I have taken off the air box & I can now get to the carbs & the cable. What I can't figure out is how to make it let go. You can tell there is no tension on the choke cable. It is moving but where ever it hooks is stuck. Quad runs fine, but I can not stand when everything is not perfect. Any ideas?

 

Order the beefier springs from kawi.

 

Where are the stock springs? I have my bike apart & have removed the slides & all I see is two copper things trying to move but they are stuck.

 

my dealer just replaced my choke springs this week.they said kawi was out of upgrade springs so on another 650 and mine they used springs off a yamaha phazer snowmobile.they are much heavier and there is no doubt about them being on or off.

 

2fat4moto take out your plungers from the carbs the spring you are looking for is just before the plunger. When pull on the choke lever you can see the choke plunger operate and the spring you see moving is the one to replace, or hopefully it moves. There is a heavier spring from a KLM series motorcycle that will fit and is heavier this will prevent the thing from hanging up. When you put it back together you can use the existing spring but pull it out to stretch it, but make sure you lube the tube with a white grease and things should work fine.

 

alltoys, thank you so much. I got up the nerve to yank the plungers out. They were stuck. I believe that the yanking took care of the springs. LOL!
The choke was stuck due to sand in carbs. I sunk the quad one day & thought I had covered all bases. Did not think to clean in this area. I had cleaned the carbs & jets. Well, going to put this mess back together after I do some more cleaning. Thanks again for your help!
P.S. Do not sink quad. Stay away from deep water! At least I will after this mess![img]i/expressions/face-icon-small-smile.gif[/img]

 

Well, it is back together and working fine. Thanks again to alltoys for the help. It was enough to get me going in the right direction and to get it put back together in the correct manner. Thanks again. It works great![img]i/expressions/face-icon-small-cool.gif[/img]

 

I did take the copper pistons off and stretch stock springs. Went for a ride and WOW! This thing runs better than it ever has. I think there might have been a problem with the choke from the factory. It will do a free standing wheelie and has never been able to do this since I have had it. I thought it was the chrome wheels and big tires. Nope! I have never been able to start quad by using the choke. I always have had a little trouble starting it. But now it works like it should. I hope I don't have to go back in there and work on it again. That was not fun, but it was educational.

 

2fat4moto glad everything worked out I had this problem from day one and my first remedy was to cut the choke cable as I was in the bush the bike wouldn't start proper, couldn't run the winch and on and on. When you ride with budies that have polaris's and you feel pretty bad with a new machine and the !*$%^@)$&:" thing wont work. Choke cut the bike worked great lots of power and so on then I found the springs from a KLM bike and no more problems. Again glad to see you are happy with the remedy.

 

If you are getting dirt in the cable then you have to old style cable and it should be replaced under warranty by kawi. The new assy is essentially the same cable but with heavier springs and a rubber boot covering where the cable splits from one into two.