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#1 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Project: Better Zongshen Switchgear
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. ![]() 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. ![]()
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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 Last edited by SpudRider; 01-08-2014 at 02:40 PM. |
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#2 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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What stops you from just buying original equipment from Taobao? No mods needed, and the OEM stuff was good for 60000 miles.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#3 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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I have already used up the stock switchgear, and a replacement switch. I did buy a third switchgear assembly in my last Taobao purchase.
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__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#4 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Indeed. Your bike is becoming less and less Zong every year.
__________________
Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#5 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Is that bad?
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__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 Last edited by SpudRider; 01-09-2014 at 01:45 AM. |
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#6 |
Join Date: Mar 2012
Location: Altoona, Fl
Posts: 158
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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.
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NewStar DB 200 Facts are meaningless. You could use facts to prove anything that's even remotely true! --Homer Simpson |
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#7 | |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Quote:
The Kawasaki choke lever looks to be more solid to me.
__________________
Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#8 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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I think its a great project. I want you busy and happy Spud and ready to ride at the first sign of thaw. :-)
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Happy to serve. |
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#9 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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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
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#10 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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Heck I would consider it for the KLX.
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#11 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
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__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#12 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
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__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#13 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
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__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#14 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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I had considered doing it with my PP400 before it started to fall apart faster than I could keep it together.
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#15 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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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!
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