mod gone wrong - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 25 Old 03-17-2011, 10:45 AM Thread Starter
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mod gone wrong

New here and performing all the recommonded upgrades. So far the ThermoBob, mercedes valve, super trapp, and will do the doohicky this weekend. Bought all parts from recommended links from this site - good work!
Just completed the klx needle, drilled out the slide, 142.5 jet, snorkel removel and promtly broke the plastic body part that connects to the carb for the choke. Dumb question - Is that part of the choke cable or is that a separate piece? Does the carb need to be removed to replace? Not real good at mechanical but the step by step instructions really helped, until I missed a step about "Very Careful...."

Seriously have my head stuck up someplace where it doesn't belong.
1999 5000 miles
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post #2 of 25 Old 03-17-2011, 11:13 AM
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http://www.kawasaki.com ; owner info; view parts diagrams; go there and you'll see an exploded parts diagram, parts list, and part number.

Beyond OEM, Stead Engineering sells a METAL choke cable cap, not apt to break.
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post #3 of 25 Old 03-17-2011, 11:19 AM
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I am pretty sure that it can be replaced by itself.

Here's the metal one, if you want to drop $30 on a non-bustable one.

You could also do the KLX250 plunger mod that eliminates the choke cable entirely. Ron Ayers seems to have a decent price.

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Last edited by Tom Schmitz; 03-17-2011 at 11:28 AM.
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post #4 of 25 Old 03-17-2011, 11:23 AM Thread Starter
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appreciate the help...

Thanks, going for the metal one - and thanks for the great step by step on all the mods, I just happened to overlook the one that mentioned - carefull, breaks easily...
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post #5 of 25 Old 03-17-2011, 11:54 AM
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Kick around the KLX plunger.. It's cheap and you can take all the other stuff off the handlebar..

I tipped my bike over on soft gravel and broke the choke lever. I put the KLX plunger in and now I wish the bike had fallen over sooner!! It's a great modification!!
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post #6 of 25 Old 03-17-2011, 03:09 PM
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Which one? Paper? Tom? It was Tom, wasn't it. All that free time now. What did he do?




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

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post #7 of 25 Old 03-18-2011, 09:10 AM Thread Starter
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the fix - for now...

Doing Tom's (ordered part) and suspect will be doing Paper's before long...
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post #8 of 25 Old 03-18-2011, 09:14 AM
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Originally Posted by mrxr750 View Post
Doing Tom's (ordered part) and suspect will be doing Paper's before long...
Oh, don't blame that one on me..
I sure didn't come up with it.. If I knew who did, I'd buy he/she a case of beer tomorrow, though!! I think it was one of those "I wonder if this will work?" things..

Takes a little to get used to, since it's a small plunger under the tank, but before long you can pull it out without even thinking about it.. Bike pops right off.. Let it idle for 20-30 seconds and push it in, and ride away..
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post #9 of 25 Old 03-18-2011, 11:07 AM
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Originally Posted by mrxr750 View Post
Thanks, going for the metal one - and thanks for the great step by step on all the mods, I just happened to overlook the one that mentioned - carefull, breaks easily...

Yea I cracked mine too. I used some JB Weld to hold it together until my metal one arrived. The fitting is a booger to remove and install too.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #10 of 25 Old 03-19-2011, 10:55 AM
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I opted for the short--8"-- Harley Davidson choke cable, part # 29229-88, used on Sportsters and some other HD's that use the same Keihin 40MM carb as the KLR instead of the direct mount Kawi plunger set-up.

I fabbed up a mounting bracket for the choke cable--which I bought new for $18 w/ free shipping off ebay--also ordered the Stead Engineering aluminum choke cable fitting, and then picked up a 90* cable guide elbow from the local HD dealer for $4 to best route the cable as I wanted.

Mounted the bracket to the top bolt for the starter solenoid cover. The choke knob is well protected and out of the way nestled in behind the frame down-tube but still easily accessable--don't have to feel around blindly deep in the tight quarters under the tank for a direct-to-carb mounted knob.

Here's the HD cable with what's left of the original plastic fitting and the needle and spring attached. The Stead aluminum fitting is just above:



Here's everything installed:







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