Hello everyone, I have a 2005 Yam Kodiak 450 4x4. It had set for around 10 years and obviously had several issues. Replaced, throttle cable, new carb, fuel petcock, oil, oil filter etc.
I just want to preface by saying it does run and run well. But, that is without the choke installed. When I bought the new carb it came with a new black "nut" and boot already screwed into the new carb. I still have the original black one as well. Apparently I am missing something obvious as I have looked at any and every video forum, etc. and can't seem to find any info to help me figure out why the choke cable will not go far enough into the carb to start to screw down. It's literally probably a centimeter off and just will not go down. I have tried the old/new spring, old/new black nut and boot, adjusted the choke on th handlebar (that gives slack or takes away), also tried backing off the nut and unscrewing the part on the cable itself, nothing helps! I am stuck I have tried everything. Is there a trick I'm missing? I can get everything in and it seems lined up and slides in, but I simply can't get the black part to screw in with the choke cable attached.
I tried it on the old carb and still same issue, but if I screw the nut in without cable it goes in appropriately.
Ahhhh what am I doing wrong??!?! Any help, tip, would be greatly appreciated!!
I hope this post was semi clear...as I'm definitely not a mechanic.

 

Had hoped someone with more experience of Yams would jump in. I have done one or two, but mostly work on Hondas. The 300 Honda had two different lengths of plunger, depending on year, and the plastic bit had to match or you couldn't get it to screw down. Also most plungers have a rubber seal halfway down, which can swell and stick, so the plunger won't go down. The outer cable sleeve has to go all the way into the new black plastic bit, and finally, you have to get the threads exactly right as they are super fine and can easily get cross threaded.

 

Thank you for the reply. I actually posted a picture on another forum and let's just say dumb error on my part. I had two needles, I guess one from the old and one from the new carb. All is well now..