Heya,
I tried searching for a topic like this, but I didn't seem to find anything usefull...
I just installed full TCP-fairings on my GS500E from 1997. And now the choke-lever appears to be jammed. I had the tank off since I had to change the air-filter. I had a friend helping me with that. He does most maintanance on his own GS500. I've tried following the wire from the choke levet to the carburators and it doesn't seem to be jammed anywhere. Most times I tried the bike was either on the sidestand or on the center stand, however I have tried taking it down from center stand and then move the choke-lever. Still nothing. I haven't tried turning on the power yet. So I actually hope one of you will tell me that this is perfectly normal behavior when the power is off on the bike!

Jacob Collstrup

pretty sure thats not normal... you can always start it and see.... all you would do is run rich... that'll be easy to tell...

Prolly.... you need to

1.remove the carbs

2.disconnect the choke cable

3.  remove the choke rail (pull the two sliders to the left with your fingers [i think its left]) and pull out on the rail (really easy)

4.  push in the plastic clips holding in the choke plugers and pull each plunger out

5.  oil (ever so slightly) the plunger rod and push in and out a bunch till it moves freely



Other than that just check every part of your cable to make sure its not pinched anywhere... this will be easier than removing the carbs so check it first.... also.... make sure none of your fuel lines are in the way of the fuel rail as it moves (they can block it from moving sometimes if they're in the way).  and if you want (as it wont hurt anything) just start the bike and see if the plungers go back in or if it runs ok (i doubt it will).

Keep us posted

Is the lever pinched between the switchbox and the clutch perch/mirror mount?  Or, maybe just hanging up on something in that area?  Does the lever need to be lubed (mine does)?  Does the cable move freely in its sheath?  Can you push/pull the choke rail by itself, as mentioned by KYGS500E?

I have no idea about anything regarding the any technical detail about my bike. I'm not very good with mechanics. I haven't even tried fixing the problem yet. But I think I'll soon try and lift the tank a little and see if that does anything. And I'd need to remove some of the fairing plates. Can you remove the middle pieces with out having to remove the buttom parts too?

Jacob

 :thumb:When you get that choke problem fixed please post some pics i would like to see what those fairings looked like after you installed them. 

Quote from: dwn4whadever on March 25, 2006, 11:21:57 AM
:thumb:When you get that choke problem fixed please post some pics i would like to see what those fairings looked like after you installed them. 

I can tell you how it looks!!: Cool!

Jacob Collstrup

follow the choke cable... it will attatch to a strip of metal on your carb (you dont even have to remove anythign to see it)

push and pull on the strip of metal (choke rail... choke slider)  This opens and closes the carbs... see if it helps

Ok, the choke lever is jammed in the 'off' position. I've checked the cable all the way from the lever to the carbs. No sign of physical damage. All the moving parts on the carbs move as they should (I gather, since I don't know how the should move, they move from side to side.). I'm not taking out the carbs to mess with them. I'm too inexperienced with mechanics! The cable isn't stuck on the fairings, neither was it jammed under the fuel tank.

Jacob Collstrup

Your next step is to unscrew and seperate the two halves of the left-hand controls box (where the horn and turn signal switches are).  Once done follow the choke cable up to the box and carefully remove the cable from the plastic retainer/gude on the choke lever.  You'll see how it fits in there.  Does the choke lever turn smoothly with the cable removed?  If so, the cable is pinched or binding somewhere.  If the lever is still stuck then you'll have to examine the lever mechanism to see what the problem is.

-M

Is it easy to disassemble the control box on the left handle bar?

Jacob Collstrup

Yes, it's just two screws.  Very easy.   Do you have a service manuel?  The Haynes version that I have has good pics and illustrations to guide you through this process.  You might want to pick one up.

No I don't have the Haynes manual yet. However I did manage to get the engine running. A friend pushed the slider on the carbs while I started the engine, and then we kept it running by the gas handle, untill the engine was warm enough to drive to the shop. Horrible drive really. Wet slippery roads!  And the rear wheel blocked and the bike tried to escape from underneath me. I had to release all breakes and gas up and run over a red traffic light!!  Horrible drive!!

Jacob Collstrup