choke lever problems - 2007 klr 650

[RobertWichert]

That schematic is not correct, Fred. It only shows one washer and it doesn't show the o-ring washer at all. It also doesn't show the wave spring washer. Maybe mine isn't stock (it is the relocate bracket needed for the light switch upgrade) but mine has at least one wave spring washer and an "o-ring donut" washer and a flat washer. The stack order is: Bracket All the following are threaded onto the screw stationary choke lever portion (marked "choke") Wave spring washer Movable choke lever portion (with the handle) donut "o-ring" washer (fits into recessed slot in movable choke lever) flat washer screw head. It seems to work OK like that. Robert P. Wichert P.Eng LEED AP +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 5/18/2011 12:30 PM, Fred Hink wrote: > > Sorry my internet has been down until now. You can find the schematic > of the choke lever on the Kawasaki site here: > https://www.kawasakiepc.com/SSIConverted/2720986_110518_032619_3666.png > > Fred > http://www.arrowheadmotorsports.com > > From: RobertWichert > Sent: Tuesday, May 17, 2011 11:34 AM > To: DSN KLR650 > Subject: [DSN_KLR650] Choke Lever Problems - 2007 KLR 650 > > I replaced my choke lever and messed it up. My old one broke in one of > my numerous falls, so I replaced it with a new Kawi part. (Has anybody > ever taken their mirrors off before riding off-road to avoid knocking > them loose like I do every damned time that I fall?) > > Back to my choke lever - It now backs out the screw that holds it > together, a little bit every time I use it. After a few uses, the screw > is loose and I have to tighten it again. If I over tighten it, it's > hard to move the lever the first time I use it, but once I cycle it a > few times the screw backs out and it gets easier. Eventually the screw > is too loose and needs to be over tightened again. I know that I > assembled it wrong, but I don't know what I did wrong. It has two wave > washers, which is what I suspect I screwed up. The stacking order now > is like this: > Starting at the handlebar > Support > Stationary portion > Wave washer 1 > Wave washer 2 > Rotating portion > Small flat washer > Allen screw > > The screw may be too long or the wrong one, or it may be missing some > sort of internal tubular stop piece (grasping for solutions here) that I > have lost. > > Any ideas out there? Fred? > > -- > > Robert P. Wichert P.Eng LEED AP > +1 916 966 9060 > FAX +1 916 966 9068 > > =============================================== > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]