choke cable issue (stupid problem but a problem none the less)

Hey Guys,

So I replaced an old choke cable on my brother's 80' 650 and it seems like the cable is too long. SO, i purchased a second motion pro one only to have the same issue. The end of the cable at the handlebar side doesn't sit in the holder on the choke lever assembly. Because of this, there is about 1/4" movement on the lever that doesn't do anything. I've tried rerouting, changing the position of the cable end at the carbs, none of it works. It's like the actual wire inside the cable is too long but to have the same issue with 2 different cables is unlikely. Has anybody experienced anything like this or does anybody have any ideas? Thanks!

 

Buy one from Chacal and be guaranteed it is the correct one & guaranteed to fit properly ......sorry your motion pro's......

 

The vast majority of resellers are unaware that there is more than one sub-model of XJ.
Return the cables for a refund, and get the correct one from @chacal

 

hmmm. worth a shot i suppose. Thanks

 

Any chance you got an enricher cable instead?

 

SO....I ordered the cable from chacal. it was the same length, so the problem doesn't appear to be the cable. that being said.... what else is there haha. i'm trying to upload photos but photobucket is a bucket of garbage now. super glitchy, not working what so ever. what do you guys use to post photos now?

 

here's what i'm dealing with

 

Okay here is one thing the ferrel on the cable should be in the bracket this will pull the cable a little more taught , also look at the routing of the cable under the tank , I used some zip ties on mine to keep the cable from backing out of choke lever.

 

Other thing I see is your mirror is on the wrong side the one you show in the picture is a left hand thread( the nut has notches that indicate left hand thread) that one goes on the right hand side.

 

yeah the problem is its the inner cable length thats too long. where the barrel sits needs to be extended or something, where the sheath is doesn't matter, pics were just to show the issue, it was sitting in the bracket before.

good eye! it's my brothers bike and I haven't spent too much time actually looking at the other stuff yet, mainly just trying to get the thing running. thanks!

 

anybody else have any ideas? I've been talking to chacal and we couldn't seem to figure it out. I'm almost wondering if the switch housing that the lever is in is similar but not the exact correct one? I'm not sure, this is really perplexing me. It should be simple but there is obviously something going on.

 

shorten the cable
one of these would work depending on the size of the cable.
https://www.dubro.com/collections/e-z-connectors/products/e-z-connector
this place has all that kind of stuff
http://www.flanderscables.com/index.html

 

Bizarre, I just went and looked at mine and the bracket looks correct etc. Can you unscrew the choke lever from the bottom of the switch housing and send some pics? I can compare to mine. Worst case I will pull my cable out and measure cable length at the ends etc. for you.

 

interesting, irritating that I need it though. i feel like something is wrong still.

I can get a pic of that yeah, everything seems good there. I bought a motion pro one AND one from chacal and they were both the exact same so that leads me to believe that the cable is ok

 

I ordered one and its on the way thanks!

Does anybody have any other ideas? seems really bizarre that I would have to shorten the cable from chacal. something is going on, I just can't figure out what!?

 

Will the thumb lever take a cable adjuster screw?

 

is the choke arm properly installed on the choke rod?

 

This is the adjuster I was thinking of.

 

no it won't fit

I think so yeah

 

choke arm held in place with a screw through rod it has tobe correct.

looks like your grips are after market and short . move the perch about 12 mm then outer cable should connect

 

moving the perch won't matter as its the inner cable thats too long. I would a need a new perch that sits the cable housing to sit farther back. i wonder if it is aftermarket or from another similar bike.... hmmm

 

so , how does the new cable compare to the old one?

 

he purchased a moyion pro then a cable from chacal his cable should be correct.
I am thinking it is a routing issue combined with after market grip issue.

it is ok if there is no action when first moving lever as long as it opens the plungers full. you may be over thinking this.

also there are ways to shorten cables from kits to cutting the end off and and smelting a ne slug onto the cable.

https://www.motorcycleforum.com/169-how/102449-how-make-your-own-custom-length-control-cables.html

 

follow the "starter cable"

 

your handle bars are not stock are they??

 

The inner cable isn't too long. The sheath and the inner cable are a matched set, and it's the sheath that has to be of the correct length to keep the control end in its recepticle.
You have a cable routing issue, not a cable issue.
The controls you have are stock.

It's not clear in the routing illustration, but the choke cable exits the frame on the right side, then curves around infront of the headstock before going to the left bar.

 

Wouldn't be anything to do with the grips, the bike could be gripless and it still wouldn't affect the cable. The outer sheath is held in it's "slot" on the same switch housing that has the lever on it as well. It could be hanging from the bike and not mounted to handle bars and still would work.

I'm not clear on how it could be a cable routing issue. The outer sheath is held in place by the clamp at the carb and the slot on the control housing. How would changing the routing of the cable affect him here? I understand throttle cables getting pulled out of the holder when you turn bars when the cable is route too tight, but that is not the case here as the choke/enrichener is off and the cable is still too slacked.

I'd still like to see some pics of the choke lever unscrewed from the housing. See if something is amiss there.

 

I don't understand how it could be a routing issue. its a set length. as mentioned the controls could be hanging from the bike and still work. enlighten me if i'm missing something?

I keep meaning to get that pic but keep forgetting. will try tonight. i'm pretty sure all is good on that end, i'm almost thinking that the controls are not original and maybe from a similar-ish bike so they look the same however are slightly different. the holder for the cable sheath needs to be extended or something.

 

er?
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cg82 said: ↑
So I replaced an old choke cable on my brother's 80' 650 and it seems like the cable is too long
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so , how does the new cable compare to the old one?

 

don't remember to be honest. it was basically destroyed and seized right up when we got the bike so i tossed it in the garbage without a second thought. long gone now

 

OK. It's not a routing issue.
I have the same cable and it fit fine, so maybe Motion Pro messed up.

[EDIT] By same cable, I mean the model specific cable from Motion Pro. I also used a Motion Pro cable on a not-customer's 650 Maxim and it fit as well.

 

if a guy put the lower end in the holder, put the cable straight to the control, no routing just make it fit. hook it in and try it.
if it works as it should, it's routing. if it won't work the chokes it's a cable problem

 

what cable did you order? in your photos your handle bars do not look stock, tthat would be the reason your brothers cable was to long.
1980 650 bar ends would be pointing to the ground not like shown in your photo.

he also got a cable from chacal and said both were the same lengths

 

Took some pics for you tonight. Stock everything except handlebars but doesn't matter. Different bars only require a different cable if you can't route it effectively.

Cable at carb with choke off:



Cable at carb with choke on:



Stock control for comparison:



The choke lever:



Cable length with choke off:



Cable length with choke on:



Overall outer sheath length (irrelevant to problem really):

 

That's where I got my cables, and they were both Motion Pro brand.

 

i think it somehow must be the handlebar controls. i bought one of those kits to shorten the cable, i just really hate having to do that. i may try to source some new handlebar controls

 

he never said what cable he got from chacal. if he just got a shorter than stock one that may be the problem.
his Brothers cable was to long because it is not stock handlebars.

a good measurrement of the stock cable getting the length that the cable extends would give hin somthing to compare to his chacal cable
JayRodh has done this in his photos above.

outside sheath does not matter could be 10 feet long it is the inner cable that counts looks like choke off 1 inch to the slug is what he needs

cg82 photo shows a lot more than an inch exposed when choke is off.

 

i bought a motion pro cable off ebay AND a cable from chacal. both were exact same length.

 

for what bike and model ?
your handel bars do not look stock to me?
possible that a Seca 650 cable may work for you, it should have the same exposed cable length as a 650 maxim.
it all depends on the bars

 

XJ650 Maxim and Midnight Maxim models. Wire length = 40".
for all XJ650 Euro and XJ650RJ Seca models. Wire length = 34-3/8".

exposed length should e the same for both above cables as they use same controls and carbs

you could try adding a tube to the end to shorten your exposed wire

K&S brass tubing may work each size is built to fit inside the next size up cut a slot in both tubes for the cable

 

ok, so i'm still having this issue. moved on for a bit a rebuilt the carbs but now i'm back to trying to figure out wtf is going on. I took some measurements,
cable sheath : 37-1/16"
inside cable not counting barrels: 39-1/2"

its not the routing BUT i figured, i would try everything so i routed it as per diagram above and as k-moe said and exited on the right side and wrapped around. neither made a difference. is anybody willing to measure the inside wire of their cable for me? such a dumb problem haha

 

Updated for pics

 

I have a non-standard setup and had to make my own cable(s) so I can't help with the measuring but... if you have an inner that is too long you are half way there.

1. Cut one end off, have a go at drilling it out from the other side and end up with a end with a hole through it and chamfer it on the outside also.
2. Put the cable in place with the end on it loose and slide it to the right spot and mark it.
3. Cut the inner to length when on the end and fray the very end a smidge to sit in the chamfer.
4. Bronze or solder the end back on to the cable (flux is good but remember to clean afterwards).
5. Grind or sandpaper the end to get it back to the right shape if need be.
6. Done.

PSthe brass computer motherboard stands work pretty good as something to drill a hole through,bronze on and drill/grind to shape also if you run into issues with the existing end.)

 

That cable is way too long. I didn’t measure my inner length but you can tell just by looking at my pic where I measure the outer sheath, it was lying on the ground for that picture. I’ll happily measure it later if you like, it is still off the bike.

 

that's what I don't understand, its the cable from chacal.

 

you have a maxim but your bars do not look like maxim 650 bars that is 1 of your issues

https://www.partzilla.com/catalog/yamaha/motorcycle/1980/xj650-xj650g/handlebar-cable

 

sheath 37 inches cable 39 inches 2 inches exposed cable cable side of barrels I just picked up a set of controls with cables for the measurements given
now I have to remove a cable from my 650 to see if they match will post that info

HCP2645 Aftermarket CHOKE CABLE, for all XJ650 Maxim and Midnight Maxim models. Wire length = 40".

 

if you clamped the knurl adjuster in the carb choke bracket it may give you the extra distance to make choke cable work

 

Cable routing doesn’t matter for this issue, the cable could run through the rear wheel with the control sitting on the ground and it should still work as expected. Cable routing is an issue when things pull on the sheath in turn pulling the cable out of the holder. A tight throttle cable that gets tugged on when the bars turn is a good example.

 

I like this idea but I think his cable is waaay too long.