tri5ron
11-09-2008, 08:14 PM
I did this for my wifes 250ex, but thought some here might like the idea. It will also work for those of you who use a stock thumb throttle on your 400ex.
many people already replace the stock throttle lever from a 250ex or 400ex, with a stock lever from a 90ex due to the lever on the 90ex is about 1/2" longer.
Below is a pic of a stock 250/400ex lever on the bottom, and a stock 90ex lever on the top.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8812.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8812.jpg" border="0" alt="Photobucket"></a>
the problem my wife was having, is that her hands are not that strong, and trying to hold the grip with her 4 fingers, and keeping her thumb on the lever, would cause her hand to cramp up. and the lever got hard for her to push very quickly.
So naturally, the "quick fix" answer to that, is to put a longer lever. BUT that also creates another problem....
The longer lever causes the need to "open" the riders right hand even more than before, resulting in a lever that is easier to push, But more likely to cause cramping in the hand.
so here's what I did to fix the Cramping issue, as well as making the throttle lever eaiser to push.
First I took a stock lever from a 90ex, and bent it back a little just to where it snapped off.
(you cant bend cast aluminum much before it breaks)
Then I cut the head off of a roofing nail, and bent it to the desired angle. Next I mixed some epoxy putty, and puttied the nail shank to the back side of the lever, and covered the nail shaft with more putty to completly cover it up. let it harden overnight, then file and sand to smooth it up.
Below is a pic of the stock 250ex lever on th left, a stock lever from a 90ex in the center, and my puttied 90ex lever on the right.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8813.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8813.jpg" border="0"
alt="Photobucket"></a>
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8819.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8819.jpg" border="0" alt="Photobucket"></a>
next, I got some Plastic tool dip, to give it a little more gripping quality, and to make it look nicer too.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8817.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8817.jpg" border="0" alt="Photobucket"></a>
and end result is...
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8820.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8820.jpg" border="0" alt="Photobucket"></a>
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8822.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8822.jpg" border="0" alt="Photobucket"></a>
I will let this dry overnight, and may do a second dipping tommorow. after I get it done, I wil post some comparative pics of it installed.
BTW- before doing the dipping, I had my wife sit on the quad while I changed from original, to stock 90ex, to modified 90ex levers. She said that the modified lever was MUCH more comfortable than the stock 250ex lever, AND is eaiser for her to push.
Enjoy...
many people already replace the stock throttle lever from a 250ex or 400ex, with a stock lever from a 90ex due to the lever on the 90ex is about 1/2" longer.
Below is a pic of a stock 250/400ex lever on the bottom, and a stock 90ex lever on the top.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8812.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8812.jpg" border="0" alt="Photobucket"></a>
the problem my wife was having, is that her hands are not that strong, and trying to hold the grip with her 4 fingers, and keeping her thumb on the lever, would cause her hand to cramp up. and the lever got hard for her to push very quickly.
So naturally, the "quick fix" answer to that, is to put a longer lever. BUT that also creates another problem....
The longer lever causes the need to "open" the riders right hand even more than before, resulting in a lever that is easier to push, But more likely to cause cramping in the hand.
so here's what I did to fix the Cramping issue, as well as making the throttle lever eaiser to push.
First I took a stock lever from a 90ex, and bent it back a little just to where it snapped off.
(you cant bend cast aluminum much before it breaks)
Then I cut the head off of a roofing nail, and bent it to the desired angle. Next I mixed some epoxy putty, and puttied the nail shank to the back side of the lever, and covered the nail shaft with more putty to completly cover it up. let it harden overnight, then file and sand to smooth it up.
Below is a pic of the stock 250ex lever on th left, a stock lever from a 90ex in the center, and my puttied 90ex lever on the right.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8813.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8813.jpg" border="0"
alt="Photobucket"></a>
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8819.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8819.jpg" border="0" alt="Photobucket"></a>
next, I got some Plastic tool dip, to give it a little more gripping quality, and to make it look nicer too.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8817.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8817.jpg" border="0" alt="Photobucket"></a>
and end result is...
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8820.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8820.jpg" border="0" alt="Photobucket"></a>
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/?action=view¤t=IMG_8822.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Honda%20trx250ex%20quad/IMG_8822.jpg" border="0" alt="Photobucket"></a>
I will let this dry overnight, and may do a second dipping tommorow. after I get it done, I wil post some comparative pics of it installed.
BTW- before doing the dipping, I had my wife sit on the quad while I changed from original, to stock 90ex, to modified 90ex levers. She said that the modified lever was MUCH more comfortable than the stock 250ex lever, AND is eaiser for her to push.
Enjoy...