all right as you can see here I have a couple of new additions to the garage I hauled in a couple of Polaris Touring sleds and neither one of these are currently running they've been sitting outside for a few years so we've got some work to do and hopefully that work will result in a couple of videos today we're doing one that's quick and painless we're replacing the broken choke lever on this Polaris here and the process I go through is going to be the same or similar on a lot of other recreational vehicles with this lever type of a choke okay let's go ahead get started and now this one should be quick and painless alright well start by removing this threaded retaining ring here and if it's done real tight you might need to take pliers to get it started and there is a lock washer as well so you don't want to lose that let's go ahead and set those aside all right so whatever you're replacing the choke lever on you're going to look for cables that go to that location in this case I have three carburetors so I've got three cables and the choke mechanism looks like this and you can see that this is the threaded portion where we removed that threaded ring okay alright so you can see here we have this box where all the cables run to and at first glance it might look like it's a sealed piece but if we go ahead and grab a hold of it and give it a tug you can see that does come apart we have a spring and then we have this lever mechanism that is actually broken on this one okay so the kit includes the spring this mechanism a pin and a replacement lever let me show you the kit real quick alright so what we're gonna do is hit this with a little bit of white lithium grease here and if you had it the tube would be a little bit less messy but this won't get the job done and hopefully that will work its way down into the cables a little bit okay and we're just gonna slide this new piece into place like that put our spring on place the cover here okay all right this is where it gets a little tricky I'm doing it over a catch pan so we don't lose our pin now the problem is we don't have enough room to get our pin in because this lever is retracted in too far I could loosen up all the choke mechanisms on each carburetor or we could try to take a shortcut and that's what we're gonna do so let me get the lever on in the correct position here and there's a flat spot here I didn't point out I think when I removed it so that goes in like that we want the choke lever to be down okay I'm going to take what I like to call the dentist pick but just a pick tool here and see if I can pry that lever up enough so that we can get it where we want it okay like that and actually you can see we can test it out here so the cables aren't seized up which is good okay that's how it should work but obviously we can't ride around with this dentist pick in there so we need to get the pin in so what we're going to do put that back in the regular position is basically replace this pick with this pin and may take a couple tries or we might get it right off once you get it started you don't want to pull the pin out because it'll kind of go cockeyed you'll want to tap it in slowly started let me get something to tap that in with real quick alright what I'm gonna do now is I'm just gonna squeeze it the rest of the way in it's right there and again you don't want to break your new part so alright let's test it out for operational purposes here looks good now to get it back through the hole it has to be like that and I'll just feed it back through the hole that we took it out of and we'll put our retaining ring on here hopefully this video has been helpful and if you did find the video helpful don't forget to hit that thumbs up button I always appreciate that and if you want to see more of this type of stuff don't forget to hit that subscribe button hey thanks for watching I've got the part link down below in the comment section and stay tuned I'll be doing more videos on these two sleds as I work through the process of getting them running and ready for winter have fun you

How to Replace a Broken Choke Lever on a Polaris Snowmobile or ATV – DIY Choke Lever Replacement

3 thoughts on “How to Replace a Broken Choke Lever on a Polaris Snowmobile or ATV – DIY Choke Lever Replacement

  • June 18, 2019 at 1:02 am
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    Click Here for Replacement Choke Lever Kits: https://amzn.to/2J6qIFQ

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  • June 18, 2019 at 1:02 am
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    Great vid…just what I needed…thanks!!

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  • June 18, 2019 at 1:02 am
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    Thanks mark this was exactly the vid i was looking for!!

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