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  #1  
Old 06-10-2012, 10:12 AM
CUBuffs CUBuffs is offline
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Choke lever options

Hey guys, I have an 80 SG with broken tab on the choke lever. A replacement lever has been elusive. Does anyone have an idea for other levers that may work with the SG? Thanks.
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  #2  
Old 06-10-2012, 10:32 AM
crazy steve crazy steve is offline
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There's lots of broken levers out there....

There's two types, a zinc-plated version used on the early bikes and some later standards, and the chrome-plated ones used on later bikes including your SG. They will interchange, but are shaped slightly different.

Why not fix what you have? Faced with the same problem, I repaired mine.



If you look closely at the carbs, I cut/shaped a piece of 1/8" aluminum to fit on the back of the existing lever with a new tab sticking up and fastened it on with two 8/32 buttonhead allen screws. Works great, and is nearly invisible.

Do make sure you clean/lube all the friction points in your choke linkage so it moves easily...
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'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...

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'86 XL883/1200 Chopper
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Old 06-10-2012, 12:30 PM
CUBuffs CUBuffs is offline
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By "Early bikes" you mean earlier XS11's?
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74 KZ400
78 KZ650
78 KZ750
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  #4  
Old 06-10-2012, 02:27 PM
crazy steve crazy steve is offline
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Yes. There's two different designs/finishes used on the XS11 carbs...
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Fast, Cheap, Reliable... Pick any two

'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...

Other current bikes:
'93 XL1200 Anniversary Sportster 85RWHP
'86 XL883/1200 Chopper
'82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
Cage: '13 Mustang GT/CS with a few 'custom' touches
Yep, can't leave nuthin' alone...
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  #5  
Old 06-10-2012, 08:22 PM
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bikerphil bikerphil is offline
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I got rid of my lever altogether and attached a chrome cabinet knob, it threads on to the existing enrichener rod. IIRC, I had to use a die to make the proper threads on the rod...

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79F - owned since '89 - FJ fork mod, solo seat mod, Dyna 3Ω's, Kerker, 14MM M/C (152K miles)
79SF - every day rider, solo seat mod, Brembo 16MM M/C, Accel 3Ω's, Supertrapp (115K miles)

"If it ain't broke, modify it"

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  #6  
Old 06-11-2012, 01:14 PM
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CatatonicBug CatatonicBug is offline
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Quote:
Originally Posted by bikerphil View Post
I got rid of my lever altogether and attached a chrome cabinet knob, it threads on to the existing enrichener rod. IIRC, I had to use a die to make the proper threads on the rod...
Doing it that way, you lose the spring tension on the lever's hinge that keeps the choke lever pressed in though. Not that I would expect the choke shaft to go flopping around by itself, especially with the detent balls in there, but it might be a potential issue.

I got one from a local junkyard. It wasn't the same shape, as it was from an earlier model, but it fit just fine.
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  #7  
Old 06-11-2012, 03:46 PM
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bikerphil bikerphil is offline
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Never had any problems with it popping out of it's set position, YMMV.
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79F - owned since '89 - FJ fork mod, solo seat mod, Dyna 3Ω's, Kerker, 14MM M/C (152K miles)
79SF - every day rider, solo seat mod, Brembo 16MM M/C, Accel 3Ω's, Supertrapp (115K miles)

"If it ain't broke, modify it"

25+ year XS11 owner

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