Choke Plungers
 

What's the story with plungers getting stuck? After a few airbox/jet tweeks, my previously perfect functioning choke now takes about 10-15 seconds to kick in after firing up the engine. Previously, it was choking from the seconds she turned over.

I did crack that plastic bit that splits the choke cable right after it comes into the frame, but, taped and zip tied it fine. Are the plungers in there, or in the carbs itself? I only ask because I've heard of plungers getting stuck before. Cheers -Dave:confused:

Re: Choke Plungers
 

The choke cable comes down from the lever to the Y-piece splitter that you've damaged and repaired. Water tends to run down the cable into the Y-piece and down the cable to the carbs. This is where the plungers are, and the front carb is especially prone due to the Y-piece making this "down hill" for the water.

Disconnect the choke cables from the carb bodies and you'll see the plungers there, clean it all up, oil the choke cables using an oiler, and pack the Y-piece full of grease. If the Y-piece is damaged to the point that the cables are not moving smoothly and evenly for both plungers, you'll need a whole new choke cable assembly. Oil it and get grease into the Y-piece before fitting it.


HTH
Jambo

Re: Choke Plungers
 

Yup. Also, if you've just removed and refitted the carbs, I'd be checking to make sure the cable's not binding, and I'd check the plastic splitter to make sure all teh cables are seated right- it's possible for it to crack allowing the cable sleeves to come loose, and once that happens you can be left with the cable permanently slightly engaged, or not returning easily.

Re: Choke Plungers
 

Have had to replace the return springs a couple of times as well

Re: Choke Plungers
 

Same here... Though only one was because it was damaged, the other escaped and was last seen crossing the border at 40000 feet.

Re: Choke Plungers
 

Cheeers guys, I'll take the choke cable out for a look next time I'm in there. I did oil the cable from top and pack the switchgear full of grease, much smoother now. Still can't figure why it takes a 10 or 15 second delay until the choke kicks in though. Will really have to check the splitter and plungers I reckon. -D

Re: Choke Plungers
 

Be careful when trying to get them plungers out. The screw will more than likely be seized in place. As with most Suzuki screws, apply an sort of force and the head will sheer. If you have an impact driver, I would consider using this.

Re: Choke Plungers
 

Best way IME, that and a bit of freeze and release spray.


The choke "kicking in" is wierd and doesn't say stuck plungers at all, could be fuel taking a few seconds to work its way round the passages?