FCR conversion assistance on ‘05 - Honda TRX Forums: Honda TRX 450R Forum
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post #1 of 10 (permalink) Old 08-30-2019, 08:58 PM Thread Starter
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FCR conversion assistance on ‘05

Good evening folks,

I posted a while back for other FCR questions I had and got great help. I have two hiccups right now (my tuning barrage of questions will come later).

First: my original fuel line coming off my 05 tank and going to my 05 carb is huge. Like holly 750 double pumper huge. The FCR I picked up off an 04 Yamaha has a way smaller inlet. What are my options here? Can I just replace my 05 petcock with a later year, (What year??) if that’s even possible? Should I look for a later tank (again, what year??)? Should I keep the original line, cut it, put in a brass line reducer and run aftermarket fuel line the rest of the way? Should I buy a later model fuel line and smash it on the original petcock? Any creative ideas appreciated.

Second: my stock 05 throttle cable doesn’t seem to be compatible. There’s no threads to screw the cable into the carb. There also seems to be extra play (I wasn’t sure which hole the cable end goes into).

I’m attaching some pictures for reference. Thanks for the help.

One last thing: once the cable is set up, I’ll need to calibrate my TPS. If someone could give me the specs on closed throttle/wot, I’d appreciate it. Any other tips on the calibration would also be appreciated.
Attached Images
File Type: jpg 48F21036-4635-433F-A73D-E8D3F7DFEBD6_1567213022732.jpg (124.2 KB, 14 views)
File Type: jpg 82EA81F5-E308-4648-ACBE-D7E40E571182_1567213049926.jpg (100.3 KB, 13 views)
File Type: jpg 58F44C28-F597-405A-9950-3FDE198AEE8C_1567213077851.jpg (103.3 KB, 11 views)
File Type: jpg 9762BFF4-22B9-41D7-AF5F-24A53399F506_1567213098698.jpg (117.2 KB, 14 views)
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post #2 of 10 (permalink) Old 09-01-2019, 11:18 PM
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Get the Fuel line from a 2006 TRX450ER it will fit perfect and still an OEM part.

As for the Throttle Cable attachment you should be able to unscrew that nut more and then slide it into a little slot (I circled it in red on your picture) then just tighten the 10mm sleeve and it will tighten up and then remove the slack at the handle bar adjuster.


As for The throttle position sensor it will run fine with out it. Me personally I recommend hooking it up. You may be able to buy a used CRF450R TP Sensor and put it into that carburetor should work fine other then the wire is clocked in a different position.

You can also cut and reconnect the Yamaha style plug and replace it with the Honda plug but then the issue is (which wire on the Yamaha TP Sensor match up with the Honda Wires, then the question is... is the Resistance the same as the Honda TP Sensor, so even if you hook it up will the CDI will get unusual readings) I Say the CRF TP Sensor because it has the same plug and same wire colors and it would be 1 screw and look factory.




Sorry for the ridiculously long response

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Last edited by Ryan94Wright; 09-06-2019 at 03:15 AM.
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post #3 of 10 (permalink) Old 09-02-2019, 06:17 AM Thread Starter
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Ridiculously long? Heck no, the more info, the better! So the ‘06 fuel line will work on my ‘05 tank? I’ll give it a shot. I was just worried that if the outlet side of that hose is the same size as the inlet, then I would think the ‘06 hose would be way too small for the fuel valve on the ‘05. I’ll give it a shot though.

I didn’t think that sleeve tightened up any more to hold that cable in place on the carb side. Maybe I’m missing something there.

I already picked up the Honda TPS. It’s in there, just not calibrated yet.
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post #4 of 10 (permalink) Old 09-02-2019, 11:24 PM
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Yes the 06 Hose will fit just like it was meant to with a factory look. They're fat the PetKock valve side and then taper to a smaller diameter for the FCR carb input. You will see when you get it.

Good call on the TP Sensor.

As for the cable I posted a picture below to see how I have mine so yo can just get a better visual.
Attached Images
File Type: jpg 2006-Honda-Trx450er-Trx450r-Fuel-Hose-Gas-Line.jpg (8.0 KB, 11 views)
File Type: jpg IMG_2479.jpg (208.4 KB, 12 views)
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post #5 of 10 (permalink) Old 09-03-2019, 11:24 AM Thread Starter
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Phenomenal advice, thank you. I ordered the hose and some other random parts. I’ll let you know how I make out.
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post #6 of 10 (permalink) Old 09-03-2019, 03:33 PM
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Not a problem bud.

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post #7 of 10 (permalink) Old 09-18-2019, 06:31 PM Thread Starter
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Does anyone know how to calibrate this TPS sensor? Where do you want it within this range? On the high side? On the low side? Is this at idle, or at wot? I dont know what values I’m supposed to be going by, and I don’t know what setting my multimeter should be at either. Anyone out there that could walk me through this, I’d sure be much obliged.
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post #8 of 10 (permalink) Old 09-18-2019, 08:03 PM
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it doesnt need the TPS to run, you can simply short it out if needed by puting a jumper wire in there or wiring it together. I run a 04-05 throttle on my 06 cause I like the ability to use a longer lever off a trx90, I just wired the connection together under the hood.

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post #9 of 10 (permalink) Old Today, 03:53 AM
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here is a spec sheet from the service manual
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File Type: png Throttle Position Sensor TRX450R & ER.png (233.9 KB, 2 views)

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post #10 of 10 (permalink) Old Today, 03:54 AM
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So basicullly just se the TP sensor till the Multimeter reads anywhere from 4000 to 6000 Ohms. at "idle" position or Throttle mostly Closed.

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