Replacing a broken choke lever

nrninja · August 7th, 2012, 07:52 AM

I've spent well over an hour trying to get this ****ing thing into the housing and onto the handlebar with no luck. Is there some secret voodoo magic I don't know about? Do I have to sell my soul?

Motofool · August 7th, 2012, 09:44 AM

How are you doing it?

nrninja · August 7th, 2012, 09:46 AM

Lining up the lever with the inner part of the housing, then trying to put the housing onto the bar.

Motofool · August 7th, 2012, 09:51 AM

I did it not long ago, but I don't remember the details.

I do remember that I fixed the housing alone to the bar first; it was not something particularly difficult.

I was looking for some how-to article, but couldn't find any, sorry.

Monkeytofu · August 7th, 2012, 01:30 PM

Quote:

Originally Posted by nrninja

Is there some secret voodoo magic I don't know about? Do I have to sell my soul?

The throttle and the choke housing require copious amounts of cussing, ritual sweating, and angered pacing. So in a sense, yes it does require voodoo magic and it may just be easier to sell your soul to get it closed.

However, when I put together my throttle body I've found that roughly shaking the two pieces together until they click together is the fastest method to use. You'll need to perfectly align the plastic pieces to fit on the bar, but a couple shakes should bring them together.

CZroe · August 10th, 2012, 03:27 PM

It's a lot easier on the bar than off. In fact, you'll just be cursing again as you install it if you do it before getting the whole assembly on the bar.

Jono · August 16th, 2012, 10:45 PM

It really isn't that difficult. Haha. Throttle side is a little tricky but after you have done it once it is purty easy. Just look at how it comes apart and put it back together the same way. I recently had to remove both because I put on clip-ons. Had no trouble getting everything back together. I guess I know my voodoo magic!

nrninja · August 17th, 2012, 05:02 AM

Quote:

Originally Posted by Jono

It really isn't that difficult. Haha. Throttle side is a little tricky but after you have done it once it is purty easy. Just look at how it comes apart and put it back together the same way. I recently had to remove both because I put on clip-ons. Had no trouble getting everything back together. I guess I know my voodoo magic!

I finally got the lever on. I had to roll back the handlebar grip and loosen the perch which holds the clutch lever to the handlebar to slide it out of the way. Only took about a minute once I'd created enough space on the handlebar to work with.

August 7th, 2012, 07:52 AM	#1
nrninja ninjette.org member Name: David Location: Virginia Join Date: Jun 2012 Motorcycle(s): '99 EX500 (road bike), '99 EX500 (race bike), '74 CB125S Posts: 55	Replacing a broken choke lever I've spent well over an hour trying to get this ****ing thing into the housing and onto the handlebar with no luck. Is there some secret voodoo magic I don't know about? Do I have to sell my soul? __________________________________________________ PRE GEN IS BEST GEN

August 7th, 2012, 09:44 AM	#2
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	How are you doing it? __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

August 7th, 2012, 09:46 AM	#3
nrninja ninjette.org member Name: David Location: Virginia Join Date: Jun 2012 Motorcycle(s): '99 EX500 (road bike), '99 EX500 (race bike), '74 CB125S Posts: 55	Lining up the lever with the inner part of the housing, then trying to put the housing onto the bar. __________________________________________________ PRE GEN IS BEST GEN

August 7th, 2012, 09:51 AM	#4
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	I did it not long ago, but I don't remember the details. I do remember that I fixed the housing alone to the bar first; it was not something particularly difficult. I was looking for some how-to article, but couldn't find any, sorry. __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

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