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

Discussion in 'XJ Technical Chat' started by cg82, Sep 22, 2018.

  1. cg82

    cg82 Member

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    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!
     
  2. fiveofakind

    fiveofakind Well-Known Member

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

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    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
     
  4. cg82

    cg82 Member

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    hmmm. worth a shot i suppose. Thanks
     
  5. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Any chance you got an enricher cable instead?
     
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  6. cg82

    cg82 Member

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    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?
     
  7. cg82

    cg82 Member

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    here's what i'm dealing with
     

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  8. Jetfixer

    Jetfixer Well-Known Member

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    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.
     
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  9. Toomanybikes

    Toomanybikes Well-Known Member

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    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.
     

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  10. cg82

    cg82 Member

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    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!
     
  11. cg82

    cg82 Member

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    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.
     
  12. Polock

    Polock Well-Known Member

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  13. jayrodoh

    jayrodoh YimYam Premium Member

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    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.
     
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  14. cg82

    cg82 Member

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    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
     
  15. cg82

    cg82 Member

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  16. Boyne

    Boyne New Member

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    Will the thumb lever take a cable adjuster screw?
     
  17. XJ550H

    XJ550H Well-Known Member Premium Member

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    is the choke arm properly installed on the choke rod?
     
  18. Boyne

    Boyne New Member

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    This is the adjuster I was thinking of.

    images.jpeg
    [​IMG]
     
  19. cg82

    cg82 Member

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    no it won't fit

    I think so yeah
     
  20. XJ550H

    XJ550H Well-Known Member Premium Member

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    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
     

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