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

Discussion in 'XJ Technical Chat' started by cg82, Sep 22, 2018.

  1. cg82

    cg82 Member

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    ok, so i'm still having this issue. moved on for a bit a rebuilt the carbs but now i'm back to trying to figure out wtf is going on. I took some measurements,
    cable sheath : 37-1/16"
    inside cable not counting barrels: 39-1/2"

    its not the routing BUT i figured, i would try everything so i routed it as per diagram above and as k-moe said and exited on the right side and wrapped around. neither made a difference. is anybody willing to measure the inside wire of their cable for me? such a dumb problem haha
     
  2. cg82

    cg82 Member

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    Updated for pics
     

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  3. cds1984

    cds1984 Active Member

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    I have a non-standard setup and had to make my own cable(s) so I can't help with the measuring but... if you have an inner that is too long you are half way there.

    1. Cut one end off, have a go at drilling it out from the other side and end up with a end with a hole through it and chamfer it on the outside also.
    2. Put the cable in place with the end on it loose and slide it to the right spot and mark it.
    3. Cut the inner to length when on the end and fray the very end a smidge to sit in the chamfer.
    4. Bronze or solder the end back on to the cable (flux is good but remember to clean afterwards).
    5. Grind or sandpaper the end to get it back to the right shape if need be.
    6. Done.

    PS:(the brass computer motherboard stands work pretty good as something to drill a hole through,bronze on and drill/grind to shape also if you run into issues with the existing end.)
     
  4. jayrodoh

    jayrodoh YimYam Premium Member

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    That cable is way too long. I didn’t measure my inner length but you can tell just by looking at my pic where I measure the outer sheath, it was lying on the ground for that picture. I’ll happily measure it later if you like, it is still off the bike.
     
  5. cg82

    cg82 Member

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    that's what I don't understand, its the cable from chacal.
     
  6. XJ550H

    XJ550H Well-Known Member Premium Member

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  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    sheath 37 inches cable 39 inches 2 inches exposed cable cable side of barrels I just picked up a set of controls with cables for the measurements given
    now I have to remove a cable from my 650 to see if they match will post that info

    HCP2645 Aftermarket CHOKE CABLE, for all XJ650 Maxim and Midnight Maxim models. Wire length = 40".
     
  8. XJ550H

    XJ550H Well-Known Member Premium Member

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    if you clamped the knurl adjuster in the carb choke bracket it may give you the extra distance to make choke cable work
     
  9. jayrodoh

    jayrodoh YimYam Premium Member

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    Cable routing doesn’t matter for this issue, the cable could run through the rear wheel with the control sitting on the ground and it should still work as expected. Cable routing is an issue when things pull on the sheath in turn pulling the cable out of the holder. A tight throttle cable that gets tugged on when the bars turn is a good example.
     
  10. jayrodoh

    jayrodoh YimYam Premium Member

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    I like this idea but I think his cable is waaay too long.
     
  11. XJ550H

    XJ550H Well-Known Member Premium Member

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    he just has to shorten cable 1/2 inch (add 1/2 max to sheath)
     
  12. jayrodoh

    jayrodoh YimYam Premium Member

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    Oh yeah, if only 1/2” your idea is perfect. Weird how the cable is too long though for a new replacement.
     
  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    I got the same measurements you did in your photos 1 inch under the barrel with choke off
     
  14. jayrodoh

    jayrodoh YimYam Premium Member

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    I went out to measure mine and I have no idea what I did with it. I took it off for those pics and forgot where I put it.
     
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  15. XJ550H

    XJ550H Well-Known Member Premium Member

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    point to be made is the 1 inch under the barrel with choke off . poster has an 1-1/2 under the barrel if my math is correct
     
  16. XJ550H

    XJ550H Well-Known Member Premium Member

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    he could also pull the end back away from carbs some in the clamp but not a full 1/2 inch.
    I know my choke lever can go more around the clock than needed or allowed by its cable to engage the "choke"
     
  17. cg82

    cg82 Member

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    I got Chacal to confirm the wire length compared to other cables he has and he said they are the same. WTF is going on!?!? I'm really at a loss, I don't feel like I should have to be modifying cables here.
     
  18. Simmy

    Simmy Well-Known Member

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    I think you might have the choke cable from the XJ-X, 650 turbo or a 550 with Mikuni carbs.
    The difference between the Hitachi choke cable and Mikuni choke cable is about what you have.
     
  19. cg82

    cg82 Member

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    hmm I'll have to look into that somehow
     

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