I get the distinct impression you are an honest mechanic. One of the las of a dieing breed. Thanks for info. Liked your frankness, and detailed explanation. Son of an honest mechanic, Thank you.
Thank you. I have one that a customer brought in. Cleanes the carb. Started right up, but couldn't keep it running well. Finally quit and pulled the plug. Absolutely no spark. So I'm gonna go after that flywheel once. Thank you again.
I tell you what this video was the most informational and easy to understand what he was talking about and what I liked most about it is you did this with quickness. Thank you. You helped me with my issue considerably. From Tulsa Ok.
Great video man! I've maintained and repaired motorcycles for many years and must say that this is the first time I've heard of flywheel magnets coming loose!
Great info bud! Appreciate it VERY MUCH. I've worked on metric bikes/atvs for about 36 years now, and this is a new learning lesson for me. Thanks again.
Thanks. My Eiger was running poor. Engine missing, running rich fouling plug an overheating my engine. Exhaust header was cherry red. Bad spark was the cause. Took alot of diagnosis before I found out the flywheel was the problem. Thanks sir for sharing this information.
For the past month iv been going over my 03 z400 s ignition system w fine tooth comb,...replaced stator regulator and about to do cdi..but i bet you a nickel,this is my problem..THANK YOU
You are the man I just love watching your videos You've helped me out on two different things you help me out putting a water pump on my Mercury outboard and help me put my stator and flywheel on my 2004 Arctic cat
Great vid. I had exactly the same problem. Fouled plug, yes, but other issues also. Poor charging, and low amp battery draw when not being ridden. Depending on the age of your machine, you may want to replace the pulse coil and stator also. I did all 3 components along with the voltage rectifier. So a total of 4 items on the charging system. You definitely want to go on eBay & get the flywheel pull tool, it’s around $55. But you gotta have it.
Today is 4/6/13. My neighbor just rought over a 2006 Artic cat 400 atv. No spark. Checked the fuses, all good. Got on line and started looking, found your post. I'm going to pull the case and look at the flywheel. This is a very informative video, Thank you. PS I just subscribed.
D-Ray, I have saved your videos since I have a Artic cat 400 (previous owner changed the flywheel), and a RZR 800 (future top end rebuild)... great videos.
struggled with one on my lift all day today! they had it at another dealer and that dealer went through the carb twice and adjusted valves. I spent a good part of the afternoon finding the right jets, which werent in the carb and also trying to find the right needle. well i got the carb for sure sorted, re-checked valves and boom, no difference. i pulled the cdi box off a diff 400 and it ran for about 15 seconds and died. so tomorrow i'll have a look at the flywheel, thanks!
My Arctic Cat 400 has been sitting through the winter months so I hope the starting issue is just a gummed up carb problem, but if that doesn't fix it then I'm glad I saw this video. I'll check the fly wheel. Thanks.
On my 86 Bayou 300 the flywheel just fell apart and made a big mess inside the cover of ground up magnets. Took me forever to figure out my information problem. Good video, I just needed to see what the inside of the cover looked like. You can normally buy specialty pullers for each four wheeler model for like $10.
Great information , I learned that on a arctic cat 250 . I purchased a used one, I know what you’re thinking, yeah going to do the same thing. Absolutely right, unless you go ahead and clean the used one really good, then you get some marine epoxy and apply around each magnet and in between every magnet. When it cures , you’re ready to run, and can feel confident, that you won’t have any issues. The epoxy to use is the white marine epoxy, I know west marine carries it. (Can’t recall the brand, but it’s great stuff!! ) Thats just a way to save some money, and it works 👍 Thank you Ray 🙏 about to do the same thing on a AC 400 , I was thinking about the flywheel, but after your video, that was a great refresher course . Thanks again Ray ‼️🍻
GREAT INFO! Great video i have came across mini of these on suzuki and arctic cat 400s.People sell these atvs cheap because they cant figure out the problem.
Yep, I know about that. I work at a campground that had probably around a 2006ish Arctic Cat 400 4x4 Automatic (red) that had quit working. And unfortunately, the people there took it all apart, and had they not taken it apart, the Warranty would have fixed it, because it was a cracked flywheel which was also a common problem. (They took it apart and never fixed it....it's been sitting in a shop forgotten about for the last 2 or 3 years....I might try to fix it if I can find the rest of the engine laying around somewhere)
You Rock Brother, thanks so much for sharing this information, I am about to have to tear mine down and check this from the things I have read on the net. And thanks for the warning about pulling the flywheel because I would have been one of the ones who tried just that. Thanks again and God Bless you friend.
thanks. I have an ignition problem on mine. I had heard about the Magnets coming loose. Apparently it's not unusual with arctic cats. It was good to be able to see exactly what this looks like though. Thanks for showing it to us
thank you for posting this. 👍 My atv has been running rough intermittently and after seeing this video I’m 100% sure that’s the same problem with my 2002 Arctic Cat 375.
Now this guy is a no bull shitter, U made my point here at the shop. Really appreciate your expertise on this problem. One of the best vids i've seen on youtube
We are looking at a 2005 Arctic cat 400. Just finished the carb clean and tried to start it up. (It's in for a starting issue) Will only start up after spinning the engine over with wide open throttle. As soon as you let it go to idle it shuts down. Put a spark tester on it it noticed that the spark is shutting off at idle only. Suspected ignition issue and took a look at youtube to see what we could find. Sounds like we have the problem you pointed out in your vid. The cover is coming off and we will let you know what we find. Thanks Marc @ MD Small Engines , Ontario , Canada
Forums are great bro, used 'em many a time to source answers. I have actually come across this problem a couple a times before, luckily we were able to locate info for correct placement of the magnets and we cleaned the glue off them and re-glued them with lock-bond. Hey presto, $5 repair instead of $200 replacement cost. That were 20 odd year ago n the motor still runs to this day, after a rebuild bout 10 yr or so back. Cheers n regards to y'all my friend Lee
Yeah mine was a 05 Eiger You were talking about Damaging the crankshaft with a puller What I did was stack washers from the bigger part of the shaft and left the flywheel retaining nut On but screwed out a little ways that way the puller was resting And putting all the pressure on the big nut not the end shaft it worked perfect didn’t break anything
Great video. I have a friend's 03 400 here now that I was just going to get into the stator on. Glad I seen this. Good to know that the Suzuki has the same motor as well!!
I like how you said "it's pretty easy to get that cover off" LOL after a half hour i got mine off an 3 washer came off too an not sure were they go on at, but i'll figure it out an my magnets look good an are not loose FOR NOW i don't have 250.00 to spend on a damn flywheel Thanks for the vid though
The new magneto's are supposed to be an updated design that dont have this issue. I have read that they are a 1 piece magnet now, but havent personally seen one. You would think they would have honored all the magnetos under warranty since it was a common issue. I know some people got theirs covered but others didnt so I guess it was dependant on the dealer.
Tracking down a similar problem on my 2004 Honda Sportrax 250ex. Starts, runs for a few seconds, dies, and won't restart for awhile (between 24hrs to about a month). It's on its second stator since I've had it, and it did not fix the problem. Replaced all the electrical when I did the first stator replacement, worked for about a year, now the problem's back. Considering changing the flywheel this time, see if that fixes it.
hey d-ray I have a secondhand 2005 400 Arctic Cat 400 (about 2200 miles on it). When I bought it a year ago I had to put a new plug in it before it would run and it has run fine since. The other day it backfired and died; no start and no spark to the plug since. Waiting on a new plug since it takes a weird one I can only get from the dealer. I was following the test procedure in the manual and hooked my multi-meter to the blue/white wire from the cdi to the coil and turned the ignition on. I got a reading of -162 volts instead of the 30 volts listed for the on/run position. I cranked the engine and the reading did not change. I will be pulling the side cover to check the stator/magnets but I was told by our local dealer that here in Canada (Newfoundland to be exact); the loose magnets was never an issue and he had only seen one case in all his years working there. Before I go pulling covers any suggestions?
Nevermind. Took off the case and found the magnets not where they should be. Guess I am the second case now the dealer guy has ever seen. Boo Arctic Cat for something that should only be expected from the cheap chinese quads.
You are right about the fact that the OEM flywheels are poorly made. We got a lot of feedback about it ourselves. That's why we designed a new replacement flywheel for the Arctic Cat 400 that includes a stainless steel capping to prevent harsh oil additives to eat the epoxy. The capping also protect the stators in case the magnet would come off. We put together a complete installation video for the Arctic Cat 400 ATV flywheel here : th-cam.com/video/bXXwXngyMy8/w-d-xo.html. Hope it will help you guys changing your broken flywheel. By the way, the Arctic Cat 400 engine comes from Suzuki. The Suzuki Eiger 400 flywheel is the same as the Arctic Cat 400 flywheel.
Thanks for watchin', I wish I had more free time to do more videos, I actually have quite a bit of footage shot for other projects but just don't have the time to edit. With deer and duck season upon us, I work out in the shop sometimes till late at night. But I cant' complain about the money though! lol
this happened to my 2012 arctic cat 700 except it first only affected the charging circuit. next time i used it the engine was burning a little oil and it progressively got worse, but never so bad it wouldnt keep oil so we didnt fool with it. i kept driving it for a couple of years at the hunting lease until it finally just all together stopped working on me one day. this made me start a full rebuild of the atv starting with the stator and flywheel. metal got all throughout the engine and stopped up the oil pressure regulator so it was running high on oil pressure. i did a complete engine rebuild, new seals, rings, stator, flywheel etc. now im chasing down rust on the frame and oil leaks on the differentials and i will be putting the engine back in the frame next week. i never would have expected this problem on the 700 but i guess it can happen. im the first i know of. found a lot of other small issues along the way. one major issue was the factory engine mount failed and caused the bolt to nearly wear through the case. its sad that a 2012 has so many issues mean while i have a 1995 kawasaki bayou 400 that still runs great. same maintenance on both and they were used and stored together
Thanks for the great advice I have a 400 that will start up and then just die. Worked if I had the switch all the way on with lights on also for a while, then just quit all together. Let it sit for a few months and now it starts and runs in both positions on ignition switch🤔🤔. Ordered new ignition switch will put it in if it quits again and I'll check fly wheel magnets also.
Fuel in the oil is a common problem with that suzuki based engine, in fact, the later model suzuki atvs had an auto fuel shutoff to elimiate this problem. If the fuel petcock is left on, fuel can overflow the carb, and run past the piston rings and into the crankcase. Now the transmission, is usually trouble free on those models, and it may just be the shift mech. in the right engine case. Lots of parts though, so be careful. You may want to consult with a dealer. Best of luck on your project.
There is a dealer here locally, they will lend me the puller. The part number for that flywheel has changed also. I suspect it will look different than the old one.
Wow ive never seen that problem before, love your style DRay :-) Straight to the nub of the problem and excellent discription, so even a thick person like me can instantly understand it lol :-) My mate has a ajs regal raptor cheap-n-cheerfull motorbike, ill watch out for similar problems as the coils look identical, hope the magnets use better bonding cement.
2014 wildcat 1000x.... Help my charging system wasn't working so I bought a new battery new stator and the new rectifier.... when I first turn it on after installing everything it gave me a 14.7 volts, damm got it to work... took it out for a night riding on the dunes.... I noticed that the gasket was installed right so it was leaking oil from the stator cover I opened it and I noticed that my stator coils were scratch deep from the top metal, so Now that i saw ur video im gonna open it check it out... My question is can that be also part of the reason why my 3 yellow wires get some dammm hot, that it melt the connector? By the way after it melt the connector i ran the wires directly, but now i only get a 13.20 volts :(
thx a lot for your help im have problims with mine and they done some testingand said the nothing was comeing from the stater that it was out so now we can check this first.
you'd think that they would weld a stop in there to keep those magnets from busting loose like that or to stop them from spinning around if they do. or maybe that's just meant to let go like that when the flywheel is worn out, kinda makes you wonder why they don't just built those like the fly wheel on a lawn mower where the " permanent" magnets are permanently part of the flywheel.
I actually borrowed one from my local Suzuki dealer, they know me well there and so I have access to their special tools. Any Arctic Cat or Suzuki dealer should be able to pull your flywheel for you, just have the cover off so they can get to it. I'm sure there are aftermarket sources for a puller, just seems a waste to buy one for a one time use.
I wish I had looked for this on TH-cam before. I troubleshooted my Artic Cat 400 4X4 for almost 8 months before I found my detached magnets. I found my rotor at dealercostpartscom for $389.58 plus $22.71 for the gasket. I contacted the dealer and as expected, they assurred me that Artic knows about the problem and won't make it right. I also asked if they knew about the problem, is the new rotor of better quality? He did affirm that the new replacement rotor is improved. Hope this helps!
Could these magnets be the cause of my Eiger 400 fly wheel locking up? I removed the pull start case off and was able to free it up but now it won't start. It ran great through 15 miles of rough terrain and the next day i was taking a break when all of a sudden it was idling real slow and backfiring like crazy. once it died the pull start was completely stuck.
d-RAY JUST CHANGED THE FLYWHEEL (THANKS!) and after reassembly...the starter is binding up when I tighten the top 3-4 screws on the aluminum housing cover (near the starter gears). If I loosen the 3 top screws the engine turns over fine. If I pull start it it runs fine(so the electrical problem is fixed) I have one thin washer that fell out upon disassembly. were does this washer go? any diagrams available? Tried a variety of positions with this washer on the two starter gears (both front and back)...still binds up when screws are tightened
good video. i got suzuki eiger 400 2005 model that i put brand new carb and petcock and plug on and it idles great and will run up to about 10mph then cut out and not go any faster. did same with old carb on it. im kinda thinking it could b pulse box or flywheel problem with magnets
Thanks for the upload. I used your video to make sure I put together the transmission correctly (which I did). The guy before me was playing around inside the case to check the magneto diagnosing a no-spark and got the gears so messed up the rear wheels locked up and it wouldn't shift. I tore it appart and the gears all seem in good shape thankfully but the magneto cover gasket was so hard to find I gave up and ordered gasket paper to make my own. I just have 1 question. When the half gear is pointing down as far as it can be what gear is that on the shifter?
Hi D-Ray, can you tell me if this might be the same on a 2002 Arctic Cat 500? the previous guy replaced the stator,coil,cdi box and the plug also the voltage converter. sound familiar? ty for the video..
Very good information. I think this may be my problem. Question is where would you recommend getting a new flywheel and about how much do they cost? Thanks!
04 arctic cat with same issue no spark at the plug,replaced coil tried new cdi box no help. There is power going into coil as I have gotten bit when I touch the coil as I’m hooking wires up to coil. Any insight would be great. Thx
I got a 12 cat 350. Has new battery,cables and starter. Is laboured cranking cranks one then binds up. Engine rolls over by hand just fine. Starter bench test fine turns by hand good, I am thinging issues with the starters drive gears and one way clutch ..any thoughts.
I own a small engine dealership in Van Buren. I've got a 2004 Suzuki Eiger 400 in with the same spark issue. I too checked everything. Then got to looking online, and discovered the common problem with the flywheel magnets. It's a shame they didn't offer a recall on such a common failure. Oh well, they like their money. Although I guess that means more job security for shops too...
I operate a small engine ATV repair shop near McGregor , Texas and I've seen this problem with Artic Cats and Suzuki ATV'S many times . The problem Is a lot of oils have an additive that degrades the new glue formulation that holds the magnets in . My recommendation solution is to purchase the New RM Stator that has the magnets encased inside the stator centrifuge. They are awesome and I have NEVER had another issue with any ATV'S that I've repaired using the New RM Stator . My customers Rave on them ! ! Thanks -Matthew
Waylon McCrae Oh yeah, I found the aftermarket flywheel with the new design. Unfortunately the customer declined the repair. So I didn't get a chance to complete it.
My 02,375 is doing the same thing. I bought jb weld grey,24hr cure stuff. Ill be making a vid of repairing the ol goat in next few days. Ill put a link here after im done..
What were the symptoms I have a 05 Arctic Cat air-cooled automatic that has a bag in the middle and high RPM ranges I can't get it to go away I've cleaned the carb multiple times with no Improvement just wondering if you had the same symptoms I'm having
![HOW TO TEST A STATOR / WHAT IS A STATOR [step by step] GY6](http://i.ytimg.com/vi/VoXYzQ61tRM/mqdefault.jpg)
i learned more from this guy in 7 min than i did in 2 days of everyone else.........thank u D-RAY
I get the distinct impression you are an honest mechanic. One of the las of a dieing breed. Thanks for info. Liked your frankness, and detailed explanation.
Son of an honest mechanic, Thank you.
I like to the point information on what I am looking for. Its nice ti see a fellow mechanic who knows and understands time is precious
Well MR.D-Ray, you damn sure saved my day! Great video. Right to the point, well spoken and just great all around. Thank you so much!
Thank you. I have one that a customer brought in. Cleanes the carb. Started right up, but couldn't keep it running well. Finally quit and pulled the plug. Absolutely no spark. So I'm gonna go after that flywheel once. Thank you again.
I tell you what this video was the most informational and easy to understand what he was talking about and what I liked most about it is you did this with quickness. Thank you. You helped me with my issue considerably. From Tulsa Ok.
Great video man! I've maintained and repaired motorcycles for many years and must say that this is the first time I've heard of flywheel magnets coming loose!
did on mine cost me alot of money before we found it was the trouble..still not working so have to do this check the flywheel...
Great info bud! Appreciate it VERY MUCH. I've worked on metric bikes/atvs for about 36 years now, and this is a new learning lesson for me. Thanks again.
Thanks. My Eiger was running poor. Engine missing, running rich fouling plug an overheating my engine. Exhaust header was cherry red. Bad spark was the cause. Took alot of diagnosis before I found out the flywheel was the problem. Thanks sir for sharing this information.
For the past month iv been going over my 03 z400 s ignition system w fine tooth comb,...replaced stator regulator and about to do cdi..but i bet you a nickel,this is my problem..THANK YOU
You are the man I just love watching your videos You've helped me out on two different things you help me out putting a water pump on my Mercury outboard and help me put my stator and flywheel on my 2004 Arctic cat
Great vid. I had exactly the same problem. Fouled plug, yes, but other issues also. Poor charging, and low amp battery draw when not being ridden. Depending on the age of your machine, you may want to replace the pulse coil and stator also. I did all 3 components along with the voltage rectifier. So a total of 4 items on the charging system. You definitely want to go on eBay & get the flywheel pull tool, it’s around $55. But you gotta have it.
Today is 4/6/13. My neighbor just rought over a 2006 Artic cat 400 atv. No spark. Checked the fuses, all good. Got on line and started looking, found your post. I'm going to pull the case and look at the flywheel. This is a very informative video, Thank you. PS I just subscribed.
D-Ray, I have saved your videos since I have a Artic cat 400 (previous owner changed the flywheel), and a RZR 800 (future top end rebuild)... great videos.
Perfect. That`s how explanatory vids should be made- straight to the point with some hints & advices along the way. Keep `em comming dude!
struggled with one on my lift all day today! they had it at another dealer and that dealer went through the carb twice and adjusted valves. I spent a good part of the afternoon finding the right jets, which werent in the carb and also trying to find the right needle. well i got the carb for sure sorted, re-checked valves and boom, no difference. i pulled the cdi box off a diff 400 and it ran for about 15 seconds and died. so tomorrow i'll have a look at the flywheel, thanks!
My Arctic Cat 400 has been sitting through the winter months so I hope the starting issue is just a gummed up carb problem, but if that doesn't fix it then I'm glad I saw this video. I'll check the fly wheel. Thanks.
On my 86 Bayou 300 the flywheel just fell apart and made a big mess inside the cover of ground up magnets. Took me forever to figure out my information problem. Good video, I just needed to see what the inside of the cover looked like. You can normally buy specialty pullers for each four wheeler model for like $10.
Thanks, in all the years I've been around bikes and atv's I've never seen this before, but from what I've read, it is pretty common.
Great information , I learned that on a arctic cat 250 . I purchased a used one, I know what you’re thinking, yeah going to do the same thing. Absolutely right, unless you go ahead and clean the used one really good, then you get some marine epoxy and apply around each magnet and in between every magnet. When it cures , you’re ready to run, and can feel confident, that you won’t have any issues. The epoxy to use is the white marine epoxy, I know west marine carries it. (Can’t recall the brand, but it’s great stuff!! ) Thats just a way to save some money, and it works 👍
Thank you Ray 🙏 about to do the same thing on a AC 400 , I was thinking about the flywheel, but after your video, that was a great refresher course . Thanks again Ray ‼️🍻
GREAT INFO! Great video i have came across mini of these on suzuki and arctic cat 400s.People sell these atvs cheap because they cant figure out the problem.
You run into the wackiest problems!! Better you than me!! Fine job Bud!!☺
Yep, I know about that. I work at a campground that had probably around a 2006ish Arctic Cat 400 4x4 Automatic (red) that had quit working. And unfortunately, the people there took it all apart, and had they not taken it apart, the Warranty would have fixed it, because it was a cracked flywheel which was also a common problem. (They took it apart and never fixed it....it's been sitting in a shop forgotten about for the last 2 or 3 years....I might try to fix it if I can find the rest of the engine laying around somewhere)
You Rock Brother, thanks so much for sharing this information, I am about to have to tear mine down and check this from the things I have read on the net. And thanks for the warning about pulling the flywheel because I would have been one of the ones who tried just that. Thanks again and God Bless you friend.
Great explanation. Stopped me from tearing into it once he said I needed a special tool.
Hey. From ireland here. Really appriciate this video. thanks for passing on your knowledge
Thanks from Canada! Excellent video. helped a lot.
I worked on my artic cat for days till I seen your vidio and knew exactly what was wrong thanks for the help
thanks. I have an ignition problem on mine. I had heard about the Magnets coming loose. Apparently it's not unusual with arctic cats. It was good to be able to see exactly what this looks like though. Thanks for showing it to us
thank you for posting this. 👍
My atv has been running rough intermittently and after seeing this video I’m 100% sure that’s the same problem with my 2002 Arctic Cat 375.
Now this guy is a no bull shitter, U made my point here at the shop. Really appreciate your expertise on this problem. One of the best vids i've seen on youtube
We are looking at a 2005 Arctic cat 400. Just finished the carb clean and tried to start it up. (It's in for a starting issue) Will only start up after spinning the engine over with wide open throttle. As soon as you let it go to idle it shuts down. Put a spark tester on it it noticed that the spark is shutting off at idle only. Suspected ignition issue and took a look at youtube to see what we could find. Sounds like we have the problem you pointed out in your vid. The cover is coming off and we will let you know what we find. Thanks
Marc @ MD Small Engines , Ontario , Canada
D Ray, you're my hero. This is probably is what I've been having trouble with. Thanks for the vid man.
I suspect the new flywheel is made different, we will see. In fact, I may do a follow up video to show how they correct this problem.
That was well versed ,very descriptive and right to the point. Great job I wish you did ALL REPAIR videos for all bikes 4 wheelers!! Lol great video
Great video D-Ray. I had this exact problem in my cat 400. Thanks to this great video I was able to solve it. Thanks
this saved me lots of time and work trying to figure out what could be wrong. this was exactly what my problem was. thanks!
Forums are great bro, used 'em many a time to source answers. I have actually come across this problem a couple a times before, luckily we were able to locate info for correct placement of the magnets and we cleaned the glue off them and re-glued them with lock-bond. Hey presto, $5 repair instead of $200 replacement cost. That were 20 odd year ago n the motor still runs to this day, after a rebuild bout 10 yr or so back.
Cheers n regards to y'all my friend
Lee
Yeah mine was a 05 Eiger You were talking about Damaging the crankshaft with a puller What I did was stack washers from the bigger part of the shaft and left the flywheel retaining nut On but screwed out a little ways that way the puller was resting And putting all the pressure on the big nut not the end shaft it worked perfect didn’t break anything
Oh man I was hoping Suzuki fixed this problem by 05 because that is the year model Eiger I have.
d-ray, your a good guy to mention about pulling the flywheel, had the same problem & learned the hard way. thanks for being honest..
This guy is great! Very informative and explains things very well, good job buddy!
Great video. I have a friend's 03 400 here now that I was just going to get into the stator on. Glad I seen this. Good to know that the Suzuki has the same motor as well!!
I like how you said "it's pretty easy to get that cover off" LOL after a half hour i got mine off an 3 washer came off too an not sure were they go on at, but i'll figure it out an my magnets look good an are not loose FOR NOW i don't have 250.00 to spend on a damn flywheel Thanks for the vid though
The new magneto's are supposed to be an updated design that dont have this issue. I have read that they are a 1 piece magnet now, but havent personally seen one. You would think they would have honored all the magnetos under warranty since it was a common issue. I know some people got theirs covered but others didnt so I guess it was dependant on the dealer.
Awesome info thanks. Just picked up a AC 400 FIS 2005. Saved this video in case I have issues in the future.
Hey man thanks for the info, exactly the problem I had.... Gettin her fixed now after it has set for a couple of years ...
Tracking down a similar problem on my 2004 Honda Sportrax 250ex. Starts, runs for a few seconds, dies, and won't restart for awhile (between 24hrs to about a month). It's on its second stator since I've had it, and it did not fix the problem. Replaced all the electrical when I did the first stator replacement, worked for about a year, now the problem's back. Considering changing the flywheel this time, see if that fixes it.
Thx for the update I just got one of these it’s a 2009 model Just needs carb cleaned, It’s a fixer-upper but looks nice
hey d-ray I have a secondhand 2005 400 Arctic Cat 400 (about 2200 miles on it). When I bought it a year ago I had to put a new plug in it before it would run and it has run fine since. The other day it backfired and died; no start and no spark to the plug since. Waiting on a new plug since it takes a weird one I can only get from the dealer. I was following the test procedure in the manual and hooked my multi-meter to the blue/white wire from the cdi to the coil and turned the ignition on. I got a reading of -162 volts instead of the 30 volts listed for the on/run position. I cranked the engine and the reading did not change. I will be pulling the side cover to check the stator/magnets but I was told by our local dealer that here in Canada (Newfoundland to be exact); the loose magnets was never an issue and he had only seen one case in all his years working there. Before I go pulling covers any suggestions?
Nevermind. Took off the case and found the magnets not where they should be. Guess I am the second case now the dealer guy has ever seen. Boo Arctic Cat for something that should only be expected from the cheap chinese quads.
They have a Suzuki engine, not Chinese
Great video and thanks for helping me repair my Eiger 400
You are right about the fact that the OEM flywheels are poorly made. We got a lot of feedback about it ourselves. That's why we designed a new replacement flywheel for the Arctic Cat 400 that includes a stainless steel capping to prevent harsh oil additives to eat the epoxy. The capping also protect the stators in case the magnet would come off. We put together a complete installation video for the Arctic Cat 400 ATV flywheel here : th-cam.com/video/bXXwXngyMy8/w-d-xo.html. Hope it will help you guys changing your broken flywheel. By the way, the Arctic Cat 400 engine comes from Suzuki. The Suzuki Eiger 400 flywheel is the same as the Arctic Cat 400 flywheel.
Cat started using this engine in 2002 in the 375 model.
Thanks for watchin', I wish I had more free time to do more videos, I actually have quite a bit of footage shot for other projects but just don't have the time to edit. With deer and duck season upon us, I work out in the shop sometimes till late at night. But I cant' complain about the money though! lol
this happened to my 2012 arctic cat 700 except it first only affected the charging circuit. next time i used it the engine was burning a little oil and it progressively got worse, but never so bad it wouldnt keep oil so we didnt fool with it. i kept driving it for a couple of years at the hunting lease until it finally just all together stopped working on me one day. this made me start a full rebuild of the atv starting with the stator and flywheel. metal got all throughout the engine and stopped up the oil pressure regulator so it was running high on oil pressure. i did a complete engine rebuild, new seals, rings, stator, flywheel etc. now im chasing down rust on the frame and oil leaks on the differentials and i will be putting the engine back in the frame next week. i never would have expected this problem on the 700 but i guess it can happen. im the first i know of. found a lot of other small issues along the way. one major issue was the factory engine mount failed and caused the bolt to nearly wear through the case. its sad that a 2012 has so many issues mean while i have a 1995 kawasaki bayou 400 that still runs great. same maintenance on both and they were used and stored together
Good video on bad flywheel magnets coming lose, thank you for the info
thanks. Pulled side cover off, magnets were missing. Must have scared previous owner. Gonna buy a flywheel and hope for the best
Awesome info, that is exactly our problem & you were very thorough, thanks
Thanks for the great advice I have a 400 that will start up and then just die. Worked if I had the switch all the way on with lights on also for a while, then just quit all together. Let it sit for a few months and now it starts and runs in both positions on ignition switch🤔🤔. Ordered new ignition switch will put it in if it quits again and I'll check fly wheel magnets also.
Thanks for the same of knowledge about these 400 cats been fighting mine for awhile.
Fuel in the oil is a common problem with that suzuki based engine, in fact, the later model suzuki atvs had an auto fuel shutoff to elimiate this problem. If the fuel petcock is left on, fuel can overflow the carb, and run past the piston rings and into the crankcase. Now the transmission, is usually trouble free on those models, and it may just be the shift mech. in the right engine case. Lots of parts though, so be careful. You may want to consult with a dealer. Best of luck on your project.
I think you might have just saved the day. Thanks for the video.
There is a dealer here locally, they will lend me the puller. The part number for that flywheel has changed also. I suspect it will look different than the old one.
Help me please!!!! My arctic cat 400 2006 flywheel magnets was broken...((( Where can i purchase the magnets???
Wow ive never seen that problem before, love your style DRay :-)
Straight to the nub of the problem and excellent discription, so even a thick person like me can instantly understand it lol :-)
My mate has a ajs regal raptor cheap-n-cheerfull motorbike, ill watch out for similar problems as the coils look identical, hope the magnets use better bonding cement.
I agree, they should make good on all of them, clearly a defect in manufacturing.
2014 wildcat 1000x.... Help
my charging system wasn't working so I bought a new battery new stator and the new rectifier.... when I first turn it on after installing everything it gave me a 14.7 volts, damm got it to work... took it out for a night riding on the dunes.... I noticed that the gasket was installed right so it was leaking oil from the stator cover I opened it and I noticed that my stator coils were scratch deep from the top metal, so Now that i saw ur video im gonna open it check it out... My question is can that be also part of the reason why my 3 yellow wires get some dammm hot, that it melt the connector? By the way after it melt the connector i ran the wires directly, but now i only get a 13.20 volts :(
thx a lot for your help im have problims with mine and they done some testingand said the nothing was comeing from the stater that it was out so now we can check this first.
Well spoken and straight to the point!
you'd think that they would weld a stop in there to keep those magnets from busting loose like that or to stop them from spinning around if they do. or maybe that's just meant to let go like that when the flywheel is worn out, kinda makes you wonder why they don't just built those like the fly wheel on a lawn mower where the " permanent" magnets are permanently part of the flywheel.
Bingo, I found what I'm looking for, thank you so much!
Great info. At least I understand what my dealer is talking about now.
I actually borrowed one from my local Suzuki dealer, they know me well there and so I have access to their special tools. Any Arctic Cat or Suzuki dealer should be able to pull your flywheel for you, just have the cover off so they can get to it. I'm sure there are aftermarket sources for a puller, just seems a waste to buy one for a one time use.
Hey man hopefully you see this, how do you get the left side cover back on? I cant seem to get passed the gear change fork
Just brought mine into the shop-diagnosis was the same thing. Replacement flywheel has been re-engineered.
I would just like to say thanks much for your vidio saved me much time great deal
Thanks for the tips on the puller!! Great video!
common issue with the suzuki sv bikes as well. Apparently suzuki had some not great epoxy back in the day
clear an concise info all about the subject matter thank you 2 thumbs up
that would be cool, you know i'll be watchng. i was destined to end up here either from Tommy or John and they both know i like this sort of thing
D-Ray, I have a 2006, 400 Arctic Cat automatic. Can you do a video on removing the carburetor. It needs to be cleaned.
I wish I had looked for this on TH-cam before. I troubleshooted my Artic Cat 400 4X4 for almost 8 months before I found my detached magnets. I found my rotor at dealercostpartscom for $389.58 plus $22.71 for the gasket. I contacted the dealer and as expected, they assurred me that Artic knows about the problem and won't make it right. I also asked if they knew about the problem, is the new rotor of better quality? He did affirm that the new replacement rotor is improved. Hope this helps!
Could these magnets be the cause of my Eiger 400 fly wheel locking up? I removed the pull start case off and was able to free it up but now it won't start. It ran great through 15 miles of rough terrain and the next day i was taking a break when all of a sudden it was idling real slow and backfiring like crazy. once it died the pull start was completely stuck.
yes the magnets can slide out and stop the motor fron turning they jam against the stator
d-RAY JUST CHANGED THE FLYWHEEL (THANKS!) and after reassembly...the starter is binding up when I tighten the top 3-4 screws on the aluminum housing cover (near the starter gears). If I loosen the 3 top screws the engine turns over fine.
If I pull start it it runs fine(so the electrical problem is fixed)
I have one thin washer that fell out upon disassembly. were does this washer go? any diagrams available?
Tried a variety of positions with this washer on the two starter gears (both front and back)...still binds up when screws are tightened
good video. i got suzuki eiger 400 2005 model that i put brand new carb and petcock and plug on and it idles great and will run up to about 10mph then cut out and not go any faster. did same with old carb on it. im kinda thinking it could b pulse box or flywheel problem with magnets
It's the flywheel
great stuff , looking for this info for ages ,,thanks mate
How bout some epoxy? Seems a little cheaper than a new part. I’m sure you could tell where they were glued before.
After witching your video, I found the same issue now I'm wonder if I should replace the stator as well?
good stuff. I have a 2006 5 speed, will be watching for any problems, Thanks.
Thanks for the upload. I used your video to make sure I put together the transmission correctly (which I did). The guy before me was playing around inside the case to check the magneto diagnosing a no-spark and got the gears so messed up the rear wheels locked up and it wouldn't shift. I tore it appart and the gears all seem in good shape thankfully but the magneto cover gasket was so hard to find I gave up and ordered gasket paper to make my own. I just have 1 question. When the half gear is pointing down as far as it can be what gear is that on the shifter?
When you took off the cover for the stator is there engine oil in these compartments?
Hi D-Ray, can you tell me if this might be the same on a 2002 Arctic Cat 500? the previous guy replaced the stator,coil,cdi box and the plug also the voltage converter. sound familiar? ty for the video..
Excellent info and presentation.
THANKS good to know going to let dealer know could be my issue .have no spark
Very good information. I think this may be my problem. Question is where would you recommend getting a new flywheel and about how much do they cost? Thanks!
04 arctic cat with same issue no spark at the plug,replaced coil tried new cdi box no help. There is power going into coil as I have gotten bit when I touch the coil as I’m hooking wires up to coil. Any insight would be great. Thx
I got a 12 cat 350. Has new battery,cables and starter. Is laboured cranking cranks one then binds up. Engine rolls over by hand just fine. Starter bench test fine turns by hand good, I am thinging issues with the starters drive gears and one way clutch ..any thoughts.
I own a small engine dealership in Van Buren. I've got a 2004 Suzuki Eiger 400 in with the same spark issue. I too checked everything. Then got to looking online, and discovered the common problem with the flywheel magnets. It's a shame they didn't offer a recall on such a common failure. Oh well, they like their money. Although I guess that means more job security for shops too...
I operate a small engine ATV repair shop near McGregor , Texas and I've seen this problem with Artic Cats and Suzuki ATV'S many times . The problem Is a lot of oils have an additive that degrades the new glue formulation that holds the magnets in . My recommendation solution is to purchase the New RM Stator that has the magnets encased inside the stator centrifuge. They are awesome and I have NEVER had another issue with any ATV'S that I've repaired using the New RM Stator . My customers Rave on them ! ! Thanks -Matthew
Waylon McCrae Oh yeah, I found the aftermarket flywheel with the new design. Unfortunately the customer declined the repair. So I didn't get a chance to complete it.
Thanks for the advice definitely a good spot to start at!
I have a quad runnee lt4x4 250 and i cant figure out how to get the starter cup off in order to pull the cover and replace the started clutch assembly
My 02,375 is doing the same thing. I bought jb weld grey,24hr cure stuff. Ill be making a vid of repairing the ol goat in next few days. Ill put a link here after im done..
Appreciate the information.....have to work on one tomorrow that won't start.
What were the symptoms I have a 05 Arctic Cat air-cooled automatic that has a bag in the middle and high RPM ranges I can't get it to go away I've cleaned the carb multiple times with no Improvement just wondering if you had the same symptoms I'm having