• 1997 Yamaha Big Bear 400

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Hi all, Picked this bike up about a month ago, and started doing some work on it. I ordered a carb kit from China, but got tired of waiting for it so I went to the bike shop today and picked up a Shindy rebuild kit. Took the carb out of soak, it has been in there for a month, blew all the ports out, cleaned what I could with a guitar string, used air as best I could to make sure everything was clear. After I was satisfied the body was clean I out the kit in it. Got the floats set to 13mm as per the manual (well 12.87 on one side and 12.92 on the other, so close), set the pilot to a little less than 2 1/2 turns out (manual says 2 3/8 turns).

Put everything back together and tried to start it, it started and had a week idle. I tried adjusting the idle screw and as soon as I turned it the bike died. Backed it out and tried again, same result.

Left it backed out, started it again and gave it some throttle. As soon as the throttle is touch the bike dies. Changed the spark plug for a new one and checked the spark, good and really strong. I am thinking that I have a bad petcock and am not getting enough fuel to the carburetor. So when I press the throttle I am increasing air but starving for fuel, bike can't run on air alone so it dies.

Does this line of thinking make sense? I am gearing up a bottle with a fuel line in it, so I can try gravity feeding fuel to the carb, just have to wait for the silicone to dry so won't be able to test till tomorrow.

If it turns out to be a bad fuel valve, I will most likely just replace it with a universal one. If I go this route, what do I need to do with the breather line off the carburetor that used to go to the OEM petcock?

Block it off or leave it open? Any help, answers or other ideas of things to check would be greatly appreciated. I have a fishing trip at the end of the month and would love to have my bike running by then. By, April 15 in. 11 replies. 421 views.

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1997 Yamaha Big Bear 400

I'm looking forward to it.