[steppinthefunk]

Hey guys... I just noticed the choke flap plate on my 65 CA77 has a broken spring and it looks like the whole plate is about to be sucked into my engine!
Glad I caught this before catastrophic cylinder munching!!!

Anyway, anybody know how to remove the choke plate so I can attempt to service the hinged flap plate?
Thanks!

 

[the-chauffeur]

Pull the carb off the bike - in doing so, you'll need to take the top off and pull the slide/spring assembly out.

Look down into the top of the carb and you'll see the round chamber the slide sits in, and in behind it, a smaller, crescent shaped chamber. You can just about make it out in this drawing:

​

The plate you're referring to sits in that chamber, and is controlled by the choke lever/linkage (it's the bit on the drawing to the right of the slider that, usefully, isn't numbered). You may find that if you hold the carb upside down and shake it hard enough, the door and lever will fall out on their own, but if not, it's a case of working the peg on the lever out of the slot on the plate - you'll see what I mean. Refitting is pretty much the reverse of disassembly. It's not very complicated; it's just a bit fiddly.

Hopefully you can re-seat the spring because if the above fiche drawing is anything to go by, the plate isn't a part you can buy separately.

Hope that helps.

 

[steppinthefunk]

Thanks Chauffeur... After what seemed like forever I finally got the slide out.
But unfortunately the metal flap has one of its tabs broken off of it.
Looks like im either going to have to fab a new piece or if that doesn't work I might just permanently close up the flap door.

 

[the-chauffeur]

Good job! Although getting it out is probably the easiest bit . . .

Since it's only really used when the choke is on, it probably wouldn't do all that much harm to seal it up. Just remember not to open the choke fully (to allow for the airflow that would have made it through the flap) and it should be OK.

Cheers

 

[steppinthefunk]

Just a quick update...
I decided to seal the flap door with some JB weld.
I then cleaned out the carb and she is back to being a one-kick-wonder!
It'll be a while till we see how the choke performs in the cold but I suspect it will be better than the previous floppy flap door.