84 FJ1100 left hand switch assem trouble

[jdvorchak]

I took the clutch MC off for rebuild and also completely undid the left switch housing. Now I can't seem to get it back together and still have just a fraction of an inch of travel in the choke lever. Carbs are off for rebuild. I must be assembling it wrong but I can't seem to figure out my mistake. I have the choke lever positioned so the smaller of the two levers is up and facing away from my thumb position. Like at the 1 or 2 o'clock position. The little arrow is pointing down.  The longer lever is pointed about 7 or 8 o'clock if viewed from the front of the bike in line with the handle bar.






This is what I started with. The brake MC was in just as bad shape.



Does this look right? 

[FJ1100mjk]

Something is clocked wrong, or misaligned. You need to take it back apart again, and give it another try, or two. When I took mine apart, I know it wasn't all that intuitive when it came to its re-assembly. However, I figured it out, then had an oh yea, now I see it moment, then it fell together.

Good job on the refurbishment of your clutch's master cylinder.

[Flynt]

Should look like this...  I think you have it on the wrong side of the travel stop.





Hope that helps.

Frank

[jdvorchak]

Yes that helps a lot thanks. I'll take it back apart and see if I can get it to match yours. How much throw does it have on yours? When I had mine more upright, like yours, it barely moved a few degrees. It may be easier when I get the carbs installed. Then that cable is flopping all around.

[Urban_Legend]

Hi
By Throw, I am assuming how far does the lever turns. On my 84 it would be the equivilent of from (on the old clock face) 12  to 2 with a small arrow just below the top lever pointing to where it says choke on the switch gear..  My switch gear is relitivley new (NOS online when purchased 18 months ago - a rare find). It can take some jiggery (offical FJ Technical term) to get all the bit to line up right, especially of completely disassembled with the choke line removed. Don't loose the small wedge shaped holder for the choke cable. Impossible to find.

Mark

[Flynt]

How much throw does it have on yours?

It rotates about 1/4 turn I'd say.  There are two distinct positions, fully choked and about 1/2 choked.  They are both marked by a detent position.

Frank

[jdvorchak]

thank you for the photos. I finally got it by twisting the larger lever all the way under the horn button about 1/4 turn. that allowed me to put the top of the clam shell on the back side of the travel stop. As someone mentioned it's not intuitive. You have to rotate the choke lever almost a full turn clockwise. It helps if you have the sheath loose from the clamp on the carb.