FCR SWAP WITH ADAPTOR PLATE HOW TO GUIDE

This will show the modifications process of your Factory LTZ400 or KFX400 Air Box and fitting your new Adaptor plate to your air box. We will be using a Factory oem 400EX Intake boot for this swap.

Tools Needed for this Install:

  • Dremel Tool or Air Grinder
  • Drill & 1/8" Drill Bit
  • Center Punch (optional)
  • Cleaning Product of your choice (Alcohol, Acetone, Soapy Water)
  • Sealing Agent like Silicone, RTV, Gasket Maker, (Preferably Gasoline Resistant)
  • Rivet Gun
  • 3MM Rivets 10 or 12mm Length will work: Amazon
  • Washers for your Rivets: Amazon

Parts we used for this FCR Install:

  • ATVRevive 3D Printed FCR Adaptor Plate
  • Honda 400EX Intake Boot: 17253-HN1-A20
  • Honda Clamp Front: 90666-HN1-A20
  • Honda Clamp Rear: 90696-HN2-830
  • Suzuki DRZ400 E BOOT: 13111-29F01
  • Suzuki Clamps: 09402-58208 x2
  • Breather Box Adaptor Elbow: NBH 9923
  • Air Filter Direct Clamp on: UT-4300ST

 

1ST: assuming you have the air box already off of the ATV, you will need to cut out the old hole of the air box, and grind the top snorkel Lip flat to prepare the template to sit flat.

 

2ND: Place the template down and align it with the very bottom lip at the top of the air box, then mark your Holes and mark the square using a Marker.

3RD: Cut out the Square and drill the holes using a 1/8' Drill bit. Use a punch to make a indent in the plastic to make the drilling process easier!

4TH: We recommend to clean up the inside and deburr any plastic in the holes that may be sticking out. after that you should use alcohol or acetone to clean the inside maiting surface so that the Silicone / RTV / Gasket maker adheres and seals properly.

 

5TH: You will want to check the Adaptor plate as it may require some edges to be knocked down and the rivet holes to be reamed out with the 1/8" Drill bit.

 

6TH: Apply Your Sealant of your choice to the Adaptor plate, Apply the Sealant where the red is in this photo



7TH: Install the Adaptor Plate and Rivet the plate to the air box, it is easier if you have someone to help hold it.

8TH: At this point you should be done with the air box. We will move onto the 400ex air boot modifications, you will need to Cut the boot on the RED LINE, and sand smooth on GREEN LINE


9TH: This is what the 400ex boot should look like after you have cut and sand it smooth!



 Now you can install your Boot to your air box and carb and Gain some HP with this sweet setup!


 Here is what the Complete Assembly Looks like!


If you need assistance please feel free to Contact Us