I have a 2001 Rancher with the common choke stuck problem. Having read the fixes on this site, I decided to replace the choke cable. I unscrewed the plastic nut at the carb end but the cable is stuck. So I sprayed WD-40 into the hole and played around with it to loosen it but no luck. All I hear is the cable stretching as I pull on it (sounds like a spring) but the piston is not moving. How can I remove the cable without damamaging the carb?

 

Here's my suggestion, I've been there also, remove the carb from the bike and pull the plunger out. Take some carb cleaner and spray down into the choke tube. Next take a phillips screw driver with a course rag and wipe the inside of it out like crazy. The WD-40 will just junk it up more, adding to the problem. If there is a huge amount of corrosion in there use the phillips suggestion but put some light grit sandpaper and very carefully clean the inside with it. This should fix the problem.

 

mine was so corroded, i ended up removing the cable from the plunger, and then runining an extremly small tap directly into the plunger, finally with a screw and a vice grip and hammer got it out, lol replace the cable though for the new one, mine freezes up below 40, i don't rely on it, i use the primer, when it gets real cold