Bayou 400 issue..

[96bayou4hundo]

Hello all.. this is gonna be long..

i have a 96 400 4x4 ive owned it for idk maybe 8 years or so now.. a woman owned it before me and she was VERY nice to it.. the thing is practically brand new.

so ever since i got this thing it will only run on half choke... if you put it all the way to run it just starts fartin and coughin and will die... but it runs like a champ at half choke.. as a matter of fact i could go outside right now and tap the start button and it will start on the first compression stroke. stone cold without trying to move it from the half choke position... the thing about it is though when its idling, the exhaust sounds like the motor is under a load.. and as soon as you turn the choke all the way off.. the load goes away and then comes the farting and coughing then die.

i am very mechanically inclined i have cleaned the carb, jets, needle valve, throttle needle, and the cvk famous slide. PLUS the choke circut itself, set the air screw to spec and have tried rich and lean. also have set the float height.

NOW the fun part.
the first time i tore the carb down to nothing, i put it all back together and it ran without the choke on at all but had a quarter throttle stumble and then after about 15 mins of running it just started the cough and sputtter then dead and WILL not start again till it cooled down ( it got very hot very fast)... so i took the carb apart again. recleaned everything. put it back together and now im back to runs mint at half choke all day long..

so now im baffled. if anyone has come across something like this or has any idea about what the problem might be any help is appreciated.


thanks in advance, cody