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Author Topic: Broken choke cable - DR650  (Read 570 times)

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Offline eikeboom

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Broken choke cable - DR650
« on: September 26, 2011, 11:49:44 pm »
My DR's choke cable broke over the weekend. My DR likes some choke in the morning, so it takes a while to get going in the morning. It has corroded inside the sheath and broke somewhere in the middle. It seems that water can enter the sheath from the top when the choke lever is pulled open, so this is something to watch out for guys.

But now to fix it.
The cable enters the carburettor body, no external mounting as with the throttle cables. I am not keen to open up the carburettor, its not really my cup of tea. Would this be a cable that one can have made up, or would it be more wise to buy a new one? I  wonder how many of you have seen the carburettor end of the cable.
What do you guys recommend?
Let's go into the mountains...there's likely to be peace and quiet
 

Ganjora

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Re: Broken choke cable - DR650
« Reply #1 on: September 27, 2011, 03:24:19 am »
get a price on new 1st,  then decide - a made up one will be about r120.
be very careful when removing the fitting from the carb side,
there's a horrible plastic bolt which breaks easily.
 

Offline Wildcoast

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Re: Broken choke cable - DR650
« Reply #2 on: September 27, 2011, 07:42:08 am »
The other pricey option is to order a replacement choke knob from procycle etc. That totally illiminates cables and screws directly on to the carb.
 

Ganjora

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Re: Broken choke cable - DR650
« Reply #3 on: September 27, 2011, 07:45:01 am »
The other pricey option is to order a replacement choke knob from procycle etc. That totally illiminates cables and screws directly on to the carb.

i have a spare choke cable as well as the choke knob from procycle...
 

Offline Wildcoast

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Re: Broken choke cable - DR650
« Reply #4 on: September 27, 2011, 11:58:29 am »
My DR's choke cable broke over the weekend. My DR likes some choke in the morning, so it takes a while to get going in the morning. It has corroded inside the sheath and broke somewhere in the middle. It seems that water can enter the sheath from the top when the choke lever is pulled open, so this is something to watch out for guys.

But now to fix it.
The cable enters the carburettor body, no external mounting as with the throttle cables. I am not keen to open up the carburettor, its not really my cup of tea. Would this be a cable that one can have made up, or would it be more wise to buy a new one? I  wonder how many of you have seen the carburettor end of the cable.
What do you guys recommend?
Try having a look for a link to the BST bible on the forum, think its on advrider, link in the many pages of The dr thread, brilliant link for the stock DR carb.
 

Ganjora

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Re: Broken choke cable - DR650
« Reply #5 on: September 27, 2011, 12:11:57 pm »
here's the external fitting for the choke.

the plastic nut screws into the side of the carb.
be very careful,  it breaks easily...
« Last Edit: September 27, 2011, 12:12:53 pm by Ganjora »
 

Offline Wildcoast

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Re: Broken choke cable - DR650
« Reply #6 on: September 27, 2011, 12:18:18 pm »
here's the external fitting for the choke.

the plastic nut screws into the side of the carb.
be very careful,  it breaks easily...
Sorted  :thumleft:
 

Offline eikeboom

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Re: Broken choke cable - DR650
« Reply #7 on: September 27, 2011, 07:58:19 pm »
Hey thanks guys, this is very helpful!
I can have a new cable made up locally, so I'll carefully remove the nut, replace the cable and re-assemble. I wonder if I'll be able to re-fit the plunger assembly without removing the carb though: using a socket to tighten the nut will be impossible with the cable & sheath fitted and sticking through the socket, and swinging a ring spanner won't work there...
What do you suggest?
Let's go into the mountains...there's likely to be peace and quiet
 

Offline chopperpilot

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Re: Broken choke cable - DR650
« Reply #8 on: September 27, 2011, 09:39:46 pm »
I used an open end spanner to "tighten" the plastic nut.

I cleaned everything properly, and sprayed a bit of Q20, before fitting again.

Replaced the cable with a Suz OEM recently. Think about R 250-00 at Motorcycle Mecca in Pta.

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Offline eikeboom

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Re: Broken choke cable - DR650
« Reply #9 on: September 27, 2011, 09:55:49 pm »
I used an open end spanner to "tighten" the plastic nut.

I cleaned everything properly, and sprayed a bit of Q20, before fitting again.

Replaced the cable with a Suz OEM recently. Think about R 250-00 at Motorcycle Mecca in Pta.



Ok great, so no big hassle then. Suzuki charges slightly more for the OEM part.
Let's go into the mountains...there's likely to be peace and quiet
 

Offline lecap

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Re: Broken choke cable - DR650
« Reply #10 on: September 29, 2011, 08:33:51 am »
The handlebar end of the cable is the problem. Attaches to the switch / choke unit with some "non standard" fittinjgs. If you make your own you will have to reuse the old stuff there.
Best to remove the carb to get the choke valve out and in again. You don't want to cross thread that plastic nut. That exactly is also the reason why I don't recommend the generic brass replacements for the DR & KLR carbs choke valve nuts. Broken plastic nut: R 70 or so. Buy a spare if you're concerned. Choke valve thread stripped out of carb :o :o :o

With proper maintenance and care (cable oiler & Q20) and well fitted (no sharp bends, chafing or U-bends) the choke cables last very well. Would not want to swop for a fidgety choke under the tank.
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline eikeboom

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Re: Broken choke cable - DR650
« Reply #11 on: September 29, 2011, 07:42:20 pm »
Thanks LeCap, great advice
Let's go into the mountains...there's likely to be peace and quiet