1980 xj650 Choke lever issue

Hey guys,

here is my issue. 1980 xj650, PO really bastardized it. I ordered a replacement choke cable as last one was frayed and junk. I went to install it and had the following issues. The actual cable appears to be about 1/2" too long, I'm not sure if maybe the PO replaced the switch with a similar one but a litle different. also, the choke rail/springs on the carb pull the cable back so it won't stay open. I feel like I'm making a dumb mistake but can't see it. Would somebody mind posting a pic of their choke switch so I can see if what I have is correct. Thanks!

 

You ordered your cable from XJ4Ever - yes?

I should be able to post a couple pics tonight.

Curious - what happens when you twist your throttle and let go - Do you hear the butterflies snapping shut?

 

no i didn't order from len but have since talked to him to confirm the cable is the correct length. yeah the butterflys snap shut. upon further investigation there is supposed to be a spring in the choke lever assembly that I do not appear to have. however I'm not 100% sure thats going to fix my problem. pics would be appreciated!

 

The only spring in the handle is a "star" shaped spring that merely keeps he rotary handle pushed away from the bottom of the control switch housing, also acting as a "lockwasher" of sorts. There is no "return" spring within the choke cable/switch system, besides the plunger return springs inside the carb bodies.

 

ugh, i'm not sure then. why else would you have to hold the lever in the "on" position? there has got to be something i'm doing wrong/

 

as chacal stated
because the star washer is missing or worn out. the enrichment plungers have springs inside them that will pull the lever back

or your screw is too long or missing the washer under the head
you may be able to sub in a wave washer for the star washer if your local hardware stores carries them

or ask chacal he sells the correct washers and screw
HCP3568 OEM choke lever SPRING WASHER, special flat washer that mounts underneath the choke lever (between the lever and the control switch housing). Used on all XJ550, XJ650, XJ750, and XJ1100 models.

HCP3575 OEM choke lever mounting screw FLAT WASHER, used under the screw listed above. Used on all XJ550, XJ650, and XJ750 Seca models.


HCP3571 OEM choke lever MOUNTING SCREW, holds the lever to the control switch housing. Natural finish. Used on all XJ550, all XJ650 models, all XJ700, all XJ750 Seca, and XJ750-X models.

 

seca 550 pic

and part numbers to try at dealership


screw not available at dealer by that part number but the washers are

 

i'm gonna look closer tonight. i feel like I have all of those parts there but i'll see and report back! i've gotta be doing something stupid here. its such a simple thing

 

add a washer to screw or buy a shorter screw could just be the PO went to store and got a screw to long

 

Here are a few pics (sorry about the one out of focus one - hope this helps . . . .

Note the pic that is showing where it connects to the carbs - I found that if I do not have the sleeve end of the cable sheath positioned as shown that the other end on the handle bar falls out.