DISASSEMBLY/ASSEMBLY INSTRUCTIONS FOR KLRS AND ATVS

1985-2008 MODELS AND ATVS

  1. Loosen the choke cable adjustment at the choke lever end first.
  2. Remove the seat, then both side cowls, then the tank, remembering that there may be more than one gas tubes attached to the petcock etc.
  3. Use a 13mm wrench to undo the plastic choke barrel.
  4. Gently pull back the spring from the plunger and slide the plunger off the cable nipple. Beware of the spring disappearing into the dark recesses of the garage if you let it.
  5. Remove the small dust cap from the end of the choke barrel and slide it off the cable.

 

2008-PRESENT DAY MODELS

  1. Remove the seat, then both side cowls, then the tank, remembering that there may be more than one gas tubes attached to the petcock etc.
  2. The choke cable adjuster is to be found along the main frame about 12” from the carburetor. Loosen it to facilitate the removal of the plunger.
  3. Use a 13mm wrench to undo the plastic choke barrel.
  4. Gently pull back the spring from the plunger and slide the plunger off the cable nipple. Beware of the spring disappearing into the dark recesses of the garage if you let it.
  5. Remove the small dust cap from the end of the choke barrel and slide it off the cable.

 

ASSEMBLY FOR ALL KLR MODELS/ATVs

  1. Pull the cable out of the sheath as far as it will go.
  2. If you pulled the grease cap off the sheath, replace it now on the sheath.
  3. Slide the new choke barrel onto the cable and push the sheath end into place.
  4. Slide the spring onto the cable and into the choke barrel.
  5. Gently compress the spring until the plunger can slide sideways onto the cable end nipple.
  6. Taking care not to cross-thread the barrel, screw it up into the carburetor. Tighten with a ½” wrench.  [This part is hard as there isn’t much room. You can try bending a wrench specially if you want].
  7. Slide the dust cap over the end of the choke barrel to seal.
  8. Adjust the choke cable to remove the slack and give a smooth operation.
  9. Replace the tank, side cowls and seat.
  • Item #: 0010

DISASSEMBLY/ASSEMBLY INSTRUCTIONS FOR KLRS AND ATVS

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