K100LT Choke lever details

[PaulP]

Hello,

I've decided to strip down my K100 after it's sat for the last 18 years in my shed, and tidy it up. I'm in the middle of that now.

I had a little question regarding the choke lever, I'd taken it off to polish up since the paint was chipped and I did a stupid thing!

After polishing etc, I went over to my outside tap to rinse it off. I shook it to get the water off and launched the internal washer into the darkness.

I found the little tabbed washer which locates on the top, but I am sure I heard something else fly off. Is there another washer on the underside of the lever?

I've looked through my Haynes, and tried searching for an expanded diagram on t'internet to no avail.

I wonder if anyone could be so kind as to let me know?

Many thanks!

[Laitch]

I shook it to get the water off and launched the internal washer into the darkness.

A lot of people wouldn't take on the challenge of working with small parts in the dark. I'm glad to know the spirit of adventure still thrives in the isles of Shackleton. Here's a diagram. If I'd done this, I'd reassemble it to see if it worked correctly. If it didn't, then I'd start searching.

[PaulP]

Excellent, thank you, that is exactly what I was searching for.

And yes, we're a spirited bunch here in the West of Scotland. You'll be pleased to hear my misadventure was in 50mph winds as well, aka 'Blawin' a hoolie'. Most of the work is in the shed though.

I had assembled it back together, it appears to function correctly, but it's a little wobbly. If there wasn't a washer destined for in there, I may well just add one.

Thanks again!

[Laitch]

You'll be pleased to hear my misadventure was in 50mph winds as well, aka 'Blawin' a hoolie'. .

Perfect!

[Inge K.]

It should also be a small steel ball and spring in there (for locking the lever in the first position)
which isn't present at the drawing.

[PaulP]

I've got the ball and spring intact; the tabbed washer and the semi-circular insert, but I'm convinced there is meant to be another washer underneath the lever.

Can anyone confirm whether or not their lever is slightly wobbly in use?

It has a positive click when moved and engaged, there are only two positions, open and closed, is that correct?

[TrueAce]

My levers move smoothly and firmly, no wobble, clicks. Very progressive.

[Laitch]

It has a positive click when moved and engaged, there are only two positions, open and closed, is that correct?

Mine has off, half and full. Full is ~90º from off. The lever doesn't wobble. Is the "tabbed washer" part #4 on the diagram? If the surfaces of the semi circular washer are different, try inverting it. Be sure the open end of it is in the same orientation as the drawing.

[PaulP]

Yes indeed, I mean part no.4.

It is such a simple mechanism, with next to no room for error, and I'm not a stranger to spanners. I've had it up, down and round about, but still there is quite a bit of movement in the lever.

I'm considering proceeding by means of a firm, yet judicious chap with a hammer! (Not really)

[Laitch]

I'm considering proceeding by means of a firm, yet judicious chap with a hammer! (Not really)

How about using a four-foot breaker bar extension on a right-angled slotted screwdriver? Post before and after photos. :giggles

[PaulP]

You joke, but I live on a farm and have found that there aren't many items of machinery that don't fall into line when given a fair auld wallop with a hammer. Although in this case, perhaps not.

If it can't be fixed with a hammer, gaffer tape or expanding foam, my mechanic's Tourettes kicks in.

I made a wee steel washer on the lathe, firmed it right up. Many thanks to you all for your assistance/advice. Undoubtedly, I will have more questions in the weeks ahead.

[Laitch]

I made a wee steel washer on the lathe, firmed it right up.

Using a lathe is cheating, Paul, unless it's belt-driven by hungry gerbils.

[Inge K.]

Nice that you got it sorted.....I would add some, if someone else ends up in the same situation later.

the tabbed washer and the semi-circular insert, but I'm convinced there is meant to be another washer underneath the lever.

It shouldn't be any tabbed washer present, but a rather big wave washer (#4) between the screw head
and the lever.....this wave washer adds pressure to the lever and makes the movement firm.

It has a positive click when moved and engaged, there are only two positions, open and closed, is that correct?

As Laitch says...it's off, half and full. The detent ball should lock the lever in half position, if not the spring is
to weak or the semi circular plate is out of position.

[PaulP]

Ah, thanks for that, although it has confused me further.

Part #4, which I referred to as a 'tabbed washer', is a washer with two downwards protruding 'teeth', in order to engage the mechanism below.

I have a positive click at what is presumably half choke, and then the lever doesn't want to move much further. Am I to assume it should have further movement beyond the 1st click?

I see no sign of a 'wave' washer, perhaps this is the part which has disappeared into the ether?

I think I might need to track down another K100, and whip the lever off for a gander. I'm not happy with using my fabricated washer, it firms up the lever OK, but I'd rather have the correct components.

It's frustrating all this bother for such a simple mechanism!

And to pre-empt any comments, I've already kicked myself. Hard.

[Laitch]

I have a positive click at what is presumably half choke, and then the lever doesn't want to move much further. Am I to assume it should have further movement beyond the 1st click?

Yes. It does. Your K100LT and my K75 have the same choke assemblies.  On my bike, half-choke is a 45º; full choke is at 90º.

[Inge K.]

Piccy:

[PaulP]

Thanks to all for the pictures / assistance, indeed yes I had all the components, it's just that the lever has a fraction of movement. I put it down to the fact that I'm too pernickety to allow a little play in the lever.

The lever goes to its first stop at 45deg, and then moves a little further but not quite to 90deg. I think that may be a little stiffness in the mechanism on the throttle bodies from non-use over the years, which I hope to cure with a good dose of WD40 and some full-on wiggling action.