Choke cables XRV650 AT RD03

[dod]

I decided to sort out the choke on my XRV650 as it was stiff and probably not working well.

It will not start cold with no choke, probably because it is often many days between starts so junking the choke assembly is probably not an option although I will try and make some blanking plugs if I can get a 12x1mm die. Cannot use brake caliper blanking plugs as they are 10x1mm.

As expected the cables were not running freely although the plungers were free in the carbs.

On stripping the cables the single cable lever to splitter would not loosen to completely free, Stripping it down it appears to be nylon lined, not obvious when assembled, so oiling it is not doing it any good as I have heard that oiling nylon cables expands the nylon making it stiff!!
The 2 cables splitter to carbs are not nylon lined and oiling has freed them up.

Is this the normal setup on this cable assembly.

I assume it is an original assembly, looks like a factory job as the cables are sleeved with a thick sleeve on the cable over the engine and thinner sleeve on the cable that runs on the lefthand side and have the proper elbows and rubber ends.

[BobA]

You can use white spray grease on the nylon and steel cables, it's never caused me any problems, and my choke cables are more slippery than the captain of the costa concordia.

To get the best results, clean everything up and getting all the brown gunge out, then hold the cable vertically and work the cable backwards and forwards as you spray grease down into it, so the grease works its way right in.

Always works for me.

[dod]

Made some blanking plugs and fitted them, no it will not start with no choke, did check by taking out one blanking plug assembly removing the choke plunger and refitting the blanking plug. Engine started immediately on the button although only one cylinder choked. So have freed up the cable assembly and refitted it.
Cold engine started immediately on button when choked.
When warmed and no choke idle was low 6-700. Previously I had wound down the idle some months back as it seemed fast so the chokes must have been on a bit raising the idle. Now back to correct speed.
I had a set of NTV650 (I think!) carbs, checked the parts list they use the same cable end assembly as the RD03 & 4 and 600 TA, another source of bits, I brought the tatty carb set for a few £'s at a jumble, somewhat cheaper than any individual component!

Drawing of blanking plug will fit RD03 and RD04 and some Transalp 600 (XL600VH to XL600VR)