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Discussion Starter #1
So here's another carb rebuild thread, sorry.....
What kit # do you order for an 04 450 fe? The Shindy 03-040 kit I have isn't even close. The gasket and some rubber pieces are the only things that would fit.
Luckily the pieces that were removed were in good shape so I reinstalled them after cleaning but used new rubber.
Here's a pic of the carb. The choke cable was a bear to get out and there was alot of rust build up inside the hole where it sits. I cleaned it out and reinstalled the choke cable and can't get it to move.
How does the choke operate? Is there a plunger type of thing the cable pulls on?
 

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Shindy are usually pretty good, other option is OEM.

Yes, the choke plunger just slides in and out, it should have a rubber seal midway on the plunger.
If it's jammed in its corroded badly, boil a pan of water and drop the carb in for a few seconds, the alloy should expand before the brass plunger and you should be able to free it off or at least mobe it slightly.
 

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SamUK thanks for the reply. I tried boiling water, carb cleaner, then finally oil. The oil loosened the plastic plunger enough to get it to release. Looking at replacement parts I think the OP replaced the cable before.
I found out the plastic was broke on the choke cable holder so now I'm looking to get a new one. Looks like the cable comes separate and there is a kit to attach it to the carb. If I had a 350 the kit comes complete..... Why is it so tough to buy parts for a "2004" 450?
 

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Cable is always separate.. Choke valves come as a kit.. Usually just the valve and seal I believe
 

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Thanks. I searched choke cables and found many people bought cables and the kit that fits on the end of the cable but had problems with the parts not being the same as what they had. Found a kit for 350's on Ebay from Dayspowersports in KY. Messaged them today and they very nicely made up an oem kit for my 450ES. Now I have a little time to change the fluids.....
Can't wait to ride!
 

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Always be cautious of items purchased off eBay or Amazon, there usually Chinese and fail due to poor quality standards.
By all means try a ten dollar item, it may work but I'd be very reluctant to spend more on a Chinese item.
 

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Case in point: I recently bought a starter valve kit for my TRX350 from All Balls. After a few minutes running, the rubber ring swelled to the point the plunger wouldn't move in the bore. OEM Honda part is now on the way. Waste of $19. So... if anyone needs only the plastic piece that screws into the carb, let me know.
 

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Yes, from Honda and quite possibly from an aftermarket sales company.
 

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Discussion Starter #10
The new choke cable I just received is oem and looks like the one I'm removing. The plunger in this kit is black plastic. I hit the new plunger with a little vaseline before reinstalling. The plunger on the old kit was metal so I'm wondering if a metal plunger came oem ?
Just back together now and with new gas in the tank it runs like a top. On too the axles for maintenance....
 

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Discussion Starter #11
So forgot where the air vent hose attaches to coming from the carb? The manual has a heat guard in the pic. I don't remember seeing a heat guard. Any help would help..... Thanks.
 

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Air vent? I assume you mean vent line or breather pipe, yes?

There's one on the side of the carb which runs up the frame under the fuel tank to the headstock where it connects to some small locating pegs. The overflow is on the float bowl and simply hangs down the rear of the engine
 

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the plastic part your calling plastic ?, that is the enrichment valve...and oem from honda is not plastic, they are brass. the cable is not, never has been part of the choke system as a complete set-up. you have to buy the cable, starter valve ( enrichment valve ) sperate when replacing all of the choke system.
 
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