Join Date: Jan 2011
Thanked 3 Times in 2 Posts
1997 Bearcat 454
I recently rescued a 97 bearcat 454 basket case. Rebuilt both front, and rear diffs, rebuilt one front axle, replaced the other, replaced a bad shock, bad front knuckle, bad front hub, replaced all wheel bearings, and seals, and replaced a bad gasket on the left crankcase cover to fix an oil leak.
Ran around with it all day having fun. Parked it, then found a couple days later the float needle in the carb stuck, and filled my crankcase with gas. I had left the fuel shutoff on because the tiny handle on the old one was broken off (one peice unit). I installed a new fuel shutoff in the tank, the new one has a large plastic knob, that is easier to reach up under the tank.
So I decided to clean the carb for two reasons, first, the leaking float needle flooding the motor, second, the choke did not seem to act right to me. Here's what it did before I serviced the carb. The choke is a lever on the left hand grip. It activates a cable that goes into the side of the Mikuni carb, and moves a tiny piston with a pin on the end of it in/out of a shaft on the carb. After it would start and get hot, if I would push the lever upwards, the RPM's would rise to the point the engine would race. This seemed odd to me, I'm used to chokes killing engines when they are hot. I tore down the carb, and found the spring on the top of the diaphragm broken in 2 pieces. I also found the carb dirty, especially the screen at the float bowl inlet point. I also found no spring present where that little choke plunger hooks on the choke cable, even though the parts breakdown shows one. I replaced both springs, inspected the diaphragm, flat slide and needle for wear, removed, and cleaned all jets, pilot screw, soaked the carb, and reassembled everything. At this point I should mention the airbox assembly was missing when I got the machine, and I will be taking care of that soon. I do not mind running it without the air filter in the winter. Since the rework on the carb, I can only start it cold by covering the air inlet side of the carb with my glove, acting as a makeshift choke butterfly. Once it warms up, it will idle, and drive fine, but moving the choke lever up still makes it race. I also am not sure of the pilot screw setting. I don't know if its running way to lean, or if the choke lever is even supposed to work the way it does. Is the fact the two air vent lines are not attached to the missing airbox a potential issue? Any thought are welcome, especially if you own a 97 454. Tell me how your choke lever works for starters (lol)!