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Choke Plunger Replacement

W

Wright 83 GS650

Forum Newbie
Alright Broke college kid here free bike so running a shoe string budget. I have spent the majority of my life working on vehicles and building jeeps and chevy trucks I am mechanically inclined and decided it was finally time to work on this bike.

I was given a 1982 Gs650 that has sat covered in a barn for 15 or so years with the gas drained, last year I had pulled the carbs off and rebuilt them to the best of my knowledge and ability at the time. Ended up with an amazon rebuild kit, new gaskets and orings, had several of the interals bust off when I when to un screw so hence the kit. Then the carbs sat on the shelf of my shop for the last year while I went off to school.

I pulled it down and pulled it back apart to recheck my prior work and clean the dust off everything. Well I now understand why the choke cable was busted, every single choke plunger was seized, I pulled the caps and soaked them in penetrant over night and that freed one but the other 3 were still gummed up, soaked in vinegar and with a little heat they all freed up. Cleaned them all up and put it back together and re attached the linkage and when I actuated it one of the plungers where the linkage attaches broke clean off (representative image attached) where it looks as if someone previously had used pliers or something similar to free them and twisted the thin brass. (History of this bike is extensive and there are many stripped screws and damage from what I can only assume was someone who took on the challenge of repairing these carbs using only a cheap multitool) All of the plungers have mild pliers wear.

The first thing that has been running through my head is to drill and tap the broken end for a very small machine screw and to screw it out to where the linkage attaches. I would replace it if I could find a good option but I am seeing plungers for sale that don’t have the pointy tip that goes into the carb or its slightly different or that have different actuation methods but none that seem exactly the same other than used off ebay. I’m hoping for a part number or other thoughts, I kinda want to try drilling and tapping before ordering a used one.

Haven’t split the carbs yet so I don’t have a photo of the busted one hence representing photo.

Thanks In Advance, feel free to ask anything especially if you feel I missed something!
 
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I can't offer you any specific advice on your carb situation, but just want to wish you well. Nothing wrong with having money, but I'd give it all away to be a broke college kid again. Enjoy it while it lasts! :lemo:
 
Try the Wanted to Buy forum. On eBay, you can find them for less than $20 shipped. As far as I know, all the GS bike CV carbs used the same parts.
 
Thank ya, planning to drill a 1/32 in hole and using some brass rod pin it and solder it back together. Its a good excuse to practice some brass repair and soldering to save a buck and more importantly 2 weeks shipping :)

In the research I did I haven’t been able to confirm that they all work but can confirm at least 3 different styles: one that is flat at the seal (5 bucks new I believe used on the versions of the carb for single cylinders), one that has the stem through the seal but is a cylinder ($30 new, I believe was used in the 750, 850, and 1100 carbs based on used listing), and the ones in the gs650 carbs with the cone shape at the end of the point. If its an alignment thing or some sort of passage sealing I’m unsure. Looking at the choke diagram of the carb they look to be just alignment and that it realistically doesn’t matter or isn’t necessary, kind of want to try the 5 dollar one’s just to experiment as its the cheapest new seals possible but should probably get the bike running first :rolleyes:

I’ll update on how it goes drilling and pinning, able to use a buddy’s drill press tomorrow morning to make sure my holes are straight!

Excuse the photo collage got caught trying to upload multiple attachments. Shows my broken one, and the two other styles I’ve discovered, also shows the view of the choke system which if I understand correctly the pointy end looks to be nothing other than an alignment piece
 

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