Choke Modification, works!!! - 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 17 Old 02-07-2010, 10:20 AM Thread Starter
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Cool Choke Modification, works!!!

Thanks again to the forum members for pointing me to a choke upgrade. The PO of mine had broken the cheesy choke cable lever. Someone on the list said the choke plunger from a '95 KLX250 would fit, and it does! Once the tank was off, it wasn't the hard to remove the stock plastic screw-in assembly by carefully using some very long needle nose pliers. Installation of the plunger-type choke assembly was simply the reverse. With the tank on, it is a bit difficult to find the plunger at first, but I figure it's a type of "anti-theft" device now as my bike, at least in Colorado winter, no way will start without some choke. One point to note if you plan this upgrade, the plunger does NOT stay open. You have to pull it out with your left hand and hold it, while stabbing the starter button. Again, a bit awkward but the assembly is no longer on the bars where it will break and is probably bullet-proof now. Maybe there is a part number that actually stays open, but not the one for the '95 KLX.

Cheers,

John (Go Saints!)

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #2 of 17 Old 02-07-2010, 11:42 AM
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It should pull out past a detent that holds it on. The two that I've seen (myself and double a) both stay on and I'm sure it's the exact same part.
If I remember correctly, double a didn't think his did at first, but it just needed to be pulled out a little more. (please don't break, please don't break)
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post #3 of 17 Old 02-07-2010, 11:56 AM Thread Starter
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You are correct Paper, it DOES stick open if you pull past the detent. I too, didn't want to break it, excellent, now I endorse this as a "must have" modification! Thanks! I was thinking of perhaps adding loctite to it, has your's stayed in place without a sealant?

John (still finding missing bolts, screws, etc. and need to go buy some more locktite)

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #4 of 17 Old 02-07-2010, 11:57 AM Thread Starter
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...by the way, I had some more pictures of installation items. The website won't let me post anymore pictures, do I have to upgrade my membership level or something?

John

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #5 of 17 Old 02-07-2010, 12:01 PM
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Even though I loctite most things, I don't think I did the plunger because I didn't want to risk any getting in the carb. Never been an issue and it's never loosened in 3-4 years.

I don't know why you can't put up a photo. You're way above the 15 post restriction. Maybe it's size related and the photos are too big? I'm not much help with the site's photo thing because I use Photobucket.
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post #6 of 17 Old 02-07-2010, 05:03 PM
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My stays out on the detent no problem.

Never thought of it as a security device, but that's a good idea. I may put my old cable system back in place just to fool them further!!!
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post #7 of 17 Old 02-09-2010, 11:27 PM
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Are you guys going through a dealer to order your plungers? This is one that I'd like to add to my bike.
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post #8 of 17 Old 02-10-2010, 04:03 AM
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What is the OEM part number?

Not saying this information is correct.

I found this on the '95 KX250

16016-1085

It is named "plunger".

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #9 of 17 Old 02-10-2010, 10:21 AM
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Don H
Spring Valley AZ
'03 KLR 650/DS sidecar
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post #10 of 17 Old 02-10-2010, 11:49 AM
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Quote:
Originally Posted by DonD View Post


Thanks. Ron Ayers microfiche did not list a 1995 KLX 250 but they did list a KX 250. Must be the same. Kawasaki must be the General Motors of motorcycles.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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