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.

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 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. I am guessing this situation caused the choke to be deployed and/or would not open the choke.

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?

Thanks, Dave

 

I have an 2000 big bear 400 and think that they are probally similar. If you pull the spring back from the top of the pin that goes into the choke you will see that there is a little swag on the end of the cable that you can slide out and then slide the black cap over it. SLide new one on and the rest is self explanatory. Hope this gets to you before you spend the 70$ fpr the 5 minutes of labor.

Bill