I didn't break my plastic barrel connector at the end of the choke cable, but I did plumb wear the threads off of it. It got to the point of being a regular pain in the butt. I have another one in my spares, but enough is enough.
There are a couple of solutions out there. One is the Kawasaki choke plunger, but it has the same sort of plastic barrel.
Another is the Stead Engineering alloy barrel, but with that there's still the whole choke cable thing going on. I will be putting the oil gauges back on at some point and the cable elbow gets in the way of the fitting and pressure line coming off the banjo bolt at the head.
Then there's the Harley choke, but I didn't have an easy place to mount the bracket for the cable.
Stead has a choke plunger that is all brass that I decided to try.
Here's what you get in the kit:
I've disassembled the unit so you can see the pieces. The kit comes with two grub screws to set the plunger friction.
This is what it looks like coming out of the package:
The first thing you do is take the tip and spring off of the stock cable and install it on the end of the plunger shaft:
Then you have to remove the grub screw, as it runs onto the carb vent when screwing it into the carb body:
Screw it in, snug it down a wee bit, and install the grub screw. You'll need to hold the plunger out a bit to get the first threads engaged in the carb body.:
Snug the grub screw down just a bit and pull the plunger out. Back off on the grub screw until the plunger just slips back in under the spring's pressure, then tighten the grub screw one millionth of a turn; that is just about the right tension on the plunger.
That's all there is to it!
It should be easy to reach with a stock tank and petcock. With the Raptor petcock on my IMS it takes a bit of reaching in, but it's not a huge problem. I will be doing a bit of trimming on the cover to make it easier to get to. The current cut-away was for a fuel line clearance; the second petcock has been moved.
I think that the Stead piece is very solid and quite well made. The only thing I might change is to pull it back out and install something like a small bridle ring
to make it easier to pull out.