TPS TORS removal - Yamaha YFZ450 Forum : YFZ450, YFZ450R, YFZ450X Forums

yfzracer45 · 10-01-2011, 02:40 PM

I found this on another site and thought it was helpful to me so i wanted to post it here for the YFZ owners that may be interested in this. I have a kicker only bike so this helps me with cleaning up the carb.

I TAKE NO CREDIT FOR THIS WRITE PROPS FOR THE GUY THAT DONE IT

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.

lilguy450 · 10-01-2011, 02:43 PM

Or you can call Sredrum and he will do this for you and install an idle cable. His looks a lot cleaner too. But great find!

yfzracer45 · 10-01-2011, 02:49 PM

Quote:

Originally Posted by lilguy450

Or you can call Sredrum and he will do this for you and install an idle cable. His looks a lot cleaner too. But great find!

I found the idle adjustment parts and some pictures I will post them also. I know alotta people like myself like to DIY. The yzf450 idle cable assembly and the ltz/kfx400 also work. You need a 3/16 drill bit and metric 5mm x.5 pitch thread tap.

yfzracer45 · 10-01-2011, 05:21 PM

Well i got MY carb completed today just goin to order the idle assembly now. It was about 45min mod and im satisfied with the results. Im still goin to seal it off around the throttle shaft.

yfzracer45 · 10-13-2011, 10:18 PM

UPDATE: I sent my carb to sredrum and he finished it off with a brass plug for the shaft and idle adjustment with labor and it was a good deal. awesome work for sure

#13yfz · 12-07-2011, 10:09 PM

Question, when you remove the tps and tors, what do you do with the wiring?
Unplugging both causes the machine to not run correct?

yfzracer45 · 12-07-2011, 11:20 PM

you can get a TPS bypass plug or like me my harness is gutted for kicker and i had it bypassed all together

gibbyzr2 · 05-21-2012, 03:22 PM

I have followed all of these steps but i am unclear of what to do about the idle adjustment?

gibbyzr2 · 05-21-2012, 04:32 PM

Why do u fill the cap in with glue then jb weld do u drill the hole out to screw it in and what effect will it have on shaft that was cut

yfzracer45 · 05-21-2012, 07:52 PM

Quote:

Originally Posted by gibbyzr2

I have followed all of these steps but i am unclear of what to do about the idle adjustment?

You get a oem cable style adjuster from the dirtbike model. I have since this post sent my carb to sredrum and he installed a plug in place of the cap that some guys put jb weld into. the shaft HAS to be able to move so once you fill the cap with jb weld u have to drill some out so it clears the shaft when installed

gibbyzr2 · 05-21-2012, 08:07 PM

what year and what model does that cable come off of and do u have a pic of how it is hooked up

valadezj · Yesterday, 01:51 PM

can i cut the wires of the female pug on the carb , to overide the tors, my bike has a hard time starting and idling after i re jetted it?

Bowtie · Yesterday, 11:13 PM

Quote:

Originally Posted by valadezj

can i cut the wires of the female pug on the carb , to overide the tors, my bike has a hard time starting and idling after i re jetted it?

Yes and no to your question. Yes you can cut the wires at the TORS wires at the carb, but No, that's not all you need to do. You need to jumper the harness end so that the two wires are connected. You also need to follow the two wires out of your thumb throttle and jumper those two wires at the harness connection otherwise the bike won't run right.

Cuztom Racing · Yesterday, 11:32 PM

good info here thanks

both my carbs are at sredrums at the moment ill make sure it gets done

yfzracer45 · Today, 01:28 AM

Quote:

Originally Posted by Cuztom Racing

good info here thanks

both my carbs are at sredrums at the moment ill make sure it gets done

YES just tell him to remove the TPS and TORS and put the cable idle adjuster on them. I love mine

yfzracer45 · Today, 01:33 AM

Quote:

Originally Posted by gibbyzr2

what year and what model does that cable come off of and do u have a pic of how it is hooked up

It requires drilling and tapping out with a metric tap set. If not drilled perfect the idle adjuster will not line up with the throttle plate.

heres a pic of how it works once installed. (not my carb)

yfzracer45 · Today, 01:37 AM

Fcr gasket , separate the carb body etc . - ThumperTalk

Keep in mind i dont suggest takin the carb apart because there are gaskets/orings u cant buy in case u screw urs up on accident. but here is how its done using the cable adjuster. this guy used his adjuster from the z400 kfx400 carb

yfzracer45 · Today, 01:40 AM

here is where i got all my info and pics for this post.

Fcr Carb Mods - Suzuki Z400 Forum : Z400 Forums

10-01-2011, 02:40 PM	#1 (permalink)
yfzracer45 Senior Member Join Date: Apr 2008 Location: Bowling Green Ky Posts: 2,403	TPS TORS removal I found this on another site and thought it was helpful to me so i wanted to post it here for the YFZ owners that may be interested in this. I have a kicker only bike so this helps me with cleaning up the carb. I TAKE NO CREDIT FOR THIS WRITE PROPS FOR THE GUY THAT DONE IT 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.

10-01-2011, 02:43 PM	#2 (permalink)
lilguy450 Senior Member Join Date: Jan 2011 Posts: 408	Or you can call Sredrum and he will do this for you and install an idle cable. His looks a lot cleaner too. But great find! __________________ MMAD 465cc "Do" machine

Yesterday, 11:32 PM	#14 (permalink)
Cuztom Racing Junior Member Join Date: Apr 2012 Location: Gods Country, MS Posts: 27	good info here thanks both my carbs are at sredrums at the moment ill make sure it gets done __________________ Cuervo Racing Beasley's ATV Services DEAFMAN CHASSIS Poorboy Preformance

Today, 01:37 AM	#17 (permalink)
yfzracer45 Senior Member Join Date: Apr 2008 Location: Bowling Green Ky Posts: 2,403	Fcr gasket , separate the carb body etc . - ThumperTalk Keep in mind i dont suggest takin the carb apart because there are gaskets/orings u cant buy in case u screw urs up on accident. but here is how its done using the cable adjuster. this guy used his adjuster from the z400 kfx400 carb __________________ Thanks to all my 2012 sponsors: Rath Racing, leatt brace, EKS brand goggles, Motul lubricants, DWT, motoworks, houser racing, Fox shocks, GTThunder, Fly racing, odi grips, slick offroad wash, precision, Fourtech ind, Dynamite Atv, Flexx company, zbroz racing,

Today, 01:40 AM	#18 (permalink)
yfzracer45 Senior Member Join Date: Apr 2008 Location: Bowling Green Ky Posts: 2,403	here is where i got all my info and pics for this post. Fcr Carb Mods - Suzuki Z400 Forum : Z400 Forums __________________ Thanks to all my 2012 sponsors: Rath Racing, leatt brace, EKS brand goggles, Motul lubricants, DWT, motoworks, houser racing, Fox shocks, GTThunder, Fly racing, odi grips, slick offroad wash, precision, Fourtech ind, Dynamite Atv, Flexx company, zbroz racing,

10-01-2011, 05:21 PM	#4 (permalink)
yfzracer45 Senior Member Join Date: Apr 2008 Location: Bowling Green Ky Posts: 2,403	Well i got MY carb completed today just goin to order the idle assembly now. It was about 45min mod and im satisfied with the results. Im still goin to seal it off around the throttle shaft.

10-13-2011, 10:18 PM	#5 (permalink)
yfzracer45 Senior Member Join Date: Apr 2008 Location: Bowling Green Ky Posts: 2,403	UPDATE: I sent my carb to sredrum and he finished it off with a brass plug for the shaft and idle adjustment with labor and it was a good deal. awesome work for sure

12-07-2011, 10:09 PM	#6 (permalink)
#13yfz Senior Member Join Date: Dec 2011 Posts: 269	Question, when you remove the tps and tors, what do you do with the wiring? Unplugging both causes the machine to not run correct?

12-07-2011, 11:20 PM	#7 (permalink)
yfzracer45 Senior Member Join Date: Apr 2008 Location: Bowling Green Ky Posts: 2,403	you can get a TPS bypass plug or like me my harness is gutted for kicker and i had it bypassed all together

05-21-2012, 03:22 PM	#8 (permalink)
gibbyzr2 Junior Member Join Date: Jul 2011 Posts: 16	I have followed all of these steps but i am unclear of what to do about the idle adjustment?

05-21-2012, 04:32 PM	#9 (permalink)
gibbyzr2 Junior Member Join Date: Jul 2011 Posts: 16	Why do u fill the cap in with glue then jb weld do u drill the hole out to screw it in and what effect will it have on shaft that was cut

05-21-2012, 08:07 PM	#11 (permalink)
gibbyzr2 Junior Member Join Date: Jul 2011 Posts: 16	what year and what model does that cable come off of and do u have a pic of how it is hooked up

Yesterday, 01:51 PM	#12 (permalink)
valadezj Junior Member Join Date: May 2012 Posts: 2	can i cut the wires of the female pug on the carb , to overide the tors, my bike has a hard time starting and idling after i re jetted it?

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