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Hi. I recently bought a 1991 KDX250 as a project bike, and one of the things wrong with it is that the choke knob will not stay pulled up. Does anyone know why that might be? It's a Keihin PWK38 carburetor, by the way. I have not got to the "tear it down and give it a thorough cleaning and inspection" part yet, so for now, indulge me.

Most likely the ridge on the choke boot is worn off or the groove on the choke shaft is worn out. Run a zipty around the choke boot and sinch it down good and it should stay up after that. Then you have a snazzy "custom" choke lever

-Maurice

Choke boot? Is that the black, plastic thing that is at the bottom of the choke mechanism??

Sorta - the choke lever comes out of the middle of the "boot".

Are you referring to an internal or external part? I looked on the Sudco Keihin diagram, and it just had the whole choke mechanism.

Spend the money and do it right Jason... don't be cheap 'cause when I buy it from you I want it to be right!~

LOL!!

I took my choke assembly apart and wrapped a new piece of wire around the plastic part that the shaft goes through (this will all make sense if you take the plunger assembly apart!). It now stays up on full choke only.......once again....YMMV

And a few other things.... a fresh topend, all bearings freshened, suspension freshened, a new seat cover, take that reflective tape off of the rear fender and the side cover vinyl, some real bark busters and some bold new graphics. And some new tyres (sp? ) to top it off. I'll let you know if I come up with anything else......

TD3: Thanks for the info on the choke. I will definitely be taking it apart, or at least trying to.

Indawoods: I hear you on all the repair work. I know a guy who I am going to get to check out the suspension. I am going to check out the engine first. If the cylinder needs to be replated, crankcase halves replaced or some other sort of MAJOR engine work (read expensive), it may get parted out on eBay. I have a good start so far, though. I hope to get to the top end this evening.

Go Jason !!! You ain't messing about.

Hey, that looks a lot like my brother in law's bike this past spring!

FWIW, I have a small zip tie around the boot and it works just fine.

TD3: You all have got me beat. For now!

cicone: Thanks for the info, stranger!

Oh yeah... and put a case saver on that thing for cryin' out loud!

A case saver?? Does that translate to skid plate??

Since you want all this stuff, I will let you just go ahead and order it, then have it shipped to my house. I will get it mounted, right directly, good sir.

I have an important question for you Jason. Before starting all this work on the 250, did you buy a manual?

It's on it's way, COD!

A case saver bolts on the casing in front of the chain... as to not blow your casing in case of a busted chain at speed.