Help/photos needed of XJ900 choke setup+other?

Howdy folks. I trust everybody had a good Xmas. Since I'm off till Jan 02/08, I'm continuing my task of trying to bring my XJ900 basketcase back from the dead.
After a mighty struggle I finally managed to get the rubber airbox boots onto the back of the carbs. An earlier battle was getting the carbs onto the manifold rubbers. Man, what a struggle! You've got about the width of a gnat's perenium to work with. I found that heating the rubbers up before trying to coax them onto the carb ends helps a lot. Also, I had to install them through the airbox. Seriously. It was the only way.
You can also undo the airbox itself and get it to move back about an inch, which also helps a bit, but geez, Yamaha could have provided a BIT more room!

Next I have to hook up the choke cable. I got it attached okay at the handle bar with that stupid round plastic thing that controls it. Why couldn't Yamaha just have used a regular choke lever?

The trouble is at the carbs themselves. The cable comes down to the carbs but then has to make a hard right turn (as you're sitting on the bike) to reach the choke rod, which moves sideways.

Whatever dohicky was there originally to hold the cable to the tops of the carbs is long gone. I guess I could fabricate something but while trying it out, I found that the choke rod is under enough pressure to pull the choke cable back out everytime I pull it in.

In other words, you can't turn the choke on half way. To make it work I have to pull it on all the way and hold it there, otherwise it just pulls back to it's normal position- not exactly SOP.
So if anyone has any photos/diagrams/info on how to set up the choke cable at the carbs, I'd be mightily obliged.

Also, I've figured out all but one of the hoses coming out the back of the carbs. There are four thinner vinyl overflow hoses coming off the floatbowls. They run down past the swing arm and would empty onto the road. Then there are two thicker rubber gasline hoses that run up toward the tank. I bought a brass t-connector and hooked them up. They attach to clamps on the tops of the carbs.
But then there's another rubber gasline hoses under the gasline hose between carbs 1 and 2. This I have no idea where it goes. I check the underside of the tank. Nothing. The petcock just has connections for the main gasline and the vacuum which runs from carb number 3. If anyone can tell me what this mysterious third gasline hose is for, I'd appreciate it.

As for the exhaust, the headers have some surface rust on the backside but not in bad shape. I may eventually have them rechromed rather than get a 4-into-1 system. But the endcans were toast and sounded like cucarachas when shaken.
So I put on a pair of fairly good endcans from an 85 Honda 750 Sabre I used to own. They went on nice and tight and look pretty good.

So far:
Valves checked & reshimmed where needed.
New NGK spark plugs/caps/cables.
Carbs cleaned and rebuilt.
Forks rebuilt/black rubber gaiters installed.
Front and rear calipers rebuilt with new semi-metallic pads
Disc thickness measured and okay
New headlight and surround (thanks Rickomatic)
New Silvana BrightNight halogen headlight bulb
Renntec rear sport rack finished in black satin (thanks Rich DeZago)
Rims cleaned and polished.
Tank, front fender and fairing sanded, primed and painted gloss black
Tailpiece and side panels sanded, primed and painted gloss black
New brushes in starter motor
New black-bodied turn signals installed (thanks Rich DeZ)
New YUASA battery.
New solenoid and solenoid to battery wiring.
Fuses converted from glass to blade types.


Still needed:
Tires
Clock windows (yellowed/faded)
Windscreen (yellow/faded/scratched)
Shocks.

And a final question. Does anyone know of a company or individual that rebuilds shocks at a decent price? I really like the stock XJ900 shocks with their piggyback reservoirs and would like to keep them.

That's about it. Here's a happy new year to you and everyone and their family and friends and may we all see plenty of happy riding miles in 2008!
thx,
baz

 

Had a quick look at my photos only one I have of the choke cable is this one but I dont know if it will help you. Its on a 650 european model

 

Kenbo,
Thanks for the photo but unfortunately, the XJ900 has a choke shaft that moves sideways instead of up and down. I too have a XJ650 and it's choke cable is easier to set up and makes more sense, to me at least.
But thanks again for the effort.
baz

 

Take a look here:

Mikuni Carb Pics

8)

 

Man Oh Man, I can't tell you how much I appreciate the photos! They're EXACTLY what I need. I just have one minor thing to clear up. In the 29th of 35 photos I can see a fuel hose going from a white spigot on the left and another fuel hose coming black spigot on the right. Just to make sure, the white spigot on the left and the black spigot on the right are the fuel lines that meet at a t-junction above the carbs - corect? The white spigot that's just below the black spigot on the right is a breather hose? And it just runs down behind the swingarm and would empty onto the street? Is that correct?
Again, I can't tell you what a huge help these pics are.
And I have one more question. I can see now how the choke secures to the top of carb #3 thanks to your photos. My bike came without the upper choke attachment plate but I think I can fabricate something. I'm doing this resto on the cheap since women and children come first unfortunately... (Just kidding, honey!) My question is: When I do hook the choke cable up in a temporary manner, the choke rod at the top of the carbs is under enough pressure to pull the choke cable back to the choke's closed position. The choke only stays on if I hold it at the handlebar mechanism. Any idea what's causing this?
thx a million and a very happy new year to you and yours,
baz in snowy toronto

 

No... There is only one fuel in and it's the black one, the 2 white ones are breathers

Yes

Not sure But I'll take a look at mine later and let you know what I find... As far as I'm aware it's in the hand grip

 

Oh and you're welcome

 

Thanks a lot for all your help. The hose routing issue has finaly been cleared up. I'm still trying to figure out the problem with the choke cable but at least I've fabricated a little plate that hold the cable end to the top of carb #3. Now if I can figure out why it won't hold the choke rod at half on, I'd be laughing. Right now I have to hold the choke on with the handlebar mechanism to keep it on. Also, I'm wondering if my choke cable might be a bit too long - ie- I was given the wrong one by the dealer. It just seems too long for it's routing. Thanks again for all the help.
baz