Not My Z, DS 250 Custom Dash & Blob Removal

[yOGi420™]

So I'm currently working on a custom dash which will eliminate the big ugly plastic dash and relocate the idiot lights and key to a nice flat aluminum or stainless dash similar to the one I have on my z. I'm also working on removing the blob (I just wish that there was a way to do a push/pull choke instead of the cable actuated one. I may just mount the existing one next to the dc outlet on the plastics.) I will up date this thread with pictures as I progress with this mod project.

[yOGi420™]

Here is what I've drawn up for the dash, which will most likely be stainless.

[yOGi420™]

Here is where I'm at with re-wiring everything going into the blob. This is currently temporarily done with wire nuts to verify that it is all working but once it come time to do the final assembly I will be soldering it and heat shrinking it all. I am wiring in a Fly Racing billet MX kill switch for the "Start" button which just connects to the two wires to the current POS start button. (BTW, every time my kids end up rolling the quad at the beach, sand gets into the blob and causes the start button to no longer make the contact to re-start. VERY POOR DESIGN CAN-AM!!) Wired the "RUN" switch wires together to eliminate it and just use the key to kill the engine. Wired the Reverse Rev limiter together to eliminate that as well. I have not decided what to do with the lights yet but that is not too important to me at this time since I have removed the front lights and am planning on getting some Trail Tech type of bar mounted lights later on down the road.

[yOGi420™]

Just placed an order for some ODI Rogues for the kids. I have been wanting to do this stuff for the DS since I bought it. I'm also looking to get some wheel spacers to widen its stance, which currently is too narrow and a little tipsy.

[decentZ89]

Now where are you goin to get those made up

[Pulido221]

Looks good! I need to do the blob removal on my 400 still, just haven't had any "me time" lately. Was it as easy to do as your Z? Also is your can am fuel injected or carberated? Reason I ask is I heard that if you clip a pink wire in there somewhere it will run a little richer for a full exhaust and k&n? I'm not sure if this was true or not, or I was drinking while reading a dirtwheels magazine lol...

[TRMN8TR]

Tell youre kids to quit rolling it and you wont have to do all that, lol.

[yOGi420™]

Originally Posted by decentZ89

Now where are you goin to get those made up

Can you make up some wheel spacers as well? Interesting, if you can do it for less than you can get them for on fleabay then we may have another project for you....

[yOGi420™]

Originally Posted by Pulido221

Looks good! I need to do the blob removal on my 400 still, just haven't had any "me time" lately. Was it as easy to do as your Z? Also is your can am fuel injected or carberated? Reason I ask is I heard that if you clip a pink wire in there somewhere it will run a little richer for a full exhaust and k&n? I'm not sure if this was true or not, or I was drinking while reading a dirtwheels magazine lol...

It has been a little easier than on my z only because I have done it before and because I disassembled the blob to trace down all the wires since thre is no how-to for doing it on the DS. It's carberated so I need to rejet it from the original jetting to get it to run richer that EPA allows. I will also be getting a performance clutch kit to make it so it will engage at a higher rpm thus giving more torque.

I wish I could get them to stop rolling it but it just happens, hell, I do it from time to time as well

[decentZ89]

Originally Posted by yOGi420™

Can you make up some wheel spacers as well? Interesting, if you can do it for less than you can get them for on fleabay then we may have another project for you....

it could be possible but to do something like that i wouldnt feel comfortable..god forbid someone got hurt as a result of something i made i would feel terrible and like i was responsible..ill stick to simple cosmetic things for now

[yOGi420™]

Probably a good idea. I would hate to be under that pressure as well.

[yOGi420™]

So, I have wired everything in a permanent way. It is all tied together as pictured above and in addition I have decided to just eliminate the wiring for the lights for the time being since we don't ride at night. I also got a set of Fly Racing Aero Flex bars and some ODI Rogue grips (best grips money can buy). Just need to get the custom dash completed. I had decentz89 make upa pro type of a thinner gage stainless to check everything out and it seems like my hole measurements (diameters) didn't quite transfer over to the program right so now just fine tuning them and should have the dash made up fairly soon. A soon as I get it completed I will update with the final product pictures.

[decentZ89]

ok i changed the holes to the correct size (i hope lol) and the overall profile. let me know if you like it..if not i can change it again. i know you said you wanted it more round that square so this is what we came up with

[yOGi420™]

looks cool, the notches in the light/key holes looks way to long though. the stock dash has notches that look to be about 1/8" off the circular holes.

[decentZ89]

Ok that's a quick fix. It was hard to gauge from your caliper readings. I will fix that and have it shipped out Monday