Motorcycle Repair: Choke stuck closed, suzuki rf600r, plunger

Question
Chris,

I just picked up a 1994 Suzuki RF600r that had sat for about 4 years. I Pulled the carbs and cleaned them the best that I could. Now I am running into the problem that the choke is stuck closed. I released the cable to check its movement and it works fine. The only way I can get the choke to come on is if I remove the tank and physically pull on the outside plunger. Then soon as I close it back, it sticks again. Any ideas of how to fix this?

Answer
Hi Jason.

Clearly, there is an issue with the position of something near the carb.  Possibly choke cable routing or something else interfering with choke mechanism movement.

It could also be that the choke itself is still not clean enough to move freely on it's own.  Does the mechanism move freely with the tank off?  Look very carefully and see if there is something there under the tank in the way of the choke.

Start with that and see what you find.
Good luck and ride safe.
FALCON