JAVIK Choke Lever Switch Instruction Manual

1. Product Overview and Compatibility

This manual provides instructions for the JAVIK Choke Lever Switch, designed as a direct replacement for Kawasaki OEM part number 46092-1217. This choke lever is constructed from polyhexamethylene adipamide (PA66), offering impact resistance and high strength for reliable performance.

1.1 Compatible Models

The JAVIK Choke Lever Switch is compatible with the following Kawasaki ATV models:

• Kawasaki Brute Force 650 KVF650 (2005-2013)
• Kawasaki Brute Force 750 KVF750 (2005-2007)
• Kawasaki Prairie 300 KVF300 (2002)
• Kawasaki Prairie 360 KVF360 (2003-2013)
• Kawasaki Prairie 400 KVF400 (2002)
• Kawasaki Prairie 650 KVF650 (2002-2003)
• Kawasaki Prairie 700 KVF700 (2004-2006)
• Kawasaki KFX700 (2004-2011)

Image 1.1: JAVIK Choke Lever Switch shown with a Kawasaki ATV and a list of compatible models.

Image 1.2: The JAVIK Choke Lever Switch, highlighting its OEM replacement number 46092-1217.

2. Installation (Setup)

This choke lever is designed for straightforward installation and does not typically require professional assistance. However, basic mechanical knowledge and appropriate tools are recommended. Always ensure the vehicle is turned off and cool before beginning any installation.

2.1 Required Tools (Typical)

• Screwdriver (Phillips or flathead, depending on existing fasteners)
• Pliers (optional, for cable manipulation)
• Work gloves

2.2 Installation Steps

1. Locate the Existing Choke Lever: Identify the current choke lever assembly on your ATV's handlebars.
2. Disconnect the Choke Cable: Carefully loosen any retaining screws or clamps holding the choke cable to the old lever. Detach the cable from the lever mechanism.
3. Remove the Old Lever: Unscrew or unclip the old choke lever from the handlebar.
4. Position the New Lever: Place the JAVIK Choke Lever Switch in the desired position on the handlebar. Ensure it does not interfere with other controls.
5. Attach the Choke Cable: Connect the choke cable to the new lever mechanism. Ensure the cable is properly seated and moves freely.
6. Secure the New Lever: Fasten the new choke lever to the handlebar using the appropriate screws or clamps. Tighten securely, but do not overtighten to avoid damaging the plastic.
7. Test Functionality: Operate the choke lever several times to ensure smooth movement and proper engagement/disengagement of the choke mechanism. Verify that the choke cable pulls and releases correctly.

Image 2.1: The JAVIK Choke Lever Switch, emphasizing its ease of installation.

3. Operating Instructions

The choke lever is used to enrich the fuel-air mixture for easier starting of the engine, especially in cold conditions. It is typically a temporary measure used only during startup.

3.1 Using the Choke Lever

1. Cold Start: When starting a cold engine, fully engage the choke lever (pull it out or move it to the "ON" position, depending on your ATV's design). This restricts airflow, creating a richer fuel mixture.
2. Engine Start: Start the engine as usual. The engine may run at a higher idle speed with the choke engaged.
3. Warm-up: As the engine warms up, gradually disengage the choke lever (push it in or move it to the "OFF" position). The engine should transition to a normal idle speed.
4. Avoid Prolonged Use: Do not operate the vehicle with the choke fully engaged for extended periods, as this can lead to poor fuel economy, fouled spark plugs, and engine damage.

Image 3.1: Detail of the textured grip on the choke lever for improved handling.

4. Maintenance

Proper maintenance ensures the longevity and reliable operation of your choke lever switch.

• Regular Cleaning: Periodically clean the choke lever and surrounding area to remove dirt, mud, and debris that could impede its movement. Use a damp cloth and mild detergent if necessary.
• Inspect Cable: Regularly inspect the choke cable for fraying, kinks, or corrosion. Ensure it moves freely within its housing. Lubricate the cable if recommended by your ATV's manufacturer.
• Check Mounting: Verify that the choke lever remains securely mounted to the handlebar. Tighten any loose fasteners as needed, but avoid overtightening.
• Avoid Harsh Chemicals: Do not use strong solvents or abrasive cleaners on the plastic lever, as this can cause damage or discoloration.

Image 4.1: The choke lever's construction from PA66 material contributes to its durability and waterproof properties.

5. Troubleshooting

If you experience issues with your choke lever, consider the following common troubleshooting steps:

• Choke Lever Sticking:
  • Check for dirt or debris around the lever mechanism. Clean thoroughly.
  • Inspect the choke cable for kinks or corrosion. Lubricate or replace the cable if necessary.
  • Ensure the lever is not overtightened on the handlebar.
• Engine Hard to Start (Cold):
  • Verify the choke lever is fully engaged when attempting a cold start.
  • Check if the choke cable is properly connected and actuating the choke mechanism on the carburetor.
  • Ensure the choke mechanism on the carburetor itself is not stuck or faulty.
• Engine Runs Rough with Choke Off:
  • Confirm the choke lever is fully disengaged.
  • Check if the choke cable is stuck, preventing the choke from fully opening.
  • This could indicate other engine issues unrelated to the choke lever.

6. Specifications

Image 6.1: Angled view of the JAVIK Choke Lever Switch, showcasing its design.

7. Warranty and Customer Support

JAVIK offers a 1-year warranty for this product. For any questions, concerns, or warranty claims, please contact JAVIK customer service. They are available 24 hours to assist you.

Please refer to your purchase documentation or the JAVIK brand store on Amazon for specific contact methods.