Hey guys,

I was wondering if anyone could help me out. I just got my bike back from the shop and had them clean the carb out from a long winter in the garage. I've ridden once since then and just today I went to start it and pull the choke. It pulled all the way outta the carb and it wont go back in. Its like something is blocking it inside the carb. Do I need to pull the carb out and take it apart for this to go back in? Any help would be appreciated. Thanks.

 

The choke plunger just screws into the carb body, but it can be a bit tricky to access the 12mm(I think) plastic nut. Maybe hold the plastic nut/threaded portion and pull the choke "out" just like you're doing when you're choking the carb. This may give you more wiggle room to thread the plastic housing back into the carb. I don't think there's anything inside the choke plunger hole that would block the choke from going in. It looks like maybe you have the choke "extended" or in the "closed" position which may make threading the plastic housing into the body more difficult.

 

Dude! That sucks! Are you going to bring it back to the shop that did the work and make them fix it? I would be pissed. I suppose you don't trust them anymore though. Put some Stabil or Seafoam in your fuel system before your bike goes to bed next Winter and you won't have to do the spring cleaning again.

 

If you have any assembly lube, put a little of that on it. If not, a dabof grease would work. It should go right back in. I would definitely let the shop know about it though.

 

Those plastic threads can get screwed up real easy, especially if trying to put it back in while the carb is still on the bike - not much finger room & hard to tell if it's seating right.

 

Good pics.
I had that same thing happen not too long after I got my 07. Mine screwed back in pretty easily once i got my fingers in there and lined it up ok. Good luck.
Dan
https://www.kawasakiforums.com/forum...terally-24523/

 

The problem i'm having is I can screw the threads back on, but the plunger itself is sticking out about 3/4 of the way, which is not normal and it wont go in any further then that. Its like its hitting something inside the carb. Maybe its just me...

 

I Got it Guys! I thought it was sticking out a bit more then it should but it started right up when i screwed it down nice and tight. Loc-tite for the win! Appreciate all the replys.

 

I hope that plastic on the plunger housing is compatible with loctite. Loctite will melt many types of plastic if you weren't aware of that. I don't think I'd recommend loctiting it anyway. Maybe some teflon tape or the like.

 

Glad you got it. I wanted to take mine out, but it would not budge. No room to get a wrench on it even when the carb is out (tm36-68). I wanted to put a remote choke on it because the remote has 1/2 choke and that is all the bike needs.

David