Choke Modification back to plunger style?

[Sarcvicious]

Suzuki "improved" the choke assembly on the 82 GS650s by moving the choke lever from the steering head to the leftside hand controls. I'm planning on wiring up aftermarket hand controls (already purchased), but completely overlooked the fact that now I dont have anything to attach the choke cable to. Is there some sort of modification/conversion kit that would allow me to use a typical choke lever?

Im used to EFI's so this is a new venture but I'm slowly piecing it all together.

GS650's come with CV Mikuni BS32 carbs.

[rphillips]

I don't remember any GS models with CV carbs & choke on carbs, dang it I hate the cables. Some of the Kawasaki's had these same carbs, but with the choke lever on the carbs. "83" KZ 1000 J, KZ 1000 Eddy Lawson, & KZ550, and maybe others. Don't know if any were 32's or not... I've never had a problem with the choke on the carbs, but several problems with the cable operated... Good luck.

[Grimly]

Suzuki "improved" the choke assembly on the 82 GS650s by moving the choke lever from the steering head to the leftside hand controls. I'm planning on wiring up aftermarket hand controls (already purchased), but completely overlooked the fact that now I dont have anything to attach the choke cable to. Is there some sort of modification/conversion kit that would allow me to use a typical choke lever?

Im used to EFI's so this is a new venture but I'm slowly piecing it all together.

GS650's come with CV Mikuni BS32 carbs.

You can weld a bung to the top steering nut and fit a manual pull choke, so that it's just like the original.

[Sarcvicious]

Alright…tell me if this is a dumb idea. I live in Texas so cold weather isn’t really an issue. Since the GS has both a prime function and a choke, could I try to bypass the choke all together?

[rphillips]

NO, Oh, I see post must have 15 characters, NONONONO

[Rob S.]

NO, Oh, I see post must have 15 characters, NONONONO

Agreed. As hot as Texas (or anyplace) is, the engine is considered cold if it hasn't been running for an hour or so.

And as Cycle World pointed out in 1982, Suzukis need more choke fiddling on startup than many other bikes.

[phydeauxmutt]

And as Cycle World pointed out in 1982, Suzukis need more choke fiddling on startup than many other bikes.

And that is only because they had been leaned out to meet EPA regulations. I think it was Motorcyclist magazine that found if you simply turned the pilot screws out about 1/2 turn and reversed the metal and plastic washers on the needle, the bike started easier, got off the "choke" quicker and got better fuel economy.

[rphillips]

I up-ed the size of the pilot jets & helped initial start-up, but still required choke on initial start. I did also shim the needles a little, but never noticed any change initial start-up,

[Gorminrider]

You can weld a bung to the top steering nut and fit a manual pull choke, so that it's just like the original.

Yeah. Something like this..after all, you only have to hold the housing in place.You could even lash it with wire or string to something...(Boy Scout knots! sailors knots!) Once done, just put something knobbish on the cable. You MIGHT want to put a spring on the carb to make it reliably pull back to ChokeOff.. I'm sure you'll find a solution to whatever arises that doesn't suit you

I don't remember any GS models with CV carbs & choke on carbs

oh yes, my GS400 twins (CV carbs) have them-. a Knob that pulls across the carbs lifting the enrichers.... I think some other twins have a lever there instead but I'm not sure which

[rphillips]

I've drilled a small hole, in the little flat piece, on the left end of the choke rod thing, small screw from inside to mount any old knob, to pull choke rod out...Big problem is to hold it out while starting. I shouldn't say it, but if you by-pass the clutch switch it works really well...Be careful !!!

[Gorminrider]

I've drilled a small hole, in the little flat piece, on the left end of the choke rod thing, small screw from inside to mount any old knob, to pull choke rod out...Big problem is to hold it out while starting. I shouldn't say it, but if you by-pass the clutch switch it works really well...Be careful !!!

an elastic band or strip of inner tube wrapped a couple of times around the steel cable and housing at end might provide the friction. Or... lightly squashing a ferrule,or two flat bits with a screw clamping them controlling "friction squash", or...

[dorkburger]

I swear I'm going to fix my choke handle situation someday..... but as rphillips said, I've done similar, but i have a small loop of string tied around the end of the rod. Pull and hold while cranking the bike. My clutch safety was bypassed ages ago, no no issue there.

[rphillips]

Dang Dork, a dangling string?? not a string!!! You can do better than that, a wire tie maybe but not a string, that sounds way too red neck for NJ... But guess it works.

[dorkburger]

Ha, don't let our Mid Atlantic location fool you... we definitely have some `necks here. Its just a short loop with a soft keyfob attached to make it easy to grab.

[rphillips]

Glad you got something working... Wish Suzuki hadn't have screwed it up to begin with... Like said never heard of a choke problem when knob, or lever, was on carbs.... Really liked how Mikuni did it for the Kawa's.