Choke Linkage?

[Riolongo]

Okay, so I removed my carbs a few weeks ago, disassembled and cleaned everything up, installed new idle jets, also picked up the rebuild kit from RPM, new fuel filter, de-rusted gas tank, new spark plugs, new air filter and reinstalled everything. I started the bike on the weekend, everything seemed okay and was going to sync carbs today. However, today bike won't start, fires, but that's it, the weather was maybe 6 or 7 degrees warmer on weekend, not so today. 

I removed the gas tank today and all looks okay, almost looks like I'm getting very little choke, if any.  The only thing I noticed is that when pulling on the choke the linkage only slides maybe 1/8", is this normal, should it move more, or am I missing something?

[FJmonkey]

1/8th is too small. the lever should pull out more than 1/2 inch, almost 3/4 inch for full choke....

[racerrad8]

Did you completely remove the choke linkages?

#1 linkage is different from the other three and will hold the choke plungers open on the other three and limit travel as well.

Randy

[Riolongo]

Any thoughts as to what would prevent the choke from moving more than it is?  I don't see anything binding along the length of linkage and I didn't remove it when cleaning the carbs, also not sure if internally anything could cause it to bind?


Thanks,

Mike

[FJmonkey]

The cable goes to the carbs, follow the choke rod and where it connects to each carb and what might cause the restriction...

[Riolongo]

Done that, can't see anything that would restrict the sliding of the linkage, as mentioned it only moves at most 1/8". I've tried moving it manually without the use of the choke cable and get the same results, even if I gently pull the plunger on #1 carb it only moves a little.  I'll keep looking as I'm sure it's something simple that I'll kick myself for once I figure it out.

[FJmonkey]

Done that, can't see anything that would restrict the sliding of the linkage, as mentioned it only moves at most 1/8". I've tried moving it manually without the use of the choke cable and get the same results, even if I gently pull the plunger on #1 carb it only moves a little.  I'll keep looking as I'm sure it's something simple that I'll kick myself for once I figure it out.

If the bar is not moving much then you have narrowed your choke problem to the the carbs. Good work. Maybe one of the screws that lock the small brackets to the carbs is out of place. Maybe something is is restricting the travel. The bar has pockets for the screws but if someone cranked a screw down where it does not belong then it could reduce the travel... Picture how the bar needs to move side ways and look for anything that stops it....

[Riolongo]

Nothing seems out of place, ripped carbs out again and have on the bench. So far no change, can't see anything out of place but will continue to investigate.  I'm able to pull the plunger out maybe another 1/8" beyond what the slide will do but that's it, so total of maybe 1/4" movement.

[movenon]

Nothing seems out of place, ripped carbs out again and have on the bench. So far no change, can't see anything out of place but will continue to investigate.  I'm able to pull the plunger out maybe another 1/8" beyond what the slide will do but that's it, so total of maybe 1/4" movement.

I don't know if this will help but... http://www.fjowners.com/index.php?action=gallery;sa=view;id=2796  When you find the answer it will be simple  
Keep at it.
George

[movenon]

I just measured mine and my choke rod moves just a bit over 1/2 inch. 9/16 inch to be exact as I can get.
George

[mr blackstock]

G'day,

I had a similar problem on my 85 FJ1100.  The cable seemed not enough to actuate the choke rod down at the carbies.  After looking at the whole system of movement, the little choke plungers were very stiff, I had to lightly emery them to get them moving smoothly.  Next I looked at the choke rod and spring.  The spring was pulling the rod from between carb 3 & 4, so I moved the spring and arm to between carb 2 & 3.

The below picture shows the choke mechanism before I altered it.


The below picture shows the new placement of the "arm"


By moving the choke cable arm and tossing the spring, to between carbie 1 & 2 the stiffness of the choke operation is greatly reduced.  The origonal position of the choke arm, between 3 & 4(as found on my bike) meant that wear through age was making the choke very hard to use.

It worked for me, not sure what year or type you have though.

cheers, Gareth

[Riolongo]

As stated I ripped the carbs out again to investigate and after a few minutes of monkeying around I found the problem. It turned out that the problem was simply  really tight plungers, not sure why as the choke was operating fine before I cleaned the carbs.  I put a drop of oil on the plungers, at least as much as I could access and waited a few minutes, I then used needle nose pliers and gently applied pressure outwards hoping they would move and they did.  The plungers at carb #1, 3 and 4 moved relatively easy but #2 was quite stubborn, a little more persuasion and out it came.  I now have full range of motion and the choke is operating properly, reinstalled carbs and she fired up right away.

Thanks for all the suggestions,

Mike

[movenon]

As stated I ripped the carbs out again to investigate and after a few minutes of monkeying around I found the problem. It turned out that the problem was simply  really tight plungers, not sure why as the choke was operating fine before I cleaned the carbs.  I put a drop of oil on the plungers, at least as much as I could access and waited a few minutes, I then used needle nose pliers and gently applied pressure outwards hoping they would move and they did.  The plungers at carb #1, 3 and 4 moved relatively easy but #2 was quite stubborn, a little more persuasion and out it came.  I now have full range of motion and the choke is operating properly, reinstalled carbs and she fired up right away.

Thanks for all the suggestions,

Mike

Told you it would be simple ). Hope all problems are that easy... Now you can sync and tune........................
George