Bare with me while I try to explain this;

With the tank and airbox off I noticed when I choke the carb (thumb lever down) the choke bar goes to the right (sitting on the bike) when I release the choke (thumb lever moving up) the choke bar stops when my thumb lever is about half way up on it's travel. Moving the lever ALL the up does nothing, the bar doesn't have enough travel to move the entire travel of the cable. Should that choke bar move the entire lentgh of the cable? Or is the choke open when it ends the travel on the bar regardless where the thumb lever is relationship to all the way up or down? Boy I hope that isn't too confusing.

 

Hard to be sure, based on your description. The slide that covers your carb mouths
has a slot in it. The slot should be centered to allow full air-flow when at rest.


There should be a spring to assist it to the return (normal operation) position.
Is your's installed? Also, there are some screws with bushings that guide the slide.
I have heard of them backing out and allowing the slide to bind, preventing it's return
to full-open.

It's also possible you just have too much slack in your cable, and may need to adjust it, instead.
Verifying the travel of the slide itself, should let you know which it is.


Hope this helps, Ern

 

I did some work on my carbs recently and I noticed something similar to what you are describing. Basically the choke mechanism on the carb has a limited range of motion and the lever on the handle bar has more than enough play to fully open the choke.

I've looked at my choke while moving the lever and the choke fully actuates but it only actually uses half of the play in the lever. My guess is that your's does something similar and is probably fine.

 

OP, that's exactly what I was trying to describe, thanks, I feel better now. One less thing to worry about. Now, on to pulling and cleaning my carbs. Thanks again.