Choke lever operation L9

Welcome to the ZXRworld forum.

Moderator: Moderators

Post Reply
MRLZXR400
Posts: 67
Joined: Mon Sep 24, 2018 7:31 am
My Bike: ZXR400

Choke lever operation L9

Post by MRLZXR400 » Sat Apr 18, 2020 8:41 am

When I put the choke on on my L9 the lever creeps back to about mid way, doesn’t stay on full choke, which is a bit of a pain when you’re trying to find the spot you need while it warms up. Before I take the tank off etc to investigate, can anyone tell me if that’s just the way they are on an L9?

Many thanks
Mark
1999 Kawasaki ZXR400 UK L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1996 Ducati 748.

User avatar
banner001
Track day God
Track day God
Posts: 2433
Joined: Sat Sep 24, 2011 3:27 pm
My Bike: ZXR400 L4
Location: Nuneaton

Re: Choke lever operation L9

Post by banner001 » Sat Apr 18, 2020 6:56 pm

The lever might come back a tiny bit, but should not really move unless you move it. Does your lever move smooth, with resistance, in jerky steps?
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

MRLZXR400
Posts: 67
Joined: Mon Sep 24, 2018 7:31 am
My Bike: ZXR400

Re: Choke lever operation L9

Post by MRLZXR400 » Sat Apr 18, 2020 9:57 pm

Hi Banner, thanks for the reply.
It moves really smoothly, I did a pretty thorough refurb on the bike and remember checking the choke cable, greasing the lever mech slightly in the casing.
I rebuilt the carbs too and remember a return spring for the choke, maybe I’ve fitted that incorrectly.

But it definitely goes back at least half way if I remove pressure.

Mark
1999 Kawasaki ZXR400 UK L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1996 Ducati 748.

watsonm359
Posts: 29
Joined: Sun Nov 29, 2015 8:00 pm
My Bike: ZXR400H2
Location: Bridgend

Re: Choke lever operation L9

Post by watsonm359 » Mon Apr 20, 2020 7:25 am

Inside the housing which holds the cable attached to the choke lever, there is a small rubber block that is pushes up against the body of the lever via a spring. This rubber block is what holds the lever in place and as ever with rubber over time, can deteriorate. I’ve seen this happen on several occasions and unfortunately you cannot just replace that rubber block. Options are to just accept it and work with it or take the chance and locate a second hand housing and see it one is any better.

Hope this makes sense.

Mike

MRLZXR400
Posts: 67
Joined: Mon Sep 24, 2018 7:31 am
My Bike: ZXR400

Re: Choke lever operation L9

Post by MRLZXR400 » Mon Apr 20, 2020 7:35 am

Hi Mike,

Thanks for your reply.

Yep I think you’ve nailed it, inside the housing is a little square bit of plastic that obviously had the rubber block attached to it, and I guess by your description that adds a bit of resistance like a brake would.

Thanks for that, I’m thinking a new one might be the only answer or a bit of trial and error with a bit of rubber and glue. Not much else to do with my spare time right now anyway!

Thanks again
Mark
1999 Kawasaki ZXR400 UK L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1996 Ducati 748.

MRLZXR400
Posts: 67
Joined: Mon Sep 24, 2018 7:31 am
My Bike: ZXR400

Re: Choke lever operation L9

Post by MRLZXR400 » Mon Apr 20, 2020 8:36 am

Hi again Mike,

In fact after further investigation I see what you mean about the little rubber shoe, it’s sort of an opaque rubber wedge with a spring inside as you described.

You were right it had worn slightly and therefore not applying enough pressure to the choke lever it should friction up against.

So I removed a little bit of the shoulder with a Stanley knife so that the shoe bit stuck out further and then put some little plastic shims that I made by cutting little squares out of an old plastic milk carton and dropped them in to the bottom of the housing. This meant the shoe stuck out more if that makes sense, allowing the little spring to do its work.

Reassembled and hey presto, works perfectly!!

Thanks again for the explainer Mike.

Very satisfying little job done.

Mark
1999 Kawasaki ZXR400 UK L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1996 Ducati 748.

watsonm359
Posts: 29
Joined: Sun Nov 29, 2015 8:00 pm
My Bike: ZXR400H2
Location: Bridgend

Re: Choke lever operation L9

Post by watsonm359 » Mon Apr 20, 2020 8:59 am

Hi Mark,

Sorted mate, excellent news. 👍

User avatar
banner001
Track day God
Track day God
Posts: 2433
Joined: Sat Sep 24, 2011 3:27 pm
My Bike: ZXR400 L4
Location: Nuneaton

Re: Choke lever operation L9

Post by banner001 » Mon Apr 20, 2020 10:07 pm

:excited
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

Post Reply