Do I need any additional parts for installing the starter plunger from the KLX300 on to my 2008 KLR650 carburetor? Or do I just remove the choke cable attachment and install the choke plunger?
I've not done this on a Generation 2 bike, so hopefully someone can chime in to show if they're the same as a Gen 1 carb..
Anyway, on my 2002, I removed the choke cable (I broke the lever, which is why I did this in the first place) and removed the nut that screws into the carb. Then just screw the plunger/nut into the place where the cable/nut was located..
It's a little tough to get at, since it only sticks out of the carb by 3/4" or so, but once you get used to it, you'll find it without looking.
It's got a detent on it, so you pull it all the way out and start the bike.. Let it run long enough so it'll idle without the choke (15-30 seconds, depending on bike and temp) and then just give it a little push and it pulls in to the no-choke position.
The first couple times you use it, it'll feel a bit stiff and you won't think you're ever going to pull it out far enough for it to hit the detent.. After a couple times you don't even think about it. Mine's been on my bike for 4 years and I used it just this morning..
Cheaper than the cable and you can't break it if the bike falls over on soft dirt, which is how I broke my lever.