Zongshen 200GY-2: Tusk Grip Heaters

[SpudRider]

Yesterday I installed Tusk Grip Heaters on my Zong. :)

http://www.rockymountainatvmc.com/p/43/53/218/998/-/23097/Tusk-Grip-Heater-Kit?term=tusk+grip+heater+kit

http://www.rockymountainatvmc.com/images/prod/400/t/tus_09_gri_hea_kit-2.jpg

I had previously installed the Tusk Grip Heaters on my Honda XR650L; I liked the Tusk Grip Heaters so much, I decided the Zong needed a set as well. ;)

The Tusk grip heaters use a 2 ohm resistor to reduce the heat generated at the grips on the "low" setting, but the resistor uses just as much energy as the "high" setting. :roll: Therefore, I installed an inexpensive, PWM (pulse width modulation) device in place of the resistor. ;) The PWM uses less energy than the resistor, and also allows for fine tuning the heat on the "low" setting. :) I purchased the lightweight, PWM device on eBay for about $5, delivered. ;)

http://www.ebay.com/itm/LED-Light-Dimmer-Adjustable-Brightness-Controller-DC-12V-24V-For-3528-5050-Strip-/121002216989?pt=US_Lighting_Parts_and_Accessories&hash=item1c2c4b4e1d

http://www.jewelrywhsle.com/e-whsle/Controller/12V-5A-Dimmer-2Plug-white.jpg

Using the following wiring diagram, I connected the PWM device to a DPDT (double pole, double throw), center-off switch I bought at Radio Shack.

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/TuskwithPWMDevice_zpsc96432d4.jpg (http://s442.photobucket.com/user/spudrider/media/Tusk%20Grip%20Heaters/TuskwithPWMDevice_zpsc96432d4.jpg.html)

I mounted the switch on top of my indicator lights, and I mounted the PWM device on top of my speedometer.

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/Zongheatedgripsfirstride008_zps889e691b.jpg (http://s442.photobucket.com/user/spudrider/media/Tusk%20Grip%20Heaters/Zongheatedgripsfirstride008_zps889e691b.jpg.html)

I ran a dedicated, fused wire from my battery to power the grip heaters. I also installed a relay, triggered by a power line controlled by the ignition key. :)

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/Zongheatedgripsfirstride010_zpsf380aaac.jpg (http://s442.photobucket.com/user/spudrider/media/Tusk%20Grip%20Heaters/Zongheatedgripsfirstride010_zpsf380aaac.jpg.html)

After finishing the installation, I took a ride along a favorite road to test the grips. I'm pleased to report they work great. :D I don't know why I waited so long to install grip heaters on my motorcycles. ;)

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/Zongheatedgripsfirstride014_zps521661ef.jpg (http://s442.photobucket.com/user/spudrider/media/Tusk%20Grip%20Heaters/Zongheatedgripsfirstride014_zps521661ef.jpg.html)

Spud :)

[zingshoen]

great idea, but i won t need thhat where i am :-)

but which protaper handle bar did you install?

[Weldangrind]

Sounds like a great idea. :idea: Do the heating elements simply wrap around the bar, before the grips are installed? Is it difficult to install the grips over the elements? Do the elements have adhesive backing?

[SpudRider]

great idea, but i won t need thhat where i am :-)

but which protaper handle bar did you install?
The lowest elevation around here is 4,400 feet above sea level; those are the lowlands. ;) I frequently ride over 9,000 feet above sea level. At these elevations, grip heaters are very nice to have even in the summertime if you are riding early in the morning, or after sunset. ;)

I installed Pro Taper SE (seven-eights) ATV High Bend handlebars on my Zong. The work great with my Tusk handguards. :D

Spud :)

[SpudRider]

Sounds like a great idea. :idea: Do the heating elements simply wrap around the bar, before the grips are installed? Is it difficult to install the grips over the elements? Do the elements have adhesive backing?
I won't be without grip heaters; I have been spoiled. :lol: After enjoying the grip heaters on my XR650L, I knew I had to install them on my Zong. If I rewind the stator on my CRF250X, I will install grip heaters on that bike, also. ;)

The heating elements have an adhesive backing; you install them by wrapping them around the handlebars before you install the handlebar grips. I use compressed air to install the grips, and the job isn't much tougher with the grip heaters in place. :) Here's are links to the installation instructions at the Rocky Mountain ATV/MC website. ;)

http://rockymountainatvmc.com/docs/grip%20heater%20instruction.pdf
http://rockymountainatvmc.com/docs/Grip%20Heater%20for%20Twist%20Throttles.pdf

Spud :)

[zingshoen]

Thank you for the info, Spud, I should like to get such a bar for mine. did you have to change the cables or were the standard zong cables long enough?

[SpudRider]

Thank you for the info, Spud, I should like to get such a bar for mine. did you have to change the cables or were the standard zong cables long enough?
You're welcome. :) I cut about 1-inch off both ends of the handlebars. Because of the way I routed the hydraulic brake line on my lower fork protector, I am at the end on the brake line. I am also near the limit on the throttle cable. ;) Come to think of it, I don't have much slack on the choke and clutch cables, either. ;)

Spud :)

[patrickzong]

maybe I'll do this next fall as well as a seat strip:D

[Weldangrind]

Thanks for the instructions; I hadn't thought about the throttle side heating up more quickly than the left side. I can see the potential for the throttle side wire to wear through between the grip and the throttle housing, and it seems prudent to protect the wire with some heat shrink or some small hose.

The relay is a smart idea on your part, as is the PWM.

[SpudRider]

Thanks for the instructions; I hadn't thought about the throttle side heating up more quickly than the left side. I can see the potential for the throttle side wire to wear through between the grip and the throttle housing, and it seems prudent to protect the wire with some heat shrink or some small hose.

The relay is a smart idea on your part, as is the PWM.
I put a piece of 1-inch, shrink wrap tubing around the clutch side of the handlebars before I installed the left grip heater on my XR650L. It insulates the grip heater from the handlebars, and does a good job keep the left grip as warm as the right grip. ;)

I put two pieces of 1-inch, shrink wrap tubing around the clutch side of the handlebars before I installed the left grip heater on my Zong. Two layers might insulate the grip heater slightly better, but I think it also made it more difficult to install the grip. Therefore, I think a single layer of shrink wrap tubing is sufficient. ;)

The throttle tube and grip heater wires will not get damaged, since the wires rotate with the throttle tube. The danger is the solder joints will fail where the wires attach to the grip heater on the throttle tube. As detailed in the instruction sheet, bending the wires, and re-enforcing them with two layers of electrical tape does a very good job strengthening them. :)

For both installations I ran a dedicated, fused wire from the battery to power the grip heaters. I installed a relay which is turned on by a wire fed from the ignition switch. This makes sure the grip heaters are turned off when the ignition switch is turned off, so I don't accidentally drain the battery when I park the motorcycle. :)

Spud :)

[SpudRider]

Saturday morning dawned cold, with rain. :( However, the sun appeared in the afternoon, so I took a nice ride in the mud with my Zong. :)

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/Zongres2001_zpse4c91622.jpg (http://s442.photobucket.com/user/spudrider/media/Tusk%20Grip%20Heaters/Zongres2001_zpse4c91622.jpg.html)

The Kenka, K760 rear tire, and Shinko, 524 front tire perform very well in all off road conditions, including mud. :D

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/Zongres2004_zps1a3c734f.jpg (http://s442.photobucket.com/user/spudrider/media/Tusk%20Grip%20Heaters/Zongres2004_zps1a3c734f.jpg.html)

My newly installed, grip heaters made this ride bearable. If your hands stay warm, it helps to keep the core of your body warm as well. ;) Also, you are much more comfortable when you have warm hands to work the bike's controls. I love my Tusk grip heaters. :D

Spud :)

[wilserchinarider]

Heated grips on a china bike...just great Spud! Bet you wish you did this 50,000 miles ago :)

[SpudRider]

Heated grips on a china bike...just great Spud! Bet you wish you did this 50,000 miles ago :)
I certainly do wish I had installed heated grips immediately! ;) Even in the summer heated grips are an asset in Idaho. :) After the sun goes down, it gets cold when you are a mile high, or higher. ;)

Spud :)