Does anyone know how to repair the choke lever on a 500 sportsman. I have a kit but dont know how to get the little black box behind handlebar pod apart to put in new pieces. Any help will be greatly appreciated.Thanks.

 

Welcome to the forum! Pull the black choke holder out to where you can "carefully" take a sharp razor knife at the bottom all around the seam and the top part of the holder,spring and plunger (usually broken) will come up. Then you can install the new plunger,spring and snap the cover back on. When you install it back in place,pull the plunger out with pliers,and if you have small vice grips,lock it at the bottom to hold the plunger out and then you can install the new lever and small pin. OPT

 

Thank you very much. I thought thats how it came apart but was afraid to break it.I have been unable to find another one on any parts sellers websites.Thanks again.

 

Yea, the plastic choke lever assy comes with the cable and adjuster at the carb so be careful! Cheapest I've found is about $42. OPT