How to Remove a Steering Tube mounted Choke

[pbdavey]

I have a 650EX and the plastic threaded assembly snapped apart. I'd like to replace it, but when the plastic lever assembly is unscrewed, the choke won't come out the top. Is there an easy way to remove it? Or is it easier to hack the cable off and install a different choke mechanism?

[BassCliff]

Hi Mr. pbdavey,

If you don't have one, download a manual from my website. Hopefully it will show you how to disassemble without hacking it apart. Keep us informed.


Thank you for your indulgence,

BassCliff

[chef1366]

Unhook it from the carbs. Unscrew it from the steering stem bolt. Pull it out from the top. You'll have to remove the tank to do this.

[JayH]

Unhook it from the carbs. Unscrew it from the steering stem bolt. Pull it out from the top. You'll have to remove the tank to do this.

Do like Chef said cause you are going to have to order a a new cable anyway. When you get the new choke cable from Suzuki it will have all the plastic parts that you broke as well as the cable.

[pbdavey]

Really?

Mmm...maybe I didn't pull hard enough then :-D, I'll try again tonight.

My carbs are off, I'm in the middle of putting them back together after a cleaning (going from the intake boots back to get this thing running).

The choke cable wasn't moving in it's housing when the lever was pulled, but rather the entire housing would move. Then I broke the plastic ...oh well. I just get quite a bit of resistence to pulling the plastic assembly out.

-Phil

[pbdavey]

the housing below the plastic assembly was exploded so I couldn't actually fit it through the small hole in the top of the steering tube! So hacksawed the choke plunger and it easily dropped out the bottom. So that's why I thought there was magic to it.

QUESTION:
I got a replacement choke. I held the plastic threaded housing w/ one hand and pulled the choke plunger with the other just to check it's action. I pulled it out a small amount but now it won't budge...I can't imagine playing with the plunger while no force is on the other end would break it, but did I? I'd even say that the plunger moving out a small amount didn't move the cable at all. Sound like a return? Did I mess it up?

[chef1366]

Loosen the ridged wheel. This should release it.