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How to Relocate Ignition switch cover, Neutral and Reverse lights
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Posted by: mak400ex

Aftermarket Handlebar Relocate cover Ignition switch, Neutral and Reverse lights

I installed the following - Lonestar Anti-vibe Steering stem and clamp with Pro Taper SE - high handlebars. Here’s what I did on Relocating the Ignition switch, Neutral and Reverse lights. After you have your aftermarket bar installed, remove the Ignition switch, Neutral and Reverse lights from the stock cover, Remove the nose cover it just pops off, I mounted the Ignition switch, Neutral and Reverse lights on the front top sides of the left and right fenders - (SEE PICS FOR LOCATIONS) the Ignition switch is centered on the flat part of the top side of the fender mark it and then drill a 1” hole this hole will need to be notched just look at your Ignition switch barrel its about 1/16 notch. Push it thru the plastic fender until it snap into place then plug in the wiring. For the Neutral and Reverse lights remove the lens from both they just pop out - (SEE PICS FOR LOCATIONS) Neutral and Reverse lights are centered on the flat part of the top side of the fender mark it and then drill a 5/8” hole I put my rev light on the side with my rev switch and the neutral light on the side I mounted my ignition switch. With the lens out push thru the rubber part of the assembly thru the inside wall of the plastic put a little spit on the lens cover lip and push it in, now repeat this for the other side – just make sure when you are drilling the hole the you have clearance to mount these items – look a the pics closely that I have attached you will see it’s a tight fit but this set up looks clean and you have no problem seeing the lights. If you need more info and or give me some feedback just add a comment to this post.

http://i155.photobucket.com/albums/s301/mikody/IMG_0090.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0094.jpg

the notch is in gold- file it out
http://i155.photobucket.com/albums/s301/mikody/IMG_0095.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0097.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0099.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0100.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0102.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0140.jpg

http://i155.photobucket.com/albums/s301/mikody/IMG_0190.jpg

Posted by: 300maniac

not tryin to take over the thread but u could also do what i did no holes in the plastics wow

Posted by: mak400ex

Looks good - i was going to make a plate but with antivibe bars i couldnt find a place to mount,

hows the panty hose outware working on your filter?

im running a k&n filter with the lid off and i was thinking about topping it off (the box) with panty hose if i could make it look good .

Posted by: Pipeless416

heres what i did on my dads z400.. maybe everybody can post good places to relocate lights and ignition switches on each different quad..

Posted by: mak400ex

That looks clean man...... great job

Posted by: mak400ex

Post up some pic's of this mod I know most of us has had to relocate the cover Ignition switch componets when moding the handle bars.

Posted by: 450r ride red

mak400ex did u get the hmf yet

Posted by: mak400ex

yea got it yeasterday and just got done installing it tonight - re jetted to a165---- it cleand up great i polished it out , sounds very nice - thanks for the deal
will post some pics and put a hit on " buy from this guy thread"
i will send ya some pics on sat.
thanks Tyler

Posted by: 450r ride red

your well come

thats a really nice 400ex ur got there

Posted by: mak400ex

Thanks T

I will send ya some pic on sat - of caks 400ex with pipe on, locked and loaded to go.....

Posted by: Splitpin

what the guys in South Africa do

get your self a clutch lever from a kicker that has a hot start lever.
move your reverse cable to this and put your ignition switch in the place your reverse lever used to be.
you N and R lights you can move them to were ever you please.

i'll take a picture of a KFX 400 that has this done, to show you how.

Posted by: mak400ex

Wow sounds cool - like to see some pics

Posted by: Splitpin

mak440ex

i have asked the guy to take some close up pic's of both
(lever and ignition) i would thing the best one to use on a ex would be from the 450r

this way you should be able to keep your park break.

Posted by: mak400ex

sounds good

Posted by: mak400ex

quote:
Originally posted by Splitpin
mak440ex

i have asked the guy to take some close up pic's of both
(lever and ignition) i would thing the best one to use on a ex would be from the 450r

this way you should be able to keep your park break.

Hey Splitpin

get any pics- would like to see - thanks

Posted by: mak400ex

new shot - got a new MSR shorty easy pull clutch lever and works triple rate springs.

http://i155.photobucket.com/albums/s301/mikody/P1202191.jpg

Posted by: Splitpin

Hey Mak400ex

decided to do the mod myself on my 05 ex
easy to do.
get your self a complete lever/perch for a CRF 450R this has the hot start lever and get your self a longer cable made about 40 - 50 cm longer and try get the cable maker to use the connections on the original cable.
to move you ignition
the ignition fits perfectly into the reverse mount (the black plastic fitting) use the metal plate on the bottem of your reverse switch as a template and make your self an new one but with a hole for the ignition body to fit through. it's all a tight fit that suits this fine.
you might have to use some rubber spacers/washers for the gap behind the reverse mounting when you tighten your new back plate to the mounting.

image 1 - new location of the ignition and back side mounting

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/ignition.jpg

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/TRRX001.jpg

image 2 - hot start lever now the reverse lever

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/hotstart.jpg

image 3 - netural & reverse light

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/lights.jpg

easy to do

Posted by: mak400ex

quote:
Originally posted by Splitpin
Hey Mak400ex

decided to do the mod myself on my 05 ex
easy to do.
get your self a complete lever/perch for a CRF 450R this has the hot start lever and get your self a longer cable made about 40 - 50 cm longer and try get the cable maker to use the connections on the original cable.
to move you ignition
the ignition fits perfectly into the reverse mount (the black plastic fitting) use the metal plate on the bottem of your reverse switch as a template and make your self an new one but with a hole for the ignition body to fit through. it's all a tight fit that suits this fine.
you might have to use some rubber spacers/washers for the gap behind the reverse mounting when you tighten your new back plate to the mounting.

image 1 - new location of the ignition and back side mounting

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/ignition.jpg

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/TRRX001.jpg

image 2 - hot start lever now the reverse lever

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/hotstart.jpg

image 3 - netural & reverse light

http://i207.photobucket.com/albums/bb313/SPLITPINPAUL/PAUL%20TRX400/lights.jpg

easy to do

Nice job Splitpin,

I like it looks clean, thanks for posting

Posted by: hondaracing0144

is all ignition switches the same size and what size hole do u think i will need to make

Posted by: mcwilly

d@mn, I didnt know this thread existed. I reloacted mine a couple of weeks ago w/ a Rox dash panel.

http://i20.photobucket.com/albums/b221/rx3732/100_0441.jpg

http://i20.photobucket.com/albums/b221/rx3732/100_0439.jpg

http://i20.photobucket.com/albums/b221/rx3732/100_0438.jpg

http://i20.photobucket.com/albums/b221/rx3732/100_0437.jpg

Posted by: mak400ex

Hey mcwilly,

that looks good, up on the bar clamp ya can see it better.

NICE JOB MAN

man i like those c/f warning label cover , thinking about getting me some.......looks awesome on black

Posted by: mcwilly

Thanks. When I wreck and bend these bars,

I think I'm gonna go w/ a fat bar setup and a clamp from RMATV w/ the 400EX logo on it. I was debating between that and the one I got.
The c/f replacements are sweet. Pics do them NO justice. I bought some for my son's black 90EX as well.