The choke cable starts out as a single cable at the lever on the handlebar lever and about half way down the cable it branches out into two cables, one for each carburetor.
1. Remove both side covers and the seat.
2. Remove the main fuel tank.
3. At the carburetor assembly, slide back the rubber boot on the choke cable.
4. Unscrew the choke valve nut and remove the choke cable, valve and spring from the carburetor.
5. Repeat steps three and four for the other carburetor.
6. Remove the clutch switch wires at the clutch lever.
Caution: Cover the frame and front wheel with a heavy cloth or a plastic tarp to protect it from accidental spills.
7. Remove the bolts and clamp securing the clutch master cylinder to the handlebar.
8. Remove the clutch master cylinder and lay it over the front fender. Keep the reservoir in an upright position to minimize loss of hydraulic fluid and to keep air from entering the clutch system.
9. Remove the screw securing the switch assembly together.
10. Remove the choke cable from the switch and the choke lever assembly on the handlebar.
11. Remove the plastic trim panels on each side of the steering head.
Note: the piece of string on the next stop will be used to pull the new choke back through the frame. So it will be routed in the same position as the old cable.
12. Tie a piece of heavy string or cord (approximately 7 feet or 2 meters long) to the carburetor end of each choke cable, wrap the end with masking or duck tape. Do not use an excessive amount of tape, as it must be pulled through the frame loop during removal. Tie the other end of the string to the frame or air box.
13. Unhook the choke cable from any clips on the frame.
14. At the choke lever end of the cable, carefully pull the cable assembly and attached string out through the frame and from behind the headlight housing. Make sure the attached strings follow the same path that the cable does through the frame.
15. Remove the tape and untie the string from the old cable assembly.
16. Lubricate the new cable assembly.
17. Tie the string to the new choke cable assembly and wrap it with tape.
18. Carefully pull the strings back through the frame, routing the new cable through the same path as the old cables.
19. Remove the tape and untie the strings from the cable and the frame.
20. Attach the choke cable onto the choke lever assembly.
21. Install the choke valve unto the carburetor body.
22. Tighten the choke valve nut by hand and then turn it an additional 1/4 turn with a 14 mm. wrench.
23. Repeat steps 20 to 22 for the other carburetor.
24. Install the switch/choke assembly on the handlebar and tighten the screws securely.
25. Install the clutch master cylinder.
26. Attach the clutch switch wires to the clutch lever.
27. Operate the choke lever and make sure the carburetor linkage is operating correctly, with no binding. If operation is incorrect or there is binding, carefully check that the cable is attached correctly and there are no tight bends in the cable.
28. Reinstall the main fuel tank, seat and sidecovers.
29. Adjust the choke cable as required.
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