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Old 27-07-11, 02:40 PM   #1
Kiyonari
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Default Seized Choke Plunger

Already found a topic on here and I've tried applying heat and I've used a full tin of WD40 and nearly broken my arms off using a set of grips to try and get the choke plunger out of the front carb but it just won't budge... any ideas?
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Old 27-07-11, 02:49 PM   #2
Nicky S
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Already found a topic on here and I've tried applying heat and I've used a full tin of WD40 and nearly broken my arms off using a set of grips to try and get the choke plunger out of the front carb but it just won't budge... any ideas?
Are you talking about the screw? Or the plunger its self. As the plunger should pretty much full out when u have undone the screw
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Old 27-07-11, 03:16 PM   #3
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Default Re: Seized Choke Plunger

Yes definitely the plunger, I had to drill the screws off as they were corroded to hell. The rear plunger came out very easily but the front is stuck fast
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Old 27-07-11, 03:28 PM   #4
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Default Re: Seized Choke Plunger

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As the plunger should pretty much full out when u have undone the screw
Mine didnt they were corroded in and I had to use a pair of pliers and yank them out.

To the OP - if its that stuck, then your other alternative might be to cut your losses and look for a 2nd hand set of carbs.

I would wait a while and see if somebody more knowledgable than me can advise you though.
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Old 27-07-11, 05:49 PM   #5
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Default Re: Seized Choke Plunger

Got it out! Took the best part of 2 hours, a full can of wd40, a set of grippers a hammer and a flat head screwdriver. It was completely seized and will have to be replaced. Now to clean the whole thing and see if the carbs are the reason for it having no power like it misfiring
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Old 27-07-11, 06:02 PM   #6
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Default Re: Seized Choke Plunger

Infact where do I get a new plunger from o_O ebay there are none :'(
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Old 27-07-11, 06:08 PM   #7
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Default Re: Seized Choke Plunger

Try a post in the wanted section here as someone might have one knocking about.Other than that I would say Mr Suzuki?
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Old 27-07-11, 11:10 PM   #8
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Infact where do I get a new plunger from o_O ebay there are none :'(
I dont think you will ever find them on ebay. Buy new from suzuki. They are cheap if i rember.

Look here http://www.robinsonsfoundry.co.uk/co...01999-2002.htm as you get split digrams as well. You can also buy from them they are a suzuki dealer

Hope this helps unlike my crapy posts earlyer
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Old 28-07-11, 07:30 AM   #9
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Default Re: Seized Choke Plunger

thanks m8 that looks a good site, just need to look up the part numbers they will be in my haynes right?
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Old 28-07-11, 09:26 AM   #10
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Default Re: Seized Choke Plunger

Part numbers on the robinsons site above. Click on carburetor sub heading and pick from the list under main diagram or click here if it works. No part numbers in my haynes, just say's plunger assembley as a whole.
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