Introduction
This instruction manual provides essential information for the proper installation, operation, and maintenance of your MotoMaster Motorcycle Choke Cable. Designed as a direct replacement for the original equipment, this cable ensures reliable performance for compatible Honda XL 600 R models.
Product Overview
The MotoMaster Choke Cable (OEM Part Number: 17950-MA6-010, Manufacturer Part Number: 161-264) is engineered to meet original equipment specifications, ensuring a precise fit and function. It features a durable construction designed to resist wear, friction, and environmental factors.
Image: The MotoMaster Motorcycle Choke Cable, shown coiled, highlighting its overall design and length.
Compatibility
This choke cable is specifically compatible with the following motorcycle model:
- Honda XL 600 R (Years: 1983-1987)
Please verify your motorcycle's make, model, and year before installation to ensure proper fitment. Refer to the table below for detailed compatibility information.
Image: A table detailing the compatibility of the choke cable with Honda XL 600 R models from 1983 to 1987.
Key Features
- OEM Standard Manufacturing: Produced to original equipment specifications for a perfect fit and reliable operation.
- Enhanced Durability: Utilizes advanced production methods to reduce friction and increase resistance to premature breakage.
- Weather Resistance: Oiled with a special compound to prevent freezing in low temperatures and reduce dust attraction, maintaining flexibility.
- Friction Reduction: The outer cable interior and all metal components are coated with a high-quality polyimide lining to protect the inner cable from friction.
- Corrosion-Resistant Inner Cable: Features a durable inner wire made with a corrosion-retardant alloy, minimizing stretching and seizing.
Installation Instructions
Safety First: Before beginning installation, ensure the motorcycle is turned off, cooled down, and securely placed on a stand. Disconnect the battery if necessary to prevent accidental starts.
- Locate Existing Choke Cable: Identify the current choke cable on your motorcycle, typically running from the carburetor to the handlebar control.
- Disconnect at Carburetor: Carefully disconnect the choke cable from the carburetor. This usually involves unscrewing a cap or fitting and detaching the cable end from the choke plunger mechanism.
- Disconnect at Handlebar Control: Detach the other end of the choke cable from the handlebar-mounted choke lever. This may require removing a cover or loosening a clamp.
- Remove Old Cable: Gently pull the old cable out, noting its routing path through the motorcycle frame to ensure the new cable is installed correctly.
- Install New Cable: Route the new MotoMaster choke cable along the same path as the old one, ensuring it does not kink or interfere with moving parts.
- Connect to Handlebar Control: Attach one end of the new cable to the choke lever on the handlebar. Ensure it is securely seated and the lever operates smoothly.
- Connect to Carburetor: Connect the other end of the cable to the carburetor's choke mechanism. Ensure the cable end is properly engaged with the plunger and the fitting is tightened securely.
- Adjust Cable Tension: With the cable connected, check for proper choke operation. Adjust the cable tension using the inline adjusters (if present) or the adjusters at the carburetor/handlebar until the choke operates smoothly without excessive slack or binding. The choke should fully engage and disengage.
- Test Operation: Start the motorcycle and test the choke function. Ensure it enriches the fuel mixture when engaged and allows the engine to return to normal idle when disengaged.
If you are unsure about any step, it is recommended to consult a qualified motorcycle mechanic.
Image: A detailed view of one end of the choke cable, showing the metal fitting and inner wire.
Image: A detailed view of the other end of the choke cable, featuring a rubber boot for protection.
Image: Both ends of the choke cable displayed side-by-side, illustrating the different terminal types.
Operating the Choke
The choke cable controls the choke mechanism on your carburetor, which is used to enrich the fuel-air mixture for easier cold starting. This is typically done by partially closing an air passage or opening a fuel passage.
- Engaging the Choke: For cold starts, move the choke lever on your handlebar to the "ON" or "FULL CHOKE" position. This will pull the inner cable, activating the choke mechanism.
- Starting the Engine: Start the motorcycle as usual. The engine should start more easily and idle at a slightly higher RPM.
- Disengaging the Choke: As the engine warms up (typically within a minute or two, or when the engine can idle smoothly without it), gradually move the choke lever to the "OFF" or "RUN" position. Operating the motorcycle with the choke engaged for too long can lead to excessive fuel consumption and carbon buildup.
Maintenance
Regular maintenance of your choke cable ensures its longevity and smooth operation.
- Inspection: Periodically inspect the entire length of the cable for any signs of fraying, kinking, cracking in the outer casing, or corrosion on the metal ends.
- Lubrication: Although MotoMaster cables are pre-lubricated, occasional re-lubrication with a suitable cable lubricant can extend its life, especially if the motorcycle is exposed to harsh weather conditions. Apply lubricant at both ends where the inner cable enters the outer casing.
- Cleaning: Keep the cable free from dirt, mud, and debris. Clean the outer casing with a damp cloth.
- Adjustment: Check the cable tension regularly. If the choke lever feels loose or stiff, or if the choke does not fully engage/disengage, adjust the cable tension as described in the installation section.
- Replacement: If the cable shows significant signs of wear, damage, or if adjustments no longer provide smooth operation, replace it immediately to prevent operational issues.
Troubleshooting
If you encounter issues with your choke cable, consider the following:
- Choke Not Engaging/Disengaging Fully:
- Check cable tension and adjust if too loose or too tight.
- Inspect for kinks or sharp bends in the cable routing that might impede movement.
- Ensure the cable ends are properly seated in the carburetor and handlebar lever mechanisms.
- Lubricate the cable if it feels stiff.
- Stiff or Sticky Choke Lever:
- Lubricate the cable.
- Check for corrosion or debris at the cable ends or within the lever mechanism.
- Inspect the cable for internal damage or fraying.
- Engine Not Starting in Cold Weather (with choke engaged):
- Verify the choke cable is fully engaging the carburetor's choke mechanism.
- Ensure the carburetor's choke plunger is not stuck or obstructed.
- This could indicate other engine-related issues beyond the choke cable.
If troubleshooting steps do not resolve the issue, professional inspection by a qualified mechanic is recommended.
Specifications
| Brand | MotoMaster |
| Model Number | 161-264 |
| OEM Part Number | 17950-MA6-010 |
| Compatible Models | Honda XL 600 R (1983-1987) |
| Item Weight | 2.89 ounces |
| Package Dimensions | 10.71 x 6.81 x 0.16 inches |
Support
For further assistance, questions regarding compatibility, installation, or any other product-related inquiries, please contact MotoMaster customer support. Always provide your product model number (161-264) and motorcycle details when seeking support.
You can find contact information through the official MotoMaster brand store on Amazon or their official website.
