A cure for a cluster-ferrule! - Kawasaki KLR 650 Forum
Gadgets & Gizmos Discussion on the latest "toys" to enhance the adventure.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 33 Old 01-29-2013, 11:17 PM Thread Starter
2nd Gear
 
PNWcrazymike's Avatar
 
Join Date: Dec 2012
Location: Bend, Oregon
Posts: 108
A cure for a cluster-ferrule!

I was performing the "22cent mod" this week and everything went smoothly... Except when I maneuvered the carb the second time to fine tune the air mixture screw. I wasn't thinking about the choke cable and heard the "snap" you don't want to ever hear. If you (or your mechanic) ever clean the carb, change the jetting, install or adjust the 22cent mod, there is a really good chance the plastic ferrule where the choke cable enters the carb is going to break.

It's the weakest link for the whole system: The choke cable has a steel 90 degree radius "noodle" that directs the choke cable into the carb. It's about three inches long thus has enough leverage when bumped (and you WILL bump it) to crack the plastic ferrule. Once cracked, air gets sucked in around the cable which throws all carb adjustment off. Kawasaki only offers the ferrule in a kit with a new seal, spring and brass choke plunger for $62.

1. You'd be buying a bunch of parts you'll never need and 2. It's the same weak plastic ferrule. This made no sense to me so I googled around to discover a stronger aluminum ferrule is available for less than half the price! I received this most valuable piece of farkle within days, installed it and the bike is now 100%!

I'm only ranting because I couldn't believe Kawasaki would make such an important carb component so fragile, and what a fantastic piece of preventive maintenance this aluminum ferrule is!
-crazymike

Last edited by PNWcrazymike; 01-29-2013 at 11:23 PM.
PNWcrazymike is offline  
Sponsored Links
Advertisement
 
post #2 of 33 Old 01-29-2013, 11:27 PM
Moderator
 
klr4evr's Avatar
 
Join Date: Mar 2007
Location: Fort Sask , Alberta, Canada
Posts: 3,439
Garage
Send a message via Skype™ to klr4evr
Maybe link us to the replacement part. I know I have seen it but alas I haven't broken mine yet LOL.

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. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

This information makes it much easier for other members to answer/comment on your posts.
klr4evr is offline  
post #3 of 33 Old 01-30-2013, 12:27 AM Thread Starter
2nd Gear
 
PNWcrazymike's Avatar
 
Join Date: Dec 2012
Location: Bend, Oregon
Posts: 108
PNWcrazymike is offline  
 
post #4 of 33 Old 01-30-2013, 12:30 AM Thread Starter
2nd Gear
 
PNWcrazymike's Avatar
 
Join Date: Dec 2012
Location: Bend, Oregon
Posts: 108
BTW, I LOVE your signature klr4evr! So true!
PNWcrazymike is offline  
post #5 of 33 Old 01-30-2013, 12:37 AM
2nd Gear
 
jazzman's Avatar
 
Join Date: Jan 2013
Location: Lincoln, NE
Posts: 123
Thanks for the link, looks like a smart upgrade. Bookmarked it for later!
jazzman is offline  
post #6 of 33 Old 01-30-2013, 08:11 AM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,314
I haven't broken mine yet, but may go ahead and replace it because, as the details note, "It also looks way more trick than the original plastic part!" I can hear the praise now, "Man, that's one nice-looking aftermarket choke cable ferrule you've got on there!"

Seriously, though, it strikes me as a fine and worthy product, though I must say if I were to consider buying one, I would most likely spend the extra $15 and try their Cable-Less Choke Conversion Kit and just get rid of the entire handlebar-mounted choke system altogether even though some on here have ingeniously cobbled together their own direct-mount choke levers for probably less. Even so, I wouldn't have a problem spending $43 to get rid of the cable and handlebar lever.

This may very well go on my list for next year. I've been wanting to do it for awhile but didn't want to mess with scrounging around for Harley or lawnmower parts or whatever is needed for a DYI "direct drive" choke actuator as I'm too lazy to MacGyver one up.

Cable-less option ramblings aside, thanks for the link on the metal ferrule for the standard setup. I would think it falls into the "If I don't need it right now, I might as well buy one and keep it around" category. Good info.



planalp is online now  
post #7 of 33 Old 01-30-2013, 08:14 AM
4th Gear
 
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
I've been installing those little plastic replacements for years.....Yes it's stead that has them.....I thought it was common knowledge....sorry....

They are an excellent product and nice guys to deal with. An expensive little item but solves the nasty snap you will hear sooner than later! Plus the threads will not strip out like the plastic ones will if you start them wrong. It is easy to feel it going in incorrectly with the new one compared to the plastic junk. If you bend a 12 or 13 mm wrench in a 90 degree angle you will have a tool that easily deals with this problem too. The bend has to be as close to the head of the wrench as possible to get it where it needs to be.

Hope this helps......

Willys
willys is offline  
post #8 of 33 Old 01-30-2013, 10:24 AM
Moderator
 
klr4evr's Avatar
 
Join Date: Mar 2007
Location: Fort Sask , Alberta, Canada
Posts: 3,439
Garage
Send a message via Skype™ to klr4evr
Going with the cable less choke would be the way to go IMO.

Wonder what shipping to Canada would cost?

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. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

This information makes it much easier for other members to answer/comment on your posts.
klr4evr is offline  
post #9 of 33 Old 01-30-2013, 12:17 PM Thread Starter
2nd Gear
 
PNWcrazymike's Avatar
 
Join Date: Dec 2012
Location: Bend, Oregon
Posts: 108
I like the idea of the cable less version but I have a 2nd generation KLR. The choke lever is is incorporated into the same housing as the light switches. If I went cable-less I'd still have a choke lever located on the bars. The cable-less chokes ARE kinda hard to find when you have heavy gloves on (winter is when you need the choke the most) and I do like the convenient bar mounted switch.

I only WISH I had one of these ferrules on my work bench before I cracked the plastic one! This cost me three days of riding because my two days off from work were too cold to start the bike without a choke, had the charge the battery three times and once I finally got it started I didn't DARE shut it off because I'd never get it started again. The shipping is pretty inexpensive because they use USPS. It all came to $32 and I would have paid double to have already had one!
PNWcrazymike is offline  
post #10 of 33 Old 01-30-2013, 12:30 PM
4th Gear
 
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
I used to stock these and the thumb screw for the pilot jet....but people bitched so much about the cost and I wasn't adding anything to the cost, I make my money installing items and repairing etc....not on distributing parts....so I stopped stocking any parts at all now.
Both of these little gems are a great thing to have when it matters but try and explain that to someone who doesn't think they are important!

I'm glad people are reading of someone's misfortune, no offence......it just brings it back to the forefront so perhaps people will understand what us old timers know that can help you down the road so to speak.

I had the same thing happen to me......that is why I started stocking them.

It's a real piss off when you could be riding and it's a stupid little item like this that keeps you from riding .......

Willys
willys is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Cure for Anemic horns larry31 KLR & Other Motorcycle Related Discussion 16 07-04-2012 09:14 AM
Loose instrument cluster NorCalKLR 1987 to 2007 Wrenching & Mods 4 09-14-2007 07:38 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome