[Reverse Lever on Handlebar] - ATV Riders Forums - Honda, Yamaha, Suzuki, Kawasaki, Polaris, CanAm, Arctic Cat, Kymco ATVs

Pages:1

Reverse Lever on Handlebar
(Click here to view the original thread with full colors/images)

Posted by: SG1

From my old 660 Raptor I had a DR.D reverse lever that goes on the handlebar. I put it on my 06 400ex the cable is to long but I cut the end off enough to make it work. I JB welded a small round aluminum Piece where the pin went into the reverse lever on the motor. I will take pictures and put them up soon. Anyways I was wondering if someone has done this or knows if they make a reverse handlebar lever for the 400ex. So far it works great. I left the reverse knob on my fender and took the stock cable out.

Posted by: X400EX

Interesting! Never seen that before.

Posted by: bobkunkle

Please post pictures, if possible. I would be interested in this mod.

Posted by: exman

300ex clutch perch,,,,and 300 ex reverse cable,,,and 300ex reverse cable bracket on engine......

use those....and move your key switch to the open reverse hole on fender..

you know have handlebar reverse

Posted by: SG1

Dr. D Raptor660 reverse handlebar mount on 400ex Pic.

Posted by: SG1

Pic of Reverse wire connected to lever on motor.

Posted by: SG1

GPS Holder with cord to 12v car socket by battery.

Posted by: SG1

whole bike from back

Posted by: SG1

cup holder

Posted by: SG1

12v car plug and airbox

Posted by: klutch

My buddy has that same lever but for his Z400

Posted by: SG1

The msr lever kinda sucks because it just isn't made very well and I had to modify it to make it work and I think I would have rather the long handle instead of the shorty.

Posted by: bobkunkle

That is a really clean install. I wonder why there is not a 400ex version from Dr. D.

Posted by: Splitpin

SG1
Check this out from another post

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: quadman 05400ex

were did u get that tip for your exhust

Posted by: SG1

quote:
Originally posted by quadman 05400ex
were did u get that tip for your exhust

EHSRacing.com it comes with a spark arrestor screen also.

Posted by: b4wheeler

quote:
Originally posted by exman
300ex clutch perch,,,,and 300 ex reverse cable,,,and 300ex reverse cable bracket on engine......

use those....and move your key switch to the open reverse hole on fender..

you know have handlebar reverse

Thanks for the idea. Now I don't have to cut up my new plastics.....

Posted by: b4wheeler

Update.....

Purchased all the 300ex parts as listed. Got the clutch perch, lever complete, 300ex reverse cable and all brackets.

The clutch perch on the 400ex is exactly the same as on the 300ex, except for the addition of the reverse lever and the clutch lever has the reverse button on it. You could purchase just the 300ex lever and the small reverse lever and use your perch.

The reverse cable is too long to use with the 400ex brackets and none of the 300ex brackets line up to anything and are unusable.

I ended up using parts from both clutch lever/perch assemblies, the 300ex cable and a lot of really tight zip ties to hold the cable secure.

This has worked fine through testing. We will see how it fairs under race conditions.

Overall I am pleased as it keep my plastics clean and allows one hand reverse operation....

Posted by: bobkunkle

I just moved my reverse to the clutch perch also. I have a 2005 400ex that I purchased from 08400ex back in December. The quad has a Magura hydraulic clutch.
I called Magura and ordered the decompression lever and the replacement reservoir lid and I ordered the 300ex reverse cable from Honda.
I cut the reverse cable to length at the opposite end of the cable than the handle bar. I found a bolt that was the same size as the ferrell that I had just cut off. I drilled a small hole through the new ferrell and then used a center punch to pinch the ferrell onto the new cut brake wire.\
There is no adjustment at the clutch end of the cable. All of the adjustment is at the reverse interlock end of the cable.
Project total $47. ($32 for magura parts & shipping and $15 for Honda cable)
http://i293.photobucket.com/albums/mm72/bobkunkle01/P5301037.jpg