Taking off nuetral light panel on a 2007 400ex

[f4iracer]

Hey all

I don't have a service manual for this newer model and the display panels seem to be a little different.

How do i remove the wires that are attached to the reverse and neutral lights on the panel?

I am replacing my handlebars with renthal bars and i'm gonna have to get this out of the way so i can do the swap. Or am i able to leave this thing in there?

Also, any other advice for swapping out bars on this quad? It seems pretty easy, i believe i'll have to disconnect a couple wires at the clutch perch also??? i'm really not sure and was hoping some of you could give some insight.

[Ryan'07400ex]

I cant remember exactly but i am pretty sure the two dummy lights just popped of (the colored lens comes apart from the actual lens) Then for the key I think I unplugged it at the front of the bike somewhere close to the cdi then just pulled it out though the top. It shouldnt be hard to do. Don't be afraid to give it a little force but if it aint coming try something different of course.

[Ryan'07400ex]

Originally posted by f4iracer

Also, any other advice for swapping out bars on this quad? It seems pretty easy, i believe i'll have to disconnect a couple wires at the clutch perch also??? i'm really not sure and was hoping some of you could give some insight.

As for that I would say it would be a good idea to take a pic from the front of teh quad and the back so you know what order everything goes back on without guessing and the height of your levers and maybe hanguards if you have those. When I did mine I messed up a couple times cause I didn't remember what order to put em on and my levers were at different heights and I wasn't exactly used to it.
Hope that helps

are you relocating the key and lights or putting it back in the panel thing? I got a ROX dash and it works pretty good if your going in that direction.

Good Luck

[katch26]

are you scrapping them all together or just moving them?

[f4iracer]

i'm trying to keep the panel and put it on the renthal bars i got. I'm basically trying to keep everything stock and just replace the bars.

The renthals have a removable cross bar, i wasn't sure if the panel would even fit or not.

Thanks for the advice guys i'm gonna do this swap tomorrow!

Any advice for the grips? On my fiddy i used a phillips head screwdriver with pb blaster and got under the grip and then just twisted and they popped right off.. we will see how these come off.

[slightlybent47]

I didn’t take the dash off or apart, I just moved it out of the way and installed the bars and put everything back like stock.

This is mine with renthal bars and the stock dash.


http://i34.tinypic.com/1zb5w95.jpg

http://i33.tinypic.com/jhahi8.jpg

[slightlybent47]

I drilled and taped the steering stem and put two screws to hold the dash on.


http://i37.tinypic.com/2yybek1.jpg

[f4iracer]

those look to be the same bars that i ordered.

So, i take it you couldn't get the display piece to fit back on the mounting screw it uses for stock?

I'll prolly end up doing some ziptie or something if it doesn't mount back like it was, or i could drill holes like you did.

edit = just noticed that mountin screw was on the stock bars. I've got the old bars off and i'm waiting on the new bars to arrive!

[slightlybent47]

Yeah I had to put the holes in the front cuz the old mounting hole won't work with the new bars. If you'll look at the front of the dash I had to cut the point off so the wires could run under them without binding when you turn the bars. I don’t think zip ties will hold it secure very long. That’s just the way I did it you may find a better way. I don’t care about the neutral light its not hard to find neutral. I didn't want to put the light or the key switch on the finder, cuz I take the plastic off quite a bit to work on it so I didn’t want to be unplugging it every time I take the plastic off.

Also I think I had to grind the nipple off where the old screw was on the dash.
It was a long time ago and I cant remember if I did or not.

Hope that helps.

[f4iracer]

Hmm, i just noticed that you had to cut it.

Do the wires shorten up with the new bars? I'm just gonna have to feel around and see how the wires run, i'm hoping to get them in there like they were stock, the ignition is over the bars and the other wires are under the center of the bars in between the clamps.

I'll let ya know how it goes, but i think i'll be able to get it hooked up without cutting my plastic.

[slightlybent47]

Also I think I had to grind the nipple off where the old screw was on the dash.
It was a long time ago and I cant remember if I did or not.

Hope that helps.

[slightlybent47]

I just left every thing hooked up, it was a tite fit cuz the wires are not very long.

[f4iracer]

I just finished it up.

Here's some pics i took along the way.

Bent stockers....

http://i102.photobucket.com/albums/m93/rschaef83/IMG_0032-1.jpg

http://i102.photobucket.com/albums/m93/rschaef83/IMG_0035.jpg

new bars
http://i102.photobucket.com/albums/m93/rschaef83/IMG_0052.jpg

http://i102.photobucket.com/albums/m93/rschaef83/IMG_0055.jpg

there was enough clearance to allow the stock setup to remain in tact.
http://i102.photobucket.com/albums/m93/rschaef83/IMG_0056-1.jpg

[f4iracer]

I was out yesterday and i noticed my quad was stumbling a couple times in reverse.

I then continued to try to back up with lots of gas, and even in reverse with the clutch in, while i tried to rev, it was popping and flooding out.

I doubled check the wires that go into the clutch and they are just as they were before i changed the bars out. green wire towards the seat and the gray wire towards the front of the quad.

I know reverse probably has a governer but i've never noticed this type of stumble. It will still go but like i said it pops and doesn't rev very high.

Any ideas?