xr 600 carb problem

11 replies to this topic
  • dzrtrat1111

Posted December 07, 2005 - 05:20 PM


i'm new to the world of XR's i have a 96 xr 600. the problem is the choke butterfly is sticking. when i opperate the choke lever i have to manually reach to the carb and move the butterfly lever. i know that it is supposed to spring closed on it's own.. i've tried cleaning the carb really well but still no difference.. .. PLEASE HELP!! any suggestion greatly appriciated thanks

  • Shawn_Mc

Posted December 07, 2005 - 05:28 PM


What makes you think its supposed to spring back by itself?

Im not saying it doesnt, but Ive never seen one that did, or was supposed to :applause:

  • dzrtrat1111

Posted December 07, 2005 - 05:34 PM


i have a friend with an xr 400 that has the same choke set up, and his springs back.

  • kehale

Posted December 07, 2005 - 11:55 PM


springs back after warming up?
Mine has a bit of spring action to it, but it's not moving on its own...that's for sure.

The choke is a manual choke. It's not like the bi-metalic coil auto setting chokes on older holley carbs :applause:

  • snaggleXR650

Posted December 08, 2005 - 05:29 AM


The choke lever has 3 positions, there is a spring loaded ball that pops into 3 different holes to lock it into the off/half choke/full choke position. Under no circumstances do any XR choke levers open/close by themselves unless they are broke, I've had an XR 200, 400 and now 650R since '87. Maybe your friend has an aftermarket carb? Pull your seat/tank and inspect how the lever works. It should lock into each position.

On a separate note, the XR600's did have a problem with the choke flap spring breaking. Look into it, XR's Only has a replacement that supposedly fixes the weak stock setup. Otherwise, it will make short work of your motor when it gets sucked through the carb into the head.

  • Shawn_Mc

Posted December 08, 2005 - 07:04 PM


Ive seen some of the carnage from the OEM choke plate disassembling itself while the motor was running...not good....

Visit the ThumperTalk Store for the lowest prices on motorcycle / ATV parts and accessories - Guaranteed
  • bigboredbiker

Posted December 10, 2005 - 04:14 AM


I agree with Snaggle on this one...Get that choke flap looked into first, then sort out the lever. Have you checked that the pivot screw on the lever is tight? If it has worked loose there is a slim chance that the sprung ball is not locating in its positioning holes.. :applause:

  • dzrtrat1111

Posted December 10, 2005 - 09:58 AM


i may have not been clear enough, but it's not the lever that i'm having problems with. it locks in position just fine. but when you put the choke lever to the choke position the choke flap does not close like it should . i have to manually close it.. any ideas???

  • bigboredbiker

Posted December 13, 2005 - 04:55 AM


First question is: how do you close it manually? I'm assuming its a standard Keihin carb? Sounds to me like the arm isn't locating on the pivot pin.
Is the lever on the bars or the carb?

  • dzrtrat1111

Posted December 13, 2005 - 12:16 PM


the arm is on the carb, i'll take a picture to better explain it!

  • dzrtrat1111

Posted December 16, 2005 - 06:07 PM


Posted Image

notice in both pics wether the choke arm is up or down, the silver choke piece stays in the same position.. that is what i have to manually rotate to turn on the choke.. hope this helps!

Posted Image

  • Blade Man

Posted December 17, 2005 - 11:41 AM


Hey. I have the same prob on my bike ( 94 xr600r ). Its not that big of a deal. I think that a spring that holds it against the lever is broke or missing. I just pull the lever down to choke position and then push the butterfly arm down to the lever. once the bike starts it will usualy go back half way on its own.
let it run a minute and you can close, Or rather open the choke completly and not worry about it again untill you next time you start it with a cold engine !!!

Related Content


Wiseco 101MM Spark Knock Low Engine Temps by imandrewparks

Dirt Bike   Make / Model Specific   Honda   XR600/650
  • 9 replies
Want to add a kickstart to your XR650L?  Here's how - last post by clc3251

Want to add a kickstart to your XR650L? Here's how

  • 1 reply

93 xr650l Restoration Project by Zigster

Dirt Bike   Make / Model Specific   Honda   XR600/650
  • 17 replies

XR650L super moto wheels by greggkklee

Dirt Bike   Make / Model Specific   Honda   XR600/650
  • Hot  29 replies

Supercross Preview 2017 Part 1: Championship Contenders by Chris Cooksey

Dirt Bike   Special Interest Forums   Pro Racing
  • Hot  186 replies

Join Our Community!

Even if you don't want to post, registered members get access to tools that make finding & following the good stuff easier.

If you enjoyed reading about "" here in the ThumperTalk archive, you'll LOVE our community. Come join ThumperTalk today!

The views and opinions expressed on this page are strictly those of the author, and have not been reviewed or approved by ThumperTalk.