Choke Cable - 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 8 Old 06-24-2010, 04:26 PM Thread Starter
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Choke Cable

Any place on the internet to buy a new choke cable for a 88 klr 650. Can't find one anywhere. Broke the plastic nut that screws into the carb. What a PITA.
Thanks Again (The responses to my fuel in the airbox and cylinder problem were very helpful)
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post #2 of 8 Old 06-24-2010, 05:50 PM
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post #3 of 8 Old 06-24-2010, 07:55 PM
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You can also get a metal replacement for that nut.
http://www.steadengineering.com/
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post #4 of 8 Old 06-24-2010, 09:50 PM
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Or you can skip the cable and just get a choke plunger that mount in the same place.
Just reach under the tank and pull the spring loaded plunger.. Once warm, give it a quick push and it's ready to ride..

It's a plunger from an older KLX 250 or 300.. Can't remember.. I hate getting old..

Go to http://www.kawasakipartshouse.net/pa...FQQMDQodfmWg5g

Part number 16016 $23.46 and if you check around, I'm sure you can find it cheaper..

I looked at both 250 and 300 KLX carbs and it's the same part.
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post #5 of 8 Old 07-06-2010, 07:09 PM
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I just ordered the metel choke cable nut, does it come with instructions on how to take the plastic one off and the new one on? thank you...julie
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post #6 of 8 Old 07-09-2010, 01:55 PM
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starter plunger

Quote:
Originally Posted by Paper View Post
Or you can skip the cable and just get a choke plunger that mount in the same place.
Just reach under the tank and pull the spring loaded plunger.. Once warm, give it a quick push and it's ready to ride..

It's a plunger from an older KLX 250 or 300.. Can't remember.. I hate getting old..

Go to http://www.kawasakipartshouse.net/pa...FQQMDQodfmWg5g

Part number 16016 $23.46 and if you check around, I'm sure you can find it cheaper..

I looked at both 250 and 300 KLX carbs and it's the same part.
Paper
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?
Additional instructions will be appreciated!
Thanks

Last edited by pismocycleguy; 07-09-2010 at 01:56 PM. Reason: addition
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post #7 of 8 Old 07-09-2010, 02:02 PM
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Quote:
Originally Posted by pismocycleguy View Post
Paper
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?
Thanks
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.
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post #8 of 8 Old 07-09-2010, 11:44 PM
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Quote:
Originally Posted by julies klr650 View Post
I just ordered the metel choke cable nut, does it come with instructions on how to take the plastic one off and the new one on? thank you...julie
No, it does not.

Take a long handled 90 degree pair of needle nose pliers. Unscrew the factory, all you should have to do is spread the it apart and it should come off. Then slip the new one on. I was able to save my factory and carry it to tech days. You might want to test fit the metal nut before running the choke cable through it.
Not that hard to install took me just a few minutes.

Craig
KLR 650 - A18
Triumph Sprint ST - 2008
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Polaris Sports Man 400 HO 4x4
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