Handlebar Changed, Switch Removed, Key & LEDS Moved

2985 Views 23 Replies 17 Participants Last post by BR1GHT_Y3LL0W_Z, Dec 17, 2002

ZRacer

Discussion Starter · Aug 30, 2002

My latest Z Project was to change the handlebars and clean up the clutter on the bars.

I first removed the Start/On-off/Light Switch/Choke. This was no easy task because I didn't have a wiring diagram, and I had to come up with a way to remove the choke. The choke was replaced with a pull choke with parts from the DRZ400. If anyone is interested, I will list the parts needed. Then I replaced the switch with a YZ250 Stop Engine Switch. It works great on the Z. I then installed a Pro-Design Kill cord. Then, I replaced the the Stock clutch lever with a RTC Lever which is by far the best I have ever had. Then I moved the LEDs to the Front Fender and made a quick dissconnect for them to easily remove the front fender. Finally, I used a LT250R Key housing to mount to the handlebars for my Z Key.

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1 - 20 of 24 Posts

Jocky_Wilson

· #2 · Aug 30, 2002

Good job ZRacer! That looks really clean. The LEDs look like they were made to go to there.

sduncan

· #3 · Aug 30, 2002

I moved my LEDs to the same spot. I thought I would make a piece of aluminum to mount the key switch but I think I like your idea better. What year did the key housing come from?

ZRacer

Discussion Starter · #4 · Aug 30, 2002

The Key Housing came from a 91 LT250R Quad Racer

aproy

· #5 · Aug 30, 2002

do you have any pics that show the wheels and tires? id like to see them on a Z.

Adam496

· #6 · Aug 30, 2002

do u still have to pull in the cluctch to start it

fasterz

· #7 · Aug 30, 2002

IT LOOKS GREAT, DO YOU HAVE TO PUT A COVER UNDER THE BARS?

ZRacer

Discussion Starter · #8 · Aug 31, 2002

Yes, you still pull the choke with your hand, and I am not sure what you mean by cover under the bars. I will be posting Quad pics soon.

Big Air

· #9 · Sep 4, 2002

Zracer that looks awesome. where did you get the RTC lever. i have removed my parking brake and was thinking of getting those same renthal bars. but if i don't get the bars, i still would like to clean up the perch for the clutch. also when you buy that lever, does the new perch come with it or was it part of the bars...............thanks.

ZRacer

Discussion Starter · #10 · Sep 4, 2002

the RTC lever comes with the Perch. It is the best clutch lever that I have ever used. It cost about $55.00, but is well worthed it.

Big Air

· #11 · Sep 4, 2002

that sounds good. 55 bones is cheap enough. could you tell me where to order one. i have looked a few places but they don't list one for the Z. I appreciate the help.

kentuckycat

· #12 · Sep 5, 2002

Very nice work. I'm also looking for the perch/lever, so I would like to know where you got it, too. Thanks!

VooDuu Child

· #13 · Sep 6, 2002

the LED install, one word,
PIMP! looks awesome.
I may do that too once I get some new bars.

TAC2745

· #14 · Oct 5, 2002

PLease list the DRZ400 parts needed to change the choke setup.

jeffksf

· #15 · Oct 8, 2002

How does the headlight operate now? Is the clutch pull the same easy feel with that RTC lever? I love the stock clutch lever feel. Does that RTC lever have a bearing for the pivot?

WP

· #16 · Oct 9, 2002

When I removed my light switch, I wired it on high beam always. Really cleans up the bars with it missing now.

popo35

· #17 · Oct 16, 2002

Zracer, Nice job. Where did you locate the starter switch at?

Also did you just end up using a rear brake block off plate for the parking brake?

This was helpful in transforming my Z with 250R plastic.

ZRacer

Discussion Starter · #18 · Oct 16, 2002

The starter switch is the YZ250 Kill button. It is the red square by the left grip.

KFX-Musky

· #19 · Nov 6, 2002

I'm surprised you didn't put a twist throttle on when you were "cleaning up your bars" Looks good though. I wish I was that creative.

mikez400

· #20 · Nov 8, 2002

EAST COAST ATV AND K & K SELL RTC LEVERS
OR YOU CAN GO TO THE QUAD SHOP WEB SITE. THERE IS A PHONE NUMBER
FOR THE GUY WHO MAKES THEM.
I HAVE THEM ON MY R. CLUTCH LEVER IS OF THE "EASY PULL" TYPE.
VERY NICE

1 - 20 of 24 Posts

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