC
R C
arb
Reb
uild
With
Zip
-Ty
Racin
g - D
r. Dirt
Bik
e: P
erfo
rman
ce Fo
ur-S
trokes
From the July, 2007 issue of D
irt Rider
By K
arel Kram
erPhotography by K
arel Kram
er
Tech
Ho
w-T
oA
good portion of m
odern four-stroke engine
performance
is due to
the Keihin
FCR
carburetor.An accelerator pum
p and
a high-tech
slidesupported
by four wheels m
ake the FC
R a
relatively complex
design. There are many parts
that can w
ear out and get dirty or gum
med
up.There are a
few shops that specialize in m
odsand
service for these carburetors. S
ome, such
asJD
Jetting (w
ww
.jdjetting.com; 253.939.7114)
and Factory Pro (w
ww
.factorypro.com;
800.869.0497), sell kits that you install yourself, and others, such
as Zip-
Ty Racing
(ww
w.ziptyracing.com
; 760.244.7028) and Tokyom
ods(w
ww
.tokyomods.com
; 888.457.9403), will set up
the carburetor for youor actually m
odify it for increased
performance
and response. W
hiteBrothers offers both
options.
As com
plex as the FC
R carburetor is, it is m
oreintim
idating to
look at than it is to
work on. You
will still need
a good
manual.
Getting
the carburetor off and back
on will be the
hardest part. You'll need to
remove the cover on
the side of the carburetor, disconnect the throttle
cables, make
sure the vent hoses are all free from
the bike and
disconnect the wire to
the TPS. D
o not remove the TPS
from the
carburetor; it is synched to
the throttle shaft with
a m
eter, and it m
ust beresynched if rem
oved. With
perimeter-fram
e machines, it is alm
ost always
easier to take
off the subframe and
the shock before removing the
carburetor.
Rela
ted
Ph
oto
s
Rela
ted
Article
s
Zip
-Ty R
acin
g B
illet A
ir Scre
wM
odern tw
o-stroke m
otocross and off-road
bikes seem to
come jetted
far better than everbefore. The... m
ore
Zip
-Ty R
acin
g X
F+ W
ate
rless R
ace
Co
ola
nt
Avoid
all the hassles of traditional water-based
coolants, from m
etal-jacket oxidation to... m
ore
Th
e T
ortu
re T
est - Z
ip-T
y Racin
gH
usq
varn
a T
XC
45
0
04.05.10 07:29Keihin Fcr Carb Tech Carburetor Photo
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Keihin Fcr Carb Tech Carburetor
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
View Related Article
04.05.10 07:31Keihin Fcr Carb Tech Fcr Body Cleaning Photo
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Keihin Fcr Carb Tech Fcr Body Cleaning
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
01 Ty Davis starts by thoroughly cleaning the FCR body in a solvent tank filled with Simple Green rather than using apetroleum-based solvent or contact cleaner. He warns that you should never spray contact cleaner into the mouth of acarb. View Related Article
04.05.10 07:35Keihin Fcr Carb Tech Fuel Screw Photo
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Keihin Fcr Carb Tech Fuel Screw
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
02 If you have an aftermarket fuel screw installed, this is a good time to remove it. Take care so you don't lose the smallspring, washer or O-ring. If you still have the stock fuel screw, removing it can wait. View Related Article
04.05.10 07:36Keihin Fcr Carb Tech Remove Bolt Photo
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Keihin Fcr Carb Tech Remove Bolt
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
03 You will need to extract this bolt from the throttle linkage above the slide. It may be a secure Torx with a tiny post inthe middle. You may need to visit a special tool store to find a dimpled Torx socket. View Related Article
04.05.10 07:37Keihin Fcr Carb Tech Torx Removed Photo
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Home » Tech » The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt » Photo 6
Keihin Fcr Carb Tech Torx Removed
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
04 With the Torx removed, the slide's lifting arm can rotate out of the way, and the slide can be pulled out. The brassfitting on top of the slide holds the needle in place. View Related Article
04.05.10 07:38Keihin Fcr Carb Tech Replacing Wear Plate Photo
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Home » Tech » The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt » Photo 7
Keihin Fcr Carb Tech Replacing Wear Plate
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
05 The slide has a wear plate that lifts off. Some companies recommend changing it every 25 hours. It is an expensivepart, but replacing it can make a big difference in how crisply and cleanly the bike runs down low. View Related Article
04.05.10 07:39Keihin Fcr Carb Tech Replace Seal Photo
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Keihin Fcr Carb Tech Replace Seal
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
06 The back side of the wear plate has this very delicate seal. Davis warns that chemicals like contact cleaner will causethe seal to swell and ruin it. It is a good idea to replace the seal when the carb is apart. View Related Article
04.05.10 07:41Keihin Fcr Carb Tech Remove Bowl Screws Photo
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Keihin Fcr Carb Tech Remove Bowl Screws
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
07 Davis removes all the vent hoses at this point. Small brackets mounted on each rear corner of the float bowl guidesome of the vent hoses. Remove the bowl screws and the idle adjustment bracket. View Related Article
04.05.10 07:42Keihin Fcr Carb Tech Float Bowl Photo
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Keihin Fcr Carb Tech Float Bowl
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
08 Work off the float bowl and look for any dirt or other junk in the bowl. This one is quite clean. Most water andsediment will settle in the drain bolt. View Related Article
04.05.10 07:44Keihin Fcr Carb Tech Throttle Pivot Shaft Photo
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Keihin Fcr Carb Tech Throttle Pivot Shaft
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
09 With the bolt removed, the throttle pivot shaft should simply pull out. Note the return spring attachment and theplacement of the two washers. Clean up the shaft and assorted parts. Set these parts safely aside. View Related Article
04.05.10 07:46Keihin Fcr Carb Tech Needle Photo
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Keihin Fcr Carb Tech Needle
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
10 At the top of the slide will be some arrangement that allows removal of the needle. Some off-road bikes havenonadjustable needles (only one clip position), and they can be replaced with an adjustable one for tuning. View RelatedArticle
04.05.10 07:48Keihin Fcr Carb Tech Float Pin Photo
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Keihin Fcr Carb Tech Float Pin
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
11 Using a small tool, push out the float pin. A small Allen wrench or the back end of a drill bit should work fine. Once thepin is moved, you should be able to pull it out with your fingers. View Related Article
04.05.10 07:49Keihin Fcr Carb Tech Float Needle Photo
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Keihin Fcr Carb Tech Float Needle
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
12 The float manipulates this float needle to keep the fuel level in the float bowl constant. Look for damage near thepointed rubber tip. The needle is loosely attached to the float via the wire loop. Don't lose it. View Related Article
04.05.10 07:49Keihin Fcr Carb Tech Needle Jet Photo
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Keihin Fcr Carb Tech Needle Jet
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
13 The main jet is threaded into the needle jet, so remove them together. The fuel baffle (called a "spacer" in themanual) will come off easily after the needle jet tube is out. View Related Article
04.05.10 07:50Keihin Fcr Carb Tech Unscrew Starter Jet And Pilot Jet Photo
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Keihin Fcr Carb Tech Unscrew Starter Jet And Pilot Jet
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
14 Unscrew the starter jet and the pilot jet. A blade screwdriver with a tip or shaft larger than 4mm wide will jam in thepilot-jet opening. Clean all the jets, and ensure that all of the openings are unrestricted. View Related Article
04.05.10 09:25Keihin Fcr Carb Tech Screen Photo
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Keihin Fcr Carb Tech Screen
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
15 There is a screen at the bottom of the needle-valve seat that prevents trash in the fuel from entering the float bowl. Itcannot be removed for cleaning, so use compressed air to blow it clean from this side. View Related Article
04.05.10 09:25Keihin Fcr Carb Tech Accelerator Pump Rod Photo
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Keihin Fcr Carb Tech Accelerator Pump Rod
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
16 Use a finger to operate the accelerator-pump rod through a full stroke. You should feel spring resistance but no hardspots or hitches in the travel. If it doesn't move freely, pull it apart and clean it. View Related Article
04.05.10 09:26Keihin Fcr Carb Tech Greased O Rings Photo
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Keihin Fcr Carb Tech Greased O Rings
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
17 A small screw holds the fuel-line fitting in place. The carburetor was otherwise quite clean, but this fitting and passageneed a bath. View Related Article
04.05.10 09:27Keihin Fcr Carb Tech Needle Bearings Photo
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Keihin Fcr Carb Tech Needle Bearings
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
18 A little grease on the O-rings will ease the cleaned fitting back into the carburetor body. Don't get carried away withthe grease. Install the screw that holds the fuel-line fitting. It shouldn't need thread-locker. View Related Article
04.05.10 09:29Keihin Fcr Carb Tech Needle Bearings Photo
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Keihin Fcr Carb Tech Needle Bearings
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
19 The throttle shaft rides on two small needle bearings, and they should get a little grease before the shaft is installed. Acotton swab is a good tool for this job. View Related Article
04.05.10 09:35Keihin Fcr Carb Tech Engage Hook Photo
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Keihin Fcr Carb Tech Engage Hook
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
20 The throttle-return spring has a hook that must engage the throttle shaft before the shaft is reinserted. The shaftwashers fit between the body and the throttle-valve lever: the metal one against the carburetor body and the resinwasher against the lever. View Related Article
04.05.10 09:41Keihin Fcr Carb Tech Lined Up Photo
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Keihin Fcr Carb Tech Lined Up
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
21 Getting all the throttle-valve parts lined up takes a bit of fiddling, but once they are arranged, the throttle shaft shouldeasily slip through the freshly greased bearings. View Related Article
04.05.10 09:42Keihin Fcr Carb Tech Place Main Jet Combo Into Body Photo
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Keihin Fcr Carb Tech Place Main Jet Combo Into Body
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
22 After setting the plastic spacer in place, use a socket to thread the needle jet/main jet combo into the body. The pilotand starter jets go in next. The threads are brass inside aluminum, so don't go crazy tightening jets. View Related Article
04.05.10 09:42Keihin Fcr Carb Tech Wire Loop Photo
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Keihin Fcr Carb Tech Wire Loop
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
23 Before the float and needle valve go in, this wire loop attached to the needle must be slipped over this tang on thefloat. Work over a surface that will allow you to find the float needle if it is dropped. View Related Article
04.05.10 09:42Keihin Fcr Carb Tech Float And Needle Valve Photo
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Keihin Fcr Carb Tech Float And Needle Valve
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
24 Lower the float and needle valve together. Carefully guide the needle valve into the needle-valve seat. If the tip of theneedle bumps the seat, it will pop the wire loop off of the float and cause needless cursing. View Related Article
04.05.10 09:43Keihin Fcr Carb Tech Float Height Photo
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Keihin Fcr Carb Tech Float Height
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
25 The manual outlines a method for setting the float height using a caliper. Davis uses a Honda tool that measures theheight of the float while lightly blowing into the fuel line. View Related Article
04.05.10 09:43Keihin Fcr Carb Tech Throttle Slide Lever Arm Photo
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Keihin Fcr Carb Tech Throttle Slide Lever Arm
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
26 Lift the throttle-slide lever arm out of the way with one hand, and hold the slide (throttle valve) and the throttle-valveplate together with the other hand. Make sure the needle doesn't hang up while going in. View Related Article
04.05.10 09:43Keihin Fcr Carb Tech Thread Locker Photo
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Keihin Fcr Carb Tech Thread Locker
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
27 The bolt holding the lever arm to the throttle shaft is the only one in the carburetor that calls for thread-locker (blue).Again, you may need a special Torx bit that is drilled to clear the center post. View Related Article
04.05.10 09:44Keihin Fcr Carb Tech Idle Adjustment Screw And Bracket Photo
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Keihin Fcr Carb Tech Idle Adjustment Screw And Bracket
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
28 Insert the front float-bowl screws and snug them down, but remember to add the vent hose guides. Then attach andtighten the idle-adjustment screw and bracket. View Related Article
04.05.10 09:44Keihin Fcr Carb Tech Remove Screws Photo
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Keihin Fcr Carb Tech Remove Screws
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
29 Using your good #2 Phillips, take out the three small screws holding the accelerator-pump diaphragm in place. Detachthe cover carefully so you don't lose the spring that rests on the diaphragm. View Related Article
04.05.10 09:58Keihin Fcr Carb Tech Clean Membrane Photo
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Keihin Fcr Carb Tech Clean Membrane
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
30 Early FCR carburetors had much poorer accelerator-pump sealing, and the pump membrane could pack with dirt. Youcan see that only a little dirt has entered this pump and the membrane is in good condition. View Related Article
04.05.10 09:59Keihin Fcr Carb Tech Replace Diaphragm Photo
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Keihin Fcr Carb Tech Replace Diaphragm
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
31 Replace the diaphragm, spring and cover; tighten the screws; then move to the top of the carburetor body andreplace the top. On a Honda, this wire holder goes on the front screw. View Related Article
04.05.10 09:59Keihin Fcr Carb Tech Fuel Screw From Zip Ty Racing Photo
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Keihin Fcr Carb Tech Fuel Screw From Zip Ty Racing
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
32 Before installing the fuel screw in the carburetor body, first slip the spring over the end of the fuel screw, followed bythe washer and the O-ring. This Zip-Ty screw comes with the new parts. The rubber covers are separate. View Related Article
04.05.10 09:59Keihin Fcr Carb Tech Tighten Fuel Screw Photo
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Keihin Fcr Carb Tech Tighten Fuel Screw
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
33 With a stock or aftermarket fuel screw, it should take between eight and nine rotations to fully tighten. If you get lessthan eight turns, don't force it. Check the threads on the screw and in the carburetor body. View Related Article
04.05.10 10:00Keihin Fcr Carb Tech Hot Start Fitting Photo
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Keihin Fcr Carb Tech Hot Start Fitting
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
34 The stock hot-start fitting has a plastic 14mm hex that is a pain to get a wrench on. Zip-Ty Racing sells a billet-aluminum unit with a 10mm hex. If you haven't already, remove the hot-start plunger and check for corrosion. View RelatedArticle
04.05.10 10:00Keihin Fcr Carb Tech Float Bowl Drain Bolt Photo
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Keihin Fcr Carb Tech Float Bowl Drain Bolt
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
35 Zip-Ty Racing also makes a float-bowl drain bolt with a magnet in it. We've tried them, and the magnet nearly alwayshas metal stuck to it. Now install the drain bolt (stock or aftermarket). View Related Article
04.05.10 10:00Keihin Fcr Carb Tech Attach Vent Hoses Photo
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Keihin Fcr Carb Tech Attach Vent Hoses
The Keihin FCR Carb Rebuild With Zip-Ty Racing - Dr. Dirt
36 All that is left is to reattach the vent hoses neatly, and the carburetor is ready to go back on the bike. Now just keep itthis clean, and your engine will stay very happy. View Related Article