39mm FCR Carb

Installation Instructions DR-Z400S/SM All Years

START

STEP 1

Locate TPS connector

STEP 2

Unplug TPS connector

STEP 3

Unscrew air boot clamp

STEP 4

Pull air boot back out of the way

STEP 5

Remove throttle cables from carb

STEP 6

Remove manifold screw completely

STEP 7

Spread clamp open

STEP 8

Remove carb and clamp

STEP 9

Remove stock intake manifold

STEP 10

Remove upper motor mounts

Image of mounts removed

STEP 11

Remove plastic bushing, spacer, and screw from left

upper motor mount

STEP 12

Install BOTH motor mounts on left side of frame

reusing hardware

New carb pictured with adapter, o-ring, and mounting

screws pre installed (this is how we ship the carb)

STEP 13

Install new intake manifold reusing engine side clamp

STEP 14

Install new clamp on intake manifold and pull air boot

back to normal location

STEP 15

Install FCR carb into manifold and air boot and tighten

all clamps (be sure air boot is on tightly)

STEP 16

Remove lower bolt in the intake inlet. Install the

included nipple reusing copper washer

Picture of stock vacuum hose used between factory

carb and petcock

STEP 17

Modify vacuum hose to look like this

STEP 18

Re-install throttle cables and adjust cables to have 1/8”

of free play

STEP 19

Re-install vacuum hose and fuel hose

Finished view of vacuum hose installation