Title: Help! Choke cable problems
Post by: JonD on July 02, 2004, 10:17:40 AM
Post by: JonD on July 02, 2004, 10:17:40 AM
Hello Everyone,
I am a new user of this message forum and am new to the world of motorcycling. I just recently bought a 2000 GS500E from a friend and can't believe how much fun I am having with it ... that is until yesterday. I decided to lubricate the choke cable so I removed it. The problem started when I tried to put everything back together. I must be STUPID because I can't get it to fit right. I think I got it routed correctly but when I reassemble everything there is too much tension on the cable that causes the choke to always be on. When I look at the cable routing it seems that I need an extra 1 - 1.5 inches of cable length in order for the cable to be "relaxed". Did someone steal some of my cable when I wasn't looking? I have Clymer but it does not address the choke cable.
Someone help me, PLEASE!
I am a new user of this message forum and am new to the world of motorcycling. I just recently bought a 2000 GS500E from a friend and can't believe how much fun I am having with it ... that is until yesterday. I decided to lubricate the choke cable so I removed it. The problem started when I tried to put everything back together. I must be STUPID because I can't get it to fit right. I think I got it routed correctly but when I reassemble everything there is too much tension on the cable that causes the choke to always be on. When I look at the cable routing it seems that I need an extra 1 - 1.5 inches of cable length in order for the cable to be "relaxed". Did someone steal some of my cable when I wasn't looking? I have Clymer but it does not address the choke cable.
Someone help me, PLEASE!
Title: Help! Choke cable problems
Post by: Kerry on July 02, 2004, 10:45:12 AM
Post by: Kerry on July 02, 2004, 10:45:12 AM
Are you sure you reattached it correctly on the lower end? Getting the spring right can be tricky the first few times. It should look like this:
(http://www.bbburma.net/MiscFotos/100_0130_ChokeCableCloseUp.jpg)
(http://www.bbburma.net/MiscFotos/100_0130_ChokeCableCloseUp.jpg)
Title: Help! Choke cable problems
Post by: JonD on July 02, 2004, 11:23:44 AM
Post by: JonD on July 02, 2004, 11:23:44 AM
I actually disconnected it at the handlebar end. And that is why I am so confused. It looks to me like it can only be routed one way, but this causes the cable to be too tight. Do you have any pictures of the handlebar end?
Title: Help! Choke cable problems
Post by: EvilScooby on July 02, 2004, 11:40:36 AM
Post by: EvilScooby on July 02, 2004, 11:40:36 AM
Just reroute it outside the forks. Kerry suggested it to me a few weeks back and it works great
Title: Help! Choke cable problems
Post by: Kerry on July 02, 2004, 12:12:06 PM
Post by: Kerry on July 02, 2004, 12:12:06 PM
Just curious - did you check the lower end of the cable anyway? It could still be goofed up....
In the picture above, can you see the curved, silver-colored cable housing that disappears behind the cooling fins on the right? If that housing was ever pulled to the right while you were lubing the cable, it could have come back to rest ON THE LIP of the sheath-like mounting bracket rather than slipping back INTO it. That could account for half an inch (or so) of missing slack.
In the picture above, can you see the curved, silver-colored cable housing that disappears behind the cooling fins on the right? If that housing was ever pulled to the right while you were lubing the cable, it could have come back to rest ON THE LIP of the sheath-like mounting bracket rather than slipping back INTO it. That could account for half an inch (or so) of missing slack.
Title: Help! Choke cable problems
Post by: JonD on July 03, 2004, 04:40:25 AM
Post by: JonD on July 03, 2004, 04:40:25 AM
Kerry,
No I have not checked the lower end yet, but after your suggestion I will do that next. Do I have to remove the gas tank to do this?
Also, I went out and measured the length of cable extending out of the sheath (at the handlebar side) and it is about 1-1/4". Does this sound too short?
I started the engine, with the cable just hanging in the wind, and everything seemed normal. Then I pulled the cable a bit and the engine started revving higher. Since everything seemed to work OK when doing this I just assumed that nothing was pinched and nothing else was wrong with the cable.
I'll let you know what I find when I investigate the other end. Thanks for all your help.
No I have not checked the lower end yet, but after your suggestion I will do that next. Do I have to remove the gas tank to do this?
Also, I went out and measured the length of cable extending out of the sheath (at the handlebar side) and it is about 1-1/4". Does this sound too short?
I started the engine, with the cable just hanging in the wind, and everything seemed normal. Then I pulled the cable a bit and the engine started revving higher. Since everything seemed to work OK when doing this I just assumed that nothing was pinched and nothing else was wrong with the cable.
I'll let you know what I find when I investigate the other end. Thanks for all your help.
Title: Help! Choke cable problems
Post by: Kerry on July 03, 2004, 08:52:47 AM
Post by: Kerry on July 03, 2004, 08:52:47 AM
Quote from: JonDNo I have not checked the lower end yet, but after your suggestion I will do that next. Do I have to remove the gas tank to do this?Nope. To help you find the other end of the cable, here is the original view from which the picture above was cropped:
The yellow in the upper background is the fuel tank.
If you need to do more than just push the housing sideways so it will pop back into the "sheath" ... you will probably need to remove the tank to get at everything.
In fact, I'm not SURE that aything is wrong at the lower end of the cable, but removing the tank might be a good idea anyway, as that would give you full access to the cable routing.
Quote from: JonDAlso, I went out and measured the length of cable extending out of the sheath (at the handlebar side) and it is about 1-1/4". Does this sound too short?Hmmm. I'll have to check later today. Our 6.5-month-old lab puppies are holding my motorcycle hostage in the backyard shed right now. I would go out and check, but that would grant them access to the house, the bedroom, and my still-sleeping wife.... :nono:
Does anyone else (with access to their GS) have a ruler on them?
Title: Help! Choke cable problems
Post by: Kerry on July 03, 2004, 11:29:49 AM
Post by: Kerry on July 03, 2004, 11:29:49 AM
OK! Wife's awake (puppies are now ASLEEP) and I got a chance to look at my bike out in the shed.
Unfortunately, I couldn't figure out where (or what) you are measuring. So, I thought I wold post this picture in case it will be of help. (Ignore the red oval - that's to illustrate something else).
(http://www.bbburma.net/MiscFotos/100_1230_ClutchEngagementSwitch.jpg)
Does your setup look significantly different than this?
Unfortunately, I couldn't figure out where (or what) you are measuring. So, I thought I wold post this picture in case it will be of help. (Ignore the red oval - that's to illustrate something else).
(http://www.bbburma.net/MiscFotos/100_1230_ClutchEngagementSwitch.jpg)
Does your setup look significantly different than this?
Title: Help! Choke cable problems
Post by: JonD on July 06, 2004, 05:40:32 AM
Post by: JonD on July 06, 2004, 05:40:32 AM
Kerry,
You were exactly right. The problem was with the lower side of the cable. The cable housing popped out of the "sheath". I just popped it back in and everything is working perfectly. I think what happened is when I disconnected the cable from the handlebar side I pushed in on the cable, causing it to pop out on the lower side.
Anyway, your pictures were extremely helpful. Thanks again for all your help. I am a happy motorcyclist again.
You were exactly right. The problem was with the lower side of the cable. The cable housing popped out of the "sheath". I just popped it back in and everything is working perfectly. I think what happened is when I disconnected the cable from the handlebar side I pushed in on the cable, causing it to pop out on the lower side.
Anyway, your pictures were extremely helpful. Thanks again for all your help. I am a happy motorcyclist again.
Title: Help! Choke cable problems
Post by: MarkusN on July 06, 2004, 05:50:22 AM
Post by: MarkusN on July 06, 2004, 05:50:22 AM
Great! An inquirer who actually comes back and reports when his problem is solved.
Thanks for that, JonD.
Thanks for that, JonD.
Title: Help! Choke cable problems
Post by: i3randon12 on July 06, 2004, 07:03:37 AM
Post by: i3randon12 on July 06, 2004, 07:03:37 AM
kerry is never worng
ur picures rule
we should all pitch in and buy more digital camera
ur picures rule
we should all pitch in and buy more digital camera