Maybe someone out there can help me out. I have 2 Big Bear 400's, both 4wd, and I'm having problems with the choke cables "freezing" on me. I'm not totally sure if they are freezing or not, or they are just stubborn to come out. I try to open the choke lever all the way and it doesn't let me. Then I get them out and the cable doesn't go back in. It looks as if the cable on one quad is kinked, so I'm going to replace that one. The other cable on the other quad is fine. I have tried spraying WD40 and lithium grease into the choke cable line, but this has not worked. I have a fouled a plug already because the cable gets stuck out. I don't know if the engine warms up and "releases" it? The cable is definitely not working properly. This wasn't a problem until mid-2002. We purchased them in November 2000. I also noticed that the choke cable is enclosed the whole way down to the carb. Both quads have covered and are covered whenever not in use. Any one have any ideas on why this is happening?? This is a huge problem when I need to start the quads and it is very cold out. Then the cable gets stuck out.....What do I do? I'm looking for posts right now of similar problems and have not found any yet. Thanks for any help.

 

On the 01 Raptors water could get in to the choke & rust the spring & plunger.
it gets in there from riding in the wet & just from washing it.
They upgraded the Raptor cable maybe they did the same for the Big Bears.