KLR Choke Plunger - Compatible Parts - Kawasaki KLR 650 Forum
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post #1 of 12 Old 03-24-2015, 08:40 PM Thread Starter
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Question KLR Choke Plunger - Compatible Parts

Hey folks,



First up -- confession: I'm not a KLR owner. I have a DRZ400SM that I'm putting the CVK40 carb in from yall's KLRs...what can I say, it's a good carb off a good bike!


The trouble is the choke plunger...they're kinda spendy.
The compatible parts that I've found are

16016-0013
16016-1068
16016-1085

(based on ADVRider, TT, here, and KLR650 net)

However, on RonAyers, there's a whole HOST of Kawasaki 16016 parts....
including some that sell slightly cheaper on the eBays.

Obviously I want to buy one of the cheaper ones BUT...
I don't know which of the 16016 series is compatible with the KLR carb.

Does anyone have any input about what other choke plungers / starters are compatible in this role?
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post #2 of 12 Old 03-25-2015, 06:15 AM
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Why not try a Harley CV40 choke plunger?

I have a Harley "shorty" choke cable (Drag Specialties); works fine on a Kawasaki CVK40 carb from the "pull" end; the plunger may be identical.

Just to clarify: Keihin Harley carb: CV40
Keihin Kawasaki carb: CVK40

Similar, many interchangeable parts, except . . . CV40 has accelerator pump, CVK40 does not. Other differences may exist.
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post #3 of 12 Old 03-26-2015, 12:02 AM Thread Starter
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hey Damocles!

I thought of that, but the 12" whip or so would be a nightmare to deal with.
The carb isn't so buried on a DRZ... it's just kinda right there, so the Harley choke setup would kinda of hang off the bike pretty oddly--unless I could mount it somewhere...

I'd heard about the model differences... I know the airbox mount
is totally different on the CV vs the CVK.
I do wonder if the pumper CV would be a nicer upgrade on the little DRZ...

thanks for the thought!!
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post #4 of 12 Old 03-26-2015, 06:19 PM
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Quote:
Originally Posted by rogueguineapig View Post
hey Damocles!

I thought of that, but the 12" whip or so would be a nightmare to deal with.
The carb isn't so buried on a DRZ... it's just kinda right there, so the Harley choke setup would kinda of hang off the bike pretty oddly--unless I could mount it somewhere...

I'd heard about the model differences... I know the airbox mount
is totally different on the CV vs the CVK.
I do wonder if the pumper CV would be a nicer upgrade on the little DRZ...

thanks for the thought!!
Ain't no thang about the Shorty cable, rogueguineapig:



I trimmed the stem (knob permanently attached) because I wanted less outboard projection, then threaded for a screw-on knob; drilled a hole in the kickstand switch cover and wound up with this:



Not trying to proselytize you on the Shorty "choke" cable (although it's convenient, doesn't interfere with the legs, and eliminates the troublesome elbow near the attachment point with the carb); I just mentioned: The KLR enricher plunger fit the Harley cable like it was made for it, suggesting to me the Harley (CV40) plunger might work with a KLR, at considerably less cost than a "genuine" Kawasaki part.

Best wishes!
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post #5 of 12 Old 03-26-2015, 06:29 PM
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That yardstick looks like a collector's item.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #6 of 12 Old 03-26-2015, 06:51 PM
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Quote:
Originally Posted by klr4evr View Post
That yardstick looks like a collector's item.
Since Montgomery Ward has been bankrupt since about 2000, the yardstick is rather dated, I suppose!

A relic of a time when the INCH was a unit of length measurement.
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post #7 of 12 Old 03-26-2015, 08:38 PM Thread Starter
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Montgomery Ward... methinks I've fired one of their fine weapons at some point in the past...

So I've attached a photo of the DRZs current carb (the KLR CVK will sit in the same spot)
and I think you can kinda make out my dilemma about the cabled choke plunger.
I'm certainly not against it by any means... but my understanding is that it would cost
about the same as a 16016 part, but create an interesting issue because of the length.
Literally add an inch (or 25.4mm if you prefer) to the existing plunger and it's sticking out well past the frame/plastics, etc.
That's what I'm running into.
I really like the way you implemented yours though...that looks great!

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post #8 of 12 Old 03-26-2015, 10:18 PM
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Quote:
Originally Posted by rogueguineapig View Post
So I've attached a photo of the DRZs current carb (the KLR CVK will sit in the same spot)
and I think you can kinda make out my dilemma about the cabled choke plunger.
I'm certainly not against it by any means... but my understanding is that it would cost
about the same as a 16016 part, but create an interesting issue because of the length.
Silly me; I somehow didn't catch the fact you're considering 'implanting" a CVK40 on a DR or DRZ or something; I was blinded by KLRiana!

Maybe you mentioned it, and I overlooked it, but . . . what's the advantage of a CVK40 to Suzuki stock carbs? EDIT: Just re-read first post on thread; isn't a 40 mm venturi somewhat outsized? Maybe not; what was OEM venturi diameter? 34 mm?

Regardless, Harley CV40 parts generally cost less than Kawasaki CVK40 parts, even though they may be identical.

Last edited by Damocles; 03-26-2015 at 10:22 PM.
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post #9 of 12 Old 03-26-2015, 11:08 PM Thread Starter
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haha no worries!!

I'm not sure about exact diameters...it is supposed to be a tight but doable fit.
A lot of the DRZ-heads (Zed-heads?) over at ThumperTalk have done it actually.
At my altitude (Phx) they usually open up the airbox with a 3x3 and do a 148MJ and a 40 or 42 PJ.
The needle gets washered up, or set to the 3rd notch usually.
It's been a long time since I saw dyno numbers, but it does give a nice kick to the mid-and-upper range HP,
and the low range benefits from a lot better responsiveness after the slide gets drilled out a tad.
It's a nice upgrade from stock, and while not as much punch as a Keihin FCR, it's also about $300-400 less, which is nice.
Just one more way to squeeze a little more hooligan out of the DRZ.

Last edited by rogueguineapig; 03-26-2015 at 11:26 PM.
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post #10 of 12 Old 03-27-2015, 07:01 AM
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Quote:
Originally Posted by rogueguineapig View Post

I'm not sure about exact diameters...
From Suzuki specifications, 36 mm. 40 mm may not be an excessively large leap.

Please let us know how the CVK40 implant works!
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