The spring at the end of the choke cable (carb side) has rusted and broke on my Raptor. Does anyone know how it attaches to the carb. and what's the best way to detach it?
I've removed the nut that secures the cable housing to the carb and removed the rusted spring but now I need to remove the cable and replace the spring.

Thanks in advance!

 

The cable is attached to the choke plunger. I have replaced the choke cable and plunger on two Raptors and on both the spring was either broken or rusted away. In both cases the plunger was also stuck and I had to pull on the cable hard to get it out. Yamaha sells the cable for about $18.00 and the plunger kit is also about $18.00. Go to www.yamahaoftroy.com to see schematics of the carb so you can see how the cable is attached. Once you get the plunger out it is easy to unhook the cable with just a twist. This is a common problem on the 01's and I have read that Yamaha has an upgraded replacement that seals water out better. This also was the cause of poor performance due to the choke not openning all the way when it should have been after the motor was warmed up causing a rich condition.

 

From what I understand Yamaha has gone to a different choke cable on the 02' The new part# is 5lp-26331-10-00. I guess this cable is sealed on both ends to prevent water and condensation from getting down the cable to the carbs! Hope this helps

 

Thanks guys! I appreciate the help.

 

I recently replaced the plunger/spring on my '01.
It was stuck so badly, that the cable pulled off of the
plunger and left the plunger stuck inside the carb.
I found that the opening to this port was corroded up
a bit so as to narrow the opening a little. I was lucky
to get the plunger out as there is no way to put something
behind it to push it out. What I did was get some compressed
air and put it on one of the ports that the plunger is
working with and I blew it out (it went shooting around the
garage just like in the cartoons!) I installed a new plunger
and spring after carefully buffing out the corrosion in the
plunger shaft. All is well now.