Topic: 1980 CB650 Custom: End of choke cable

[TheBroschFactor]

Good day.

I recently purchased my second bike; a 1980 CB650C (first was an '89 VTR250 Interceptor).

The problem is, the plastic piece that the end of the choke cable links into has broken just enough so it doesn't stay in. On cold days, I have to stick my hand in there to hold that lever up until the bike has warmed up. I haven't been able to find that plastic piece online. Would the use of an adhesive be safe (what's the best way to go about fixing this)?

Thanks.

[cb650]

A few have the same problem but dont think there was ever a fix.

[trueblue]

I had the same problem with my 79 650 I went hunting the wreckers and found a set of carbs off of a 550 I think, which looked basically the same but they had a metal piece instead of the plastic bit, then I just split the carbs and replaced the plastic piece with the metal one, works a treat. 

[cb650]

the cv's off the 81/82 had that part out of metal.  Someone was going to try and swap it but never heard if it worked.

[trueblue]

The carbs I got mine off of looked almost identicle to the ones fitted to my 650, they weren't the cv type, and the part for the choke was a straight fit no modification necesary

[TheBroschFactor]

Thanks for the info. I'll see if I can find one of those metal ones. I was also thinking about making a mold of the cable end, then using some JB Weld around that mold at the end of the broken plastic. Then take the mold out and stick the cable end in. It should hold for a long time, while I look for an actual replacement piece.

[TheBroschFactor]

Actually, I was able to do it with two zip ties. One on the end of the cable, which went through the loop of another that was on the end of the plastic piece. Been holding well so far. Finally able to start in sub 40deg temps today. =D

[porterlu]

I bought a 1982 cb650sc somewhat recently. I had to pull the carbs for a cleaning whereupon I discovered the same thing - the plastic connector for the Choke Cable -to- Choke Relief Spring had broken off, long before it came into my possession. A fairly ugly but workable fix had been made - wire wrapped around the end of the cable and run through the tiny hole in the metal flange just underneath the plastic bit.
I'm not looking forward to redoing this hack, but alas, spending the time sourcing and installing such a replacement piece is even less desirable when I just want to get it up and running before I run out of Autumn.

[babyfood1217]

 Could someone post a pic of this item?  Perhaps it could be fabbed...

[trueblue]

I just did a search the carbs I pinched the part from were off of a CB750 K7 they are PD41A carbs

[Hush]

I remember Kit fixing her CB650 with this problem, not sure how she did it though?

[porterlu]

Could someone post a pic of this item?  Perhaps it could be fabbed...

I just bought one off eBay in November - $19, free shipping. Good price, considering the lack availability. Bad price, considering how crappy and prone to breakage it is.

Here's the pic from the sale (wish I had thought to re-photograph it before installation) which included a replacement return spring, washer and lock.



I will never understand the rationale behind making it out of plastic since replacing a broken one is a major PITA - you have to completely tear down all the the carbs, remove all choke butterflies and rods in order to access this brittle POS.

But at least it's done. Since I had everything apart I decided to give the carbs a good cleaning even though they really didn't need it. In the process I snapped one of the floatbowl gaskets. I decided that it didn't actually happen, so I just lay the gasket back in place, put the bowl back on and turned a blind eye to it. We'll se how that turns out once I finally get everything put back in.

If someone wants to go into the business of fabricating replacement aluminum Choke Relief Spring Levers, I'd happily buy one the next time I have to rerack the carbs.

BTW, has anyone ever replaced the choke butterfly screws with bolts and lockwashers as the manuals recommend? I never could find hex bolts that fit so had to use screws with locktite - makes me a little nervous frankly.

[onepieceatatime]

I had to replace that part on the carbs for my '80 650 too. I used locktite on the butterfly screws. It is good to know that there is a metal part out there that will work.

[scunny]

I used loctite on my choke butterfly screws 3 years ago. no problems.