Need help with

[alke46]

choke cable or starter cable whichever is the preferred word. I have 3 pics to show the mounting bracket the cable goes through but I don't know what is missing that holds the sheath to the hollow bolt that goes onto the mounting bracket.

IMG_20220418_123320840 by Larry Alkire, on Flickr

IMG_20220418_123556587 by Larry Alkire, on Flickr

IMG_20220418_123417925 by Larry Alkire, on Flickr

without something to hold the end of the sheath into the head of that hollow bolt, it just does not operate smoothly. Any suggestions?

 

[Gorminrider]

a suitable size of rubber hose ..like fuel hose.maybe jam something in or gluegun so the hose can't shift if the hose is loose and wants to move up

bu-u-u-t; the root cause is : that cable looks kinda short and will want to bend sharp making that 90 deg turn -can you pull some more slack or re-route for more? They will usually sit ok if the angle is right. Sometimes instead of that adjuster you have there, I see a simple clamp that holds the sheath -those adjuster screws I usually see on the throttle cables but not the choke

AND as a detail probably unnecessary, those hollow screw-adjusters usually have locknuts-10mm nuts likely fit..or a bit of threadlock if it seems important..

 

[Nessism]

Pretty sure there is supposed to be a slotted nut that's used to secure the cable end fitting. And speaking of end fitting, it's typically screwed down much lower towards the bracket, with the slot oriented so that the cable won't come out.

 

[alke46]

Thanks, what is not seen in the pic is the total length of the cable. In fact, it is a tad too long.

I wondered about locknuts, one on either side of the bracket. I'll see if I can jam some small hose on the end of the sheath.

 

[alke46]

a suitable size of rubber hose ..like fuel hose.maybe jam something in or gluegun so the hose can't shift if the hose is loose and wants to move up

bu-u-u-t; the root cause is : that cable looks kinda short and will want to bend sharp making that 90 deg turn -can you pull some more slack or re-route for more? They will usually sit ok if the angle is right. Sometimes instead of that adjuster you have there, I see a simple clamp that holds the sheath -those adjuster screws I usually see on the throttle cables but not the choke

AND as a detail probably unnecessary, those hollow screw-adjusters usually have locknuts-10mm nuts likely fit..or a bit of threadlock if it seems important..

Nope, this did not work

Pretty sure there is supposed to be a slotted nut that's used to secure the cable end fitting. And speaking of end fitting, it's typically screwed down much lower towards the bracket, with the slot oriented so that the cable won't come out.

.

This makes a lot of sense but I have never seen a slotted nut to secure the end fitting. Needless to say, the enricher has never worked like it should on this bike. I've just managed to work around it.

 

[rphillips]

Is your cable adjusted properly? with choke knob completely in there shouldn't be enough slack in the cable for the sheath to come out of the adjuster. For the sheath to come out that 1/4" you would be closing choke lever (arm) 1/4", The spring pressure pulling the choke open should be enough to hold the cable & sheath in place. & yes there should be a lock nut # 69 on parts dia. for carbs for GS1000EN. Good luck

 

[alke46]

Is your cable adjusted properly? with choke knob completely in there shouldn't be enough slack in the cable for the sheath to come out of the adjuster. For the sheath to come out that 1/4" you would be closing choke lever (arm) 1/4", The spring pressure pulling the choke open should be enough to hold the cable & sheath in place. & yes there should be a lock nut # 69 on parts dia. for carbs for GS1000EN. Good luck

There's nothing to hold the sheath in the adjuster. It only goes in like a 1/4 inch and just sits there loosely. And there's no threads on the sheath to even hold it in the adjuster.
Did the OEM choke cables have some way to be held in the adjuster? IDK. But my after market cable looks incomplete.

 

[Grimly]

That hollow bolt should have a wider drilled head to contain the cable end.
After adjustment, a locknut should be tightened up on the threads.

[/url] free border images download[/IMG]

 

[salty_monk]

It's a bit weird, usually they stay put by themselves with the adjustment. I think you need to try re-routing the cable. You may find fixing the outer cable with a zip tie at on that frame tube above it might help, you don't want the outer to move, just the inner & yes you're missing a locknut but it's nothing special....

 

[alke46]

So in a nutshell, here is my problem. See 5 photos showing the adjuster and the cable. The cable sheath measures 5.65 mm and the opening of the adjuster is 6.1 mm and the sheath only goes in 4 mm deep. Looking for a way to secure the sheath into the adjuster which may or may not be the original.

IMG_20220418_193031589 by Larry Alkire, on Flickr

IMG_20220418_193031589 by Larry Alkire, on Flickr

IMG_20220418_193104645 by Larry Alkire, on Flickr

IMG_20220418_193104645 by Larry Alkire, on Flickr

IMG_20220418_193104645 by Larry Alkire, on Flickr

 

[alke46]

Guess I could just fill it with JB weld........Just kidding, don't want it to be that permanent.

 

[rphillips]

May be the wrong adjuster, I'd have thought the metal part of the sheath would have gone maybe 8mm down in the adjuster rather than 4mm. When the cable is adjusted correctly, the there's a spring on the carbs that holds the choke in the OFF, this spring pressure will be pulling down on the cable & sheath, holding the metal part of the sheath down in the opening on top of the adjuster. Adjusted correctly, The metal part just sits in there & the spring pulling down on the choke arm holds it in...Hope I haven't forgot

 

[Grimly]

If the cable is the right length (within give or take a bit) it should sit into the top of the adjuster bolt and never come out.
The adjuster looks like the right thing, but you never know, some PO could have whanged in a bicycle brake adjuster he had lying about.

 

[alke46]

After sleeping on it tonight, I will see if I can maybe drill out some of the adjuster to get more of the sheath inside.

 

[alke46]

So I was able to drill out some of the adjuster so I could get the sheath further down inside it. But I really think my problem is with the choke cable being too long. The following two pics show the cable end in the ready position to lift the plungers but look at where the choke knob is pulled out to.

IMG_20220419_134631407 by Larry Alkire, on Flickr

IMG_20220419_134635563 by Larry Alkire, on Flickr

Now look at the position of the choke knob sitting where it should be and then look at the cable end. It is extended out of the lifting mechanism by 1.5".....

IMG_20220419_134643764 by Larry Alkire, on Flickr

IMG_20220419_134657436 by Larry Alkire, on Flickr

Does this look to you guys like it is time for a new cable? Fleabay or elsewhere?

 

[Nessism]

Why not slide a nut over the cable end and tighten it down on the bottom side of the bracket, thus securing the cable adjuster in the proper position?

 

[alke46]

Why not slide a nut over the cable end and tighten it down on the bottom side of the bracket, thus securing the cable adjuster in the proper position?

That might work but the sheath end still has no way of staying in the adjuster.

I took Dan's (salty monk) suggestion and placed a couple zip ties in strategic locations and now it is back to being in working condition. Maybe not what Suzuki recommends but hey, I'll take it.

End of story ---- thanks to all who contributed with suggestions.

 

[rphillips]

Wrong cable. Post # 15 1st & 3rd picture, choke knob all the way down & cable connected at carbs, the adjuster should back out of it's mount far enough the sheath on the cable is down in the cup on the adjuster tight enough it won't just fall out. To get the sheath out of that 4mm deep cup, you would have to pull choke arm on carbs up 4mm. Main thing, glad you got it working.