Any Yamaha ATV Mechanics On Here? (05 Big Bear 400 4WD)

[Dave1]

I have a 2005 Yamaha 400 Big Bear 4 WD atv that developed a problem this weekend. Engine began to run rough at slow speed, would cut off at idle, black smoke out the exhaust, etc. indicated it was choked and/or getting too much fuel.  PLug was sooted black.

I got to looking it over and noticed that where the choke cable enters the side of the carbrueter, it is routed thru a small black plastic or rubber gromet looking fitting that appears to be screwed into the side of the carb and the choke cable goes thru it. That black plastic or rubber gromet looking fitting has broken or separated and the choke cable housing and spring had pushed backwards out of the carb. I pushed it back in and it cranked and ran OK but it needs to be fixed.

Called my Yamaha dealer and they said that fitting is called a "Starter Set" and is about $17, labor to replace is about $70 if nothing else is wrong.

Anyone have this problem before or have any knowledge of it or the necessary repairs?

I see what has happened but am wondering why it happened.  Is the choke plate gummed up and not opening and closing easily inside the carb which creates back presure on the cable and housing which in turn caused the rubber gromet to break or separate???

Thanks for any info, Dave

[Mars]

Dave,
This is a very common on the BB. The choke cable funnels water to the choke punger. There is a small spring in there (inside the plastic plug) that rotts and causes a "choke on" condition. Remove the plastic plug and if the spring is still there.. Clean it up with some brake cleaner, give the port a shot of brake cleaner,give the plunger a shot of WD40 and put it back together. You can use carb cleaner but some brands attact the plastic/rubber parts. If the parts are toast order the kit.

 USE SAFETY GLASSES/DON'T SMOKE....

[Dave1]

The fitting or gromet that screws into the side of the carb has broken so it has to be replaced.  I order the arts called a "Starter Set" from Yam dealer and now have to figure out how to disassemble and do the R&R.

The cable is still attached to something inside there and the broken piece will have to be removed.

Dave

[Mars]

Dave.
The cable is attached to a plunger inside/behind the plastic cover. Go to bikebandit.com and look up your carb on the oem section. You will see there is not alot to it.