kick start conversions

[junkkins]

Hey, The fuel enrichener cable on my KLR recently ceased to retract when turning the lever back to the normal position. I have to manually grab the cable housing and push it back into the lever housing. Can anyone tell me how the mechanism works? Is there a spring at the carb that needs to be replaced? Lube the cable? Thanks for any suggestions. Mark

[Stuart Mumford]

> -----Original Message----- > From: kdxkawboy@... > Subject: Re: kick start conversions > > In a message dated 2003-07-06 8:29:26 PM Pacific Daylight Time, > botdave@... writes: > > > > > > > First time to post on the site, but have been following for a couple > > of weeks. This is a great site and has taught me a whole lot I > > did'nt know about my bike. My question is about a kick start > > conversion for the 650. A good friend of mine has owned a few KLR's > > over the years and told me has heard of such a thing. Being a > > mechanic by trade, I don't like being stuck broken down somewhere > > with something simple that I can't easily fix. Just wondering if > > there is a kit available, or if the KLX 600 kick starter will > > actually fit?? > > > > > > Up through the mid/late 90s Kawasaki sold a kickstarter kit for > the 650. Then > Kawasaki made a few internal/external changes, like the case is no longer > plumbed to take a kick starter, and dropped the kickstarter. At > the time Kawasaki > was saying they had sold so few retrofit kit that it wasn't worth > keeping on > the shelf. > > Pat > G'ville, Nv >

The changes made to the clutch basket in 96 occlude the kickstarter hole. It's still there in the case, but it's not functional. Thanks CA Stu A13

[junkkins]

Hey, The fuel enrichener cable on my KLR recently ceased to retract when turning the lever back to the normal position. I have to manually grab the cable housing and push it back into the lever housing. Can anyone tell me how the mechanism works? Is there a spring at the carb that needs to be replaced? Lube the cable? Thanks for any suggestions. Mark

[Devon Jarvis]

junkkins wrote:

> > Hey, > > The fuel enrichener cable on my KLR recently ceased to retract when > turning the lever back to the normal position. I have to manually > grab the cable housing and push it back into the lever housing. > > Can anyone tell me how the mechanism works? Is there a spring at the > carb that needs to be replaced? Lube the cable? Thanks for any > suggestions. > > Mark >

There's a spring in the carb body, and also a curved washer in the choke lever mount that tensions the lever. I highly doubt the spring is "tired". Maybe you need a new choke cable. You can try lubricating it first, maybe the PO used something to lube it that dried out and turned gooey. Also, someone (Motion-pro?) makes a tool for lubricating cables. You remove the end from the lever, attach the tool, attach a can of WD-40 or whatever you use, and it sprays it directly down the cable housing. I have one, they're great. I usually just use WD40, then compressed air, then WD40. (knock on wood) I'm still on my original clutch cable, and the other cables I've replaced were crash damage. Devon A15-Z -- "It's a troublesome world, all the people who are in it, are troubled with troubles almost every minute" Dr. Seuss

[Devon Jarvis]

Devon Jarvis wrote:

> > Also, someone (Motion-pro?) makes a tool for lubricating > cables. You remove the end from the lever, attach the tool, > attach a can of WD-40 or whatever you use, and it sprays it > directly down the cable housing. I have one, they're great. >

BTW if you use the cable lubing tool (or anything else for that matter) you need to remove the choke cable from the carb so the crud drains outside the carb. You'll be disgusted at what comes out of the clutch and throttle cable housings when you use WD40 and compressed air. BTW both cables appear to have a nylon sleeve in the housing, and the inner cable glides over this really well using very light lube (like WD40 after most of it's evaporated). Devon -- "It's a troublesome world, all the people who are in it, are troubled with troubles almost every minute" Dr. Seuss