CHOKE LEVER/CABLE DAMAGE - 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 7 Old 10-08-2006, 09:34 AM Thread Starter
 
Join Date: Sep 2006
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CHOKE LEVER/CABLE DAMAGE

While trailering my bike to a camping site for a few days....(I needed the truck to haul all the gear for setting up my photography project) the bike slipped over while going through some rough areas of washboard road and came to rest on the low railing of the trailer. I broke the choke lever mounted on the handlebar (at least the second one I've trashed). Not to be dismayed and I don't really need the choke anyway I just tied off the cable and kept going. However, after returning home and doing maintenance I discovered that where the choke cable enters the carb that the black plastic housing is completely broken. The cable still functions normally when the choke is applied from the handlebars. How does this plastic piece hookup to the carb? Obviously I will have to order not only the lever for the handlebars, but the cable as well. Will the carb have to be removed for this procedure? Anybody out there done this one? I have no idea how long the thing has been broken or how it could have been damaged up and in that area unless I did it when I removed the carb last year and didn't notice it. I don't even remember removing it. I suppose when the cable gets here and I dive into it all it will come back to me..... :?
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post #2 of 7 Old 10-08-2006, 10:30 AM
 
Join Date: Oct 2006
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That plastic piece on the carb threads in and is fairly fragile. A very nice alloy replacement is available from www.steadengineering.com

it's possible that when the bike fell over, when the choke lever it hit it pulled the cable housing enough to torque the plastic carb end out and break it.
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post #3 of 7 Old 10-08-2006, 10:35 AM
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X6
I attempted to change that plastic fitting with the carb still installed and had zero luck. Just couldn't get a wrench to break it loose. There is a manufacture out there that makes a metal fitting for $26.00 and in my opiniom it is well worth it. It has threads on the end that screws into the carb.

I bought the metal one but have not yet installed it. I can't recall where I sent off for this fitting but if you need help in that department I can find out Monday.
harley dogI :lol:
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post #4 of 7 Old 10-08-2006, 11:14 AM Thread Starter
 
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Thanks for the info... sounds like Gadget and HarleyDog speak of the same place. I checked it out and will probably order that part. Now.... does this new alloy part match up to the replacement choke cable? Or do I order something to mate the two together? :?:
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post #5 of 7 Old 10-08-2006, 12:09 PM
 
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Quote:
Originally Posted by X6_Hustler
Thanks for the info... sounds like Gadget and HarleyDog speak of the same place. I checked it out and will probably order that part. Now.... does this new alloy part match up to the replacement choke cable? Or do I order something to mate the two together? :?:
direct replacement, no other parts needed. the designer and manufacturer, laurie, is a KLR owner and rider.
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post #6 of 7 Old 10-08-2006, 12:23 PM Thread Starter
 
Join Date: Sep 2006
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Great. Sounds like the existing cable is salvaged with the input of a new alloy interface. Probably cheaper that the whole cable anyway. Sounds like a plan too me. :wink:
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post #7 of 7 Old 10-11-2006, 12:06 PM Thread Starter
 
Join Date: Sep 2006
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I'm getting ready to order the clutch replacement parts today and I found that in addition to the "thumb lever" assembly, that the cable itself is damaged at the top end where the adjustment wheel is. So.... now I need the thumb lever assembly, the cable itself and the metal interface. Total of three parts. Right? If I were to order the cable by itself does it come with the plastic "thingy"? If so, I guess I can take it off and put the aftermarket one on. I suspect that the stock plastic thingy is a separate part...... :?:
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