Left hand switch and choke lever

[WhiteBeard]

My left control switch gear is busted and not holding together like it should, PO seems to have stripped the threads for the screws holding it together.
I'm thinking of getting an XJR1300 switch, unless I can find a very nice FJ1100 one.
But that means relocating my choke ring assembly, since it is not built into the XJR one, or in the later FJ1200 models.
It would be cool to have the choke mounted on the fairing, like the 1200 models.

Does anybody here have any photos on how the choke is mounted on the fairing on the 1200 models?
Is there a bracket holding it in place?

Enough questions for one week...



Nat

[fj11.5]

No pics, but when I converted my 84 over to 88/89 fairings ect, I just made a bracket like this shape Π only shorter sides  with a hole in the center for the pull rod to clamp on,, used 3mm x 12mm or so wide flat steel and welded it to the chassis

[rktmanfj]

FWIW, I have one from (I think) a YZF600r that has the choke lever on it.

Might be worth a look.     

[red]

My left control switch gear is busted and not holding together like it should, PO seems to have stripped the threads for the screws holding it together.
I'm thinking of getting an XJR1300 switch, unless I can find a very nice FJ1100 one.
But that means relocating my choke ring assembly, since it is not built into the XJR one, or in the later FJ1200 models.
It would be cool to have the choke mounted on the fairing, like the 1200 models.
Enough questions for one week...
Nat

Nat,

You may be able to repair the switch housing threads.  Move the handgrip back away from the choke ring, maybe half an inch.  Remove the large screw in the switch housing, near the choke cable.  Work the choke ring to full choke, then pull down on the choke cable housing as you set the choke ring back to the OFF position.  That should free the choke cable.  Rotate the choke ring maybe half a turn, to release the choke ring from the switch housing.  Remove the other large screw from the housing, and the switch should come apart, top and bottom.  Install the two large screws gently into the switch housing threaded holes, until they just barely hit bottom.  Use an open flame (butane lighter) to warm up one screw in its' hole, slowly and carefully.  Keep testing the screw for heat by trying to turn the screw one-eighth to one-quarter turn more with the screwdriver, using no more twisting force than before.  When the screw yields to the same amount of twisting force that it had stopped before, the screw is hot enough.  Let the screw cool off completely, before you touch it with anything.  Do all the same process, for the other screw.  This job should melt new threads into the switch housing, and if you did not get the screws too hot, almost as good as new.

Plan B is the heavy-metal approach: drill, tap, and install a HeliCoil in each hole.  If you can't find HeliCoils to match the machine screws now used for the switch housing, use a more common thread, with the correct machine screws from the local nuts-and-bolts outlet, such as Fastenal.  Your phone directory should have "Nuts-and-Bolts" as a separate heading (not "Hardware").

Before you re-install the switch, wrap the handlebar with one layer of double-sided cellophane tape (not foam tape), where the switch clamps onto the handlebar.  Then you can get an excellent grip by the switch on the handlebars, without cranking the screws excessively tight.  Let me know how you do, on this repair job.

Cheers,
Red

[WhiteBeard]

Wow, great tip Red, thank you.
And thanks not a lib for the info on the YZF600r switch, very nice. 

I will see if I can fix the threads for the time being, while I search eBay in search of new alternatives.
I will give you an update when I've progressed, I managed to strip one of the screws, so that stopped me for now. 

Not my day today...

Nat

[WhiteBeard]

FWIW, I have one from (I think) a YZF600r that has the choke lever on it.

Might be worth a look.     

Not a lib, is this the switch you were talking about?
http://www.boats.net/parts/detail/yamaha/Y-2C0-83973-00-00.html

Does it fit OK, or did you need to trim it down to fit?
Are the connectors the same as on the FJ?

Thanks,
Nat

[rktmanfj]

FWIW, I have one from (I think) a YZF600r that has the choke lever on it.

Might be worth a look.     

Not a lib, is this the switch you were talking about?
http://www.boats.net/parts/detail/yamaha/Y-2C0-83973-00-00.html

Does it fit OK, or did you need to trim it down to fit?
Are the connectors the same as on the FJ?

Thanks,
Nat

Nat,

I have an FJ1200, so I don't have a bar mounted choke.

However, when I got a 2000 YZF600R front end for my '89 it came complete, with everything from bar ends down.  When I took it apart, I noticed that it had a bar mounted choke similar to the early FJ, and wondered if it would work.

I think the part number is: 4WF-83973-00-00

Regardless, here's the one I have:

[jscgdunn]

Hi
I have one as well.  On my son's 84 the signal light switch is bad so was thinking of changing.  The plugs do not match so will require cuttting splicing wires....becomes a winter project for us!




Jeff

[rktmanfj]

Hi
I have one as well.  On my son's 84 the signal light switch is bad so was thinking of changing.  The plugs do not match so will require cuttting splicing wires....becomes a winter project for us!




Jeff

I've thought of upgrading switchgear from time to time.

I think that before cutting up and splicing the wiring, I'd consider trying to switch one side of the harness or the other to the matching plug.

[jscgdunn]

Yes for sure....no cutting on the wiring harness.  Plan would be to use the old switch's plugs and splice to them.

Jeff

[rktmanfj]

Yes for sure....no cutting on the wiring harness.  Plan would be to use the old switch's plugs and splice to them.

Jeff

You should be able to depress the tang on each terminal inside the old plug and pull them out.  If they are the same type, just insert  them into the plug.  In the case of the YZF plug, you'd have to snip off the old ones and apply the FJ style terminal ends.

[jscgdunn]

Yes just what I was thinking. 

Thanks,

Jeff

[WhiteBeard]

Hey Jeff,

just wondering if the new switchgear worked out for you.
Did you get the choke lever to work properly?


Nat

[movenon]

Sounds like you have the problem solved but if you need pictures of a 88 - 93 choke set up let me know.
George