How can I remove choke cables from carburetor?? - 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 19 Old 07-03-2009, 03:19 PM Thread Starter
 
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Angry How can I remove choke cables from carburetor??

Hello all,

Sorry if this is an amateur question, but I am having trouble removing the choke cable from the carb. The side of the nut I have to loosen is pressed so close to the carb that I can't seem to fit a common wrench around it to loosen! Also, I cannot use wrench at a right angle, since the carb and engine get in the way, and the nut is on so tight.

How can I remove this super tight nut, given that it is pressed up against the carb so close that I can't really wrap my wrench all around it? I am tempted to just remove the choke cable at the handlebars and pull it through with the carb (out the right side) if it is too hard.

Thanks,

S. Tassan

P.S. I removed the seat and tank in order to have easy access to the right side of carb.
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post #2 of 19 Old 07-04-2009, 11:44 AM
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If I remember correctly, I just used (gulp) a good pair of pliers. It just needed something that could grip it to break it loose.

I installed a KLX250 choke plunger knob on my choke to eliminate the cable and it worked perfectly. It was about as hard to get the new locknut tight as it was to get the old one off, though..
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post #3 of 19 Old 07-04-2009, 02:38 PM
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Dude, I've asked WAY more amateur questions than that. And will again.

Questions of all kinds are good...we all learn something from them.



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post #4 of 19 Old 07-05-2009, 03:02 PM Thread Starter
 
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Smile

Thanks a lot for the replies! I will give it a shot with my pliers.

Paper, did you remove your whole choke assembly after installing your KLX250 choke plunger knob? That sounds pretty cool...

Thanks,

S. Tassan
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post #5 of 19 Old 07-05-2009, 08:52 PM
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Yep.. Got rid of the entire cable/lever assembly.. Instead, I just reach under the tank and pull the choke knob.. Bike starts almost instantly and I let it run on the choke for until it'll run without it.. With the knob, you're either on or off choke.

My side stand sunk into soft dirt and the bike fell over, breaking my choke lever.. Seemed like a good time to do the knob. Been running like this for 3 years.
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post #6 of 19 Old 07-12-2009, 04:35 PM
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Paper, What year of KLX 250 did you get the from?

Faller
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post #7 of 19 Old 07-13-2009, 10:00 PM
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Quote:
Originally Posted by faller View Post
Paper, What year of KLX 250 did you get the from?

Faller
I can't remember... Double A and I both installed them and he orded them.. He's checking on it and hopefully will find it.
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post #8 of 19 Old 07-13-2009, 10:04 PM
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DSJunky's old post from 3 years ago says..

Quote:
I can't help you with the thread, but I've read that the choke from a 1996 KLX250 mounts directly to the carb lawn mower or dirt bike style, and it works well. You could order it from bike bandit, and plug and play.
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post #9 of 19 Old 07-15-2009, 12:24 PM
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Thanks, I will give it a try.
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post #10 of 19 Old 07-15-2009, 06:55 PM
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What Paper says.

Kawi part # 16016-0013

Was under $25 at dealer a year or so ago.

Good luck.
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carb, carburetor, choke cable, choke cable nut, choke cable removal

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