Project: Better Zongshen Switchgear

[SpudRider]

For some time I have been considering a project to improve the switchgear on my Zongshen 200GY-2. The project is made a little more difficult because the stock switches, clutch perch, mirror perch, and choke lever are combined into one unit.

Since my Zong employs a TW200 clutch cable, I plan to switch to the following items.

Tusk Clutch Perch for Yamaha TW200

http://www.rockymountainatvmc.com/p/...clutch%20perch



Tusk Clutch Lever for Yamaha TW200

http://www.rockymountainatvmc.com/p/...clutch%20lever

To save handlebar space, I will remove the back mounting plate of the clutch perch, and substitute a mounting plate with an integrated mirror perch.

http://www.ebay.com/itm/BLACK-MOTORC...da9c6c&vxp=mtr



Next, I can select my switchgear. I can purchase good, used, Japanese, OEM switchgear on eBay from a variety of motorcycles. I can also purchase new, aftermarket switchgear.

The final obstacle is mounting another choke lever. My carburetor is too difficult to reach, so I don't want to install a choke plunger directly on the carburetor. Therefore, I am considering two different choke levers. The first option is the choke lever for the first generation, Kawasaki KLR650. I can purchase a new, Kawaskai, OEM choke lever, part #46092-1123, for about $12. If I pursue this option, I must also buy a choke and mirror mount relocation bracket for $17.

http://www.rockymountainatvmc.com/im...1323120001.jpg

The Kawasaki choke lever would then mount in the following manner.



I don't know if my Zongshen choke cable will exactly fit the Kawasaki choke lever, but I don't think it would require too much modification.

I also discovered a Magura, Universal Choke Lever which mounts on the handlebars.

http://www.ebay.com/itm/Magura-14AL7...a9b7c2&vxp=mtr



After removing the end of my Zongshen choke cable, I would need to solder the Magura adapter in its place, as shown in the following thread.

http://www.horizonsunlimited.com/hub...ation-64290-10







However, I'm not sure the Magura Choke Lever will mount without hindering access to the switchgear. Do you gentlemen think I should purchase the KLR650 choke lever and associated perch, or the Magura choke lever?

[Weldangrind]

What stops you from just buying original equipment from Taobao? No mods needed, and the OEM stuff was good for 60000 miles.

[SpudRider]

I have already used up the stock switchgear, and a replacement switch. I did buy a third switchgear assembly in my last Taobao purchase. I would just like something better, and it doesn't cost much to make the modification. I have been known to modify my Zong on occasion.

[Weldangrind]

Indeed. Your bike is becoming less and less Zong every year.

[SpudRider]

Is that bad? Also, I forgot to mention; it's winter, and I am going stir crazy! Which choke lever do you think is best?

[edtardo]

Hey Spud, I just wanted to let you know that you may want to get a couple pair of the mirror mounts. I did the same thing on my bike and the mirror mount broke. Luckily I was stopped when I noticed the mirror falling off. I don't know if it was just a defect or not. The part the mirror threads into snapped off.

[Weldangrind]

Originally Posted by SpudRider

Is that bad? Also, I forgot to mention; it's winter, and I am going stir crazy! Which choke lever do you think is best?

Not bad at all. This is the time to perform such mods, so you have more time for riding in the Spring.

The Kawasaki choke lever looks to be more solid to me.

[FastDoc]

I think its a great project. I want you busy and happy Spud and ready to ride at the first sign of thaw. :-)

[FastDoc]

Have you considered ditching the carb and choke and going EFI?

Awesome project and not very expensive and very interesting. Immune to altitude change, and likely even better than your already amazing economy.

Just a wild thought...

http://www.mbe-motorsports.com/catal...979n77uqlnkgo4

[FastDoc]

Heck I would consider it for the KLX.

[SpudRider]

Originally Posted by edtardo

Hey Spud, I just wanted to let you know that you may want to get a couple pair of the mirror mounts. I did the same thing on my bike and the mirror mount broke. Luckily I was stopped when I noticed the mirror falling off. I don't know if it was just a defect or not. The part the mirror threads into snapped off.

Thanks for the tip, Ed. I think you got a bad pair of mirror perches. Last winter I installed those mirror perches on my CRF250X. That bike takes a beating, and the mirror perches are still in good condition.

[SpudRider]

Originally Posted by Weldangrind

Not bad at all. This is the time to perform such mods, so you have more time for riding in the Spring.

The Kawasaki choke lever looks to be more solid to me.

As usual, I think you are correct, Weld. I am strongly leaning toward the OEM, Kawasaki choke lever.

[SpudRider]

Originally Posted by FastDoc

Have you considered ditching the carb and choke and going EFI?

Awesome project and not very expensive and very interesting. Immune to altitude change, and likely even better than your already amazing economy.

Just a wild thought...

http://www.mbe-motorsports.com/catal...979n77uqlnkgo4

Wasn't one of our members going to install that EFI kit?

[FastDoc]

I had considered doing it with my PP400 before it started to fall apart faster than I could keep it together.

[FastDoc]

Leave it to a Chinarider to think about replacing a switch on the handlebars and wind up with an EFI conversion to save the issue of where to put a choke lever! LOL!