Help, Installing new hot start cable

3 replies to this topic
  • Aaron_YZ450F

Posted February 16, 2010 - 09:15 PM


I'm installing a new hot start cable on my 04' YZ450F since my old one snapped on the first ride of the season. I took the old cable out and am using the cap off the old cable. The problem is, when I route the cable to the lever it feels and looks like it is too long, it just will not stay seated in the housing on the perch. Also when I was taking off the cable, i unscrewed the cap from the carb and noticed there was no spring inside the cap or plunger? Could it have came off inside the carb, and do I need to take the carb off to install this thing.

Parts I have-

1- Hot start cable with ball on end that goes toward cap
2- Cap that was removed from old cable

Those are all the parts that I have to assemble this thing, what am I missing, because I am pretty sure I should have a spring and plunger also.

Thanks in advance!

  • grayracer513

Posted February 17, 2010 - 07:46 AM


I'm pretty sure of that, too. Unfortunately, the manual doesn't detail this very well. But the parts fiche does. Review this image:


Items 36 - 41 all belong on the carb end of the cable. If the bike runs reasonably well, the plunger is probably in the carb, but it may be corroded in place.

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  • Aaron_YZ450F

Posted February 17, 2010 - 09:05 AM


Thank you very much, that was exactly the answer I was looking for. I spent about 45 minutes last night perusing the service manual to no evail. I am almost positive the plunger is coroded into the carb, because the bike runs like a gem. Thanks for all your help.

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  • grayracer513

Posted February 17, 2010 - 10:12 AM


I am almost positive the plunger is coroded into the carb,...

If it's in there, what you will see looking down into the hot start bore is a slot, like in the head of a screw, where the cable is supposed to be. If it's gone, there will be only the bottom of the hot start bore.

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