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How to Install a Choke Cable on a 1996 883 Sportster

Chokes help cold engines start. Pulling the choke knob out increases the percentage of gasoline in the fuel air mix. Pushing the knob in decreases the amount of gasoline. The knob simply pushes and pulls a thin wire with a tiny ball on the end into and out of a slot in the back of the carburetor. When chokes are properly lubricated they last for at least a decade. Eventually they wear out or break and when they are broken their owners are often stumped because replacing a choke is a rarely performed job.

Instructions

1

Close the petcock valve. Run the engine until it dies. Unhook the old choke cable from the clip near the horn.

2

Loosen the two Allen screws on the air cleaner cover with an Allen wrench. Unplug the breather tubes from the air cleaner.

3

Loosen the air cleaner Allen screws with an Allen wrench and remove the air cleaner. Loosen the backing plate Allen screws and remove the air cleaner backing plate.

4

Loosen the fuel line hose clamp with a flathead screwdriver and unplug the fuel line from the carburetor.

5

Label the front and back throttle cables. Remove the cables from the throttle cam.

6

Gently pull the carburetor out of the intake manifold boot with both hands. Remove the carburetor and choke cable as a single unit.

7

Unscrew the black, plastic, cable sealing cap on the back of the carburetor that connects the choke assembly to the carburetor body. Remove the spring inside the sealing cab and remove the choke valve by gently lifting the cable up and out.

8

Thread the wire end of the new choke assembly into the hole in the back of the carburetor. Push the ball and wire down into the slot.

9

Replace the spring and tighten the sealing cap hand tight.

10

Thread the new choke knob under the gas tank to the choke knob clip. Replace the carburetor in the intake manifold boot. Snap the choke knob into the clip.

11

Replace and readjust both throttle cables by hand. Reattach the fuel line to the carburetor using a new hose clamp and a flathead screwdriver.

12

Reattach the air cleaner backing plate using the Allen screws and an Allen wrench. Reattach the breather tubes by hand.

13

Reinstall the air cleaner and the air cleaner cover using an Allen wrench.

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Labels: 1996, 883, a, cable, choke, how, install, on, sportster, to