choke cable issue (stupid problem but a problem none the less)

moving the perch won't matter as its the inner cable thats too long. I would a need a new perch that sits the cable housing to sit farther back. i wonder if it is aftermarket or from another similar bike.... hmmm

 

so , how does the new cable compare to the old one?

 

he purchased a moyion pro then a cable from chacal his cable should be correct.
I am thinking it is a routing issue combined with after market grip issue.

it is ok if there is no action when first moving lever as long as it opens the plungers full. you may be over thinking this.

also there are ways to shorten cables from kits to cutting the end off and and smelting a ne slug onto the cable.

https://www.motorcycleforum.com/169-how/102449-how-make-your-own-custom-length-control-cables.html

 

follow the "starter cable"

 

your handle bars are not stock are they??

 

The inner cable isn't too long. The sheath and the inner cable are a matched set, and it's the sheath that has to be of the correct length to keep the control end in its recepticle.
You have a cable routing issue, not a cable issue.
The controls you have are stock.

It's not clear in the routing illustration, but the choke cable exits the frame on the right side, then curves around infront of the headstock before going to the left bar.

 

Wouldn't be anything to do with the grips, the bike could be gripless and it still wouldn't affect the cable. The outer sheath is held in it's "slot" on the same switch housing that has the lever on it as well. It could be hanging from the bike and not mounted to handle bars and still would work.

I'm not clear on how it could be a cable routing issue. The outer sheath is held in place by the clamp at the carb and the slot on the control housing. How would changing the routing of the cable affect him here? I understand throttle cables getting pulled out of the holder when you turn bars when the cable is route too tight, but that is not the case here as the choke/enrichener is off and the cable is still too slacked.

I'd still like to see some pics of the choke lever unscrewed from the housing. See if something is amiss there.

 

I don't understand how it could be a routing issue. its a set length. as mentioned the controls could be hanging from the bike and still work. enlighten me if i'm missing something?

I keep meaning to get that pic but keep forgetting. will try tonight. i'm pretty sure all is good on that end, i'm almost thinking that the controls are not original and maybe from a similar-ish bike so they look the same however are slightly different. the holder for the cable sheath needs to be extended or something.

 

er?
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cg82 said: ↑
So I replaced an old choke cable on my brother's 80' 650 and it seems like the cable is too long
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so , how does the new cable compare to the old one?

 

don't remember to be honest. it was basically destroyed and seized right up when we got the bike so i tossed it in the garbage without a second thought. long gone now

 

OK. It's not a routing issue.
I have the same cable and it fit fine, so maybe Motion Pro messed up.

[EDIT] By same cable, I mean the model specific cable from Motion Pro. I also used a Motion Pro cable on a not-customer's 650 Maxim and it fit as well.

 

if a guy put the lower end in the holder, put the cable straight to the control, no routing just make it fit. hook it in and try it.
if it works as it should, it's routing. if it won't work the chokes it's a cable problem

 

what cable did you order? in your photos your handle bars do not look stock, tthat would be the reason your brothers cable was to long.
1980 650 bar ends would be pointing to the ground not like shown in your photo.

he also got a cable from chacal and said both were the same lengths

 

Took some pics for you tonight. Stock everything except handlebars but doesn't matter. Different bars only require a different cable if you can't route it effectively.

Cable at carb with choke off:



Cable at carb with choke on:



Stock control for comparison:



The choke lever:



Cable length with choke off:



Cable length with choke on:



Overall outer sheath length (irrelevant to problem really):

 

That's where I got my cables, and they were both Motion Pro brand.

 

i think it somehow must be the handlebar controls. i bought one of those kits to shorten the cable, i just really hate having to do that. i may try to source some new handlebar controls

 

he never said what cable he got from chacal. if he just got a shorter than stock one that may be the problem.
his Brothers cable was to long because it is not stock handlebars.

a good measurrement of the stock cable getting the length that the cable extends would give hin somthing to compare to his chacal cable
JayRodh has done this in his photos above.

outside sheath does not matter could be 10 feet long it is the inner cable that counts looks like choke off 1 inch to the slug is what he needs

cg82 photo shows a lot more than an inch exposed when choke is off.

 

i bought a motion pro cable off ebay AND a cable from chacal. both were exact same length.

 

for what bike and model ?
your handel bars do not look stock to me?
possible that a Seca 650 cable may work for you, it should have the same exposed cable length as a 650 maxim.
it all depends on the bars

 

XJ650 Maxim and Midnight Maxim models. Wire length = 40".
for all XJ650 Euro and XJ650RJ Seca models. Wire length = 34-3/8".

exposed length should e the same for both above cables as they use same controls and carbs

you could try adding a tube to the end to shorten your exposed wire

K&S brass tubing may work each size is built to fit inside the next size up cut a slot in both tubes for the cable