Stiff choke plunger

Charlie · World Chat Champion Joined: 27 May 2007 Karma :

Hi,

The choke plunger on my xt600e is starting to get stiff (oh err). It still works but I am worried that one day soon it will get stuck on. I've given it a quick squirt with WD40 and this hasn't helped.

The choke on the xt600e is directly on the carb, so it isn't a dry cable.

Short of taking the carb off and apart has anyone got any ideas?

Charlie Karma

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Past: Honda x8rs, Honda City fly, Honda Hornet 250, Honda VFR750, Yamaha xt600e.
Current: Honda CBR929RR & Yamaha XT660Z Tenere

Matt- · World Chat Champion Joined: 19 Jul 2012 Karma :

Have you tryed Oiling the cable?

Maybe it could just be a faulty plunbger, i would look at the plunger first then the cable.

Good Luck

Matt
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RIP jack (wheelie king), you will never be forgotten.
Current Bike's - Road Legal TZR 125 Pitbike, Aprilia SR50R 2010

Charlie · World Chat Champion Joined: 27 May 2007 Karma :

Matt- · World Chat Champion Joined: 19 Jul 2012 Karma :

Sorry had a late not out last night Laughing

Chances are it's got seized or the spring is worn, is their a screw holding it in ?

Matt
____________________
RIP jack (wheelie king), you will never be forgotten.
Current Bike's - Road Legal TZR 125 Pitbike, Aprilia SR50R 2010

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Charlie · World Chat Champion Joined: 27 May 2007 Karma :

Cheers Sickpup.

Used TF2 first time round as I didn't have WD40. Anyhow I gave it a good old spray and then removed part 12 whole. Gave this a good dousing and operated it a couple of time giving it a good spray in each position and cleared any muck I found. I didn't separate this part.

Moving the plunger up and down in this assembly gave the same feeling of stiffness that I get in normal operation so I assume the problem lies here and not internally within the carb. Seems to have freed up a bit, but not as easy as I remember. Maybe I am remembering wrong. Diagram here:

https://cdn.bikechatforums.com/files/screen_shot_2012-09-30_at_13.08.01.png

Bike is fairly new, 57 plate (import from Greece), so I doubt/hope that it isn't already corroding, it's only done 17,000 km! Although I've recently started using it to commute so it's now finally getting a daily use.
____________________
Past: Honda x8rs, Honda City fly, Honda Hornet 250, Honda VFR750, Yamaha xt600e.
Current: Honda CBR929RR & Yamaha XT660Z Tenere

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

The rod with the pull knob. Pull it out and oil the parts that slide through the carbs. If still stuck whip the carb tops off and out with the diaghprams and you will see the internal part of the plunger at top front. Choke off oil the pluger and pull it out. Do that till it free's up. I had this on two of my bank of four. You should get into the carb tops without having to take them off the bike.

YBR Ric · Spanner Monkey Joined: 16 Jan 2012 Karma :

Hopefully you should be able to pull the choke plunger out, then ease the rubber seal off the retaining body, unscrew it after first loosening with a suitable spanner and the whole choke assembly will be ready for inspection without having to remove the Carb from the bike.

Be careful not to damage any seal on the plunger if fitted. Also check the operation of the plunger shaft within the retaining body.

It's possible a bit of grit may have entered the plunger chamber and this is causing your problem. Having lubed up as required, check the chamber before reinstalling the plunger unit for any debris. the tiniest bit of grit could prevent the plunger from sealing correctly and this could result in additional (unwanted) fuel entering the combustion chamber.