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.
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.
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.
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.
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
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!
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 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 ‼️🍻
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.
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.
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.
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.
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.
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.
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
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
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)
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
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
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.
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
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
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
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!!
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
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.
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.
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.
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 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.
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.
Yeah, forums have saved my butt more than once. Even if they don't provide an answer, they can lead you to check something that you may not have thought about. :)
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..
thank you for the info.my dad had an old atv nut came off the end of the crankshaft could not find a nut for it so i made one drilled it out end tapped it out and die nut on end of crankshaft,voila lolo
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.
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.
This was great. Thank you so much. I have a Suzuki Eiger 400 with no spark. Changed spark plug and coil without it fixing the problem. I know where to look next thanks to you.
I'm hoping someone can explain to me WHY these magnets have anything to do with the coil trigger. The ATV has a battery , and the stator flywheel Carrie's the magnets for charging, 3 phase AC. On the outside of the Flywheel there is a magnetic strip which flys by a PM generator ( pick up ) for triggering ignition timing and spark. How do these magnets even play into the ignition side of things ??
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.
Agreed man. If this were my personal atv, you bet your ass I would be gluin' those magnets back on! lol I just dont feel safe doin' that to a customer's machine. Have a goodun' bro!
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.
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.
another good use for duct tape ? super glue ? window caulking ? hell just stick some used bubble gum on it yeah thats it bubble gum.... it will hold ...trust me.....lmao good vid dray
I'm working on my neighbor's Arctic Cat, same problem. BUT this one had another problem too, the diode was bad in the left handle bar kill switch. Sure wish somebody made an after market flywheel Suzuki is HIGH priced stuff!!!
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!
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.
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.
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.
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.
Perfect. That`s how explanatory vids should be made- straight to the point with some hints & advices along the way. Keep `em comming dude!
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
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!
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 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 explanation. Stopped me from tearing into it once he said I needed a special tool.
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.
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.
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.
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.
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.
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.
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!!☺
Hey. From ireland here. Really appriciate this video. thanks for passing on your knowledge
d-ray, your a good guy to mention about pulling the flywheel, had the same problem & learned the hard way. thanks for being honest..
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
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
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
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)
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
I worked on my artic cat for days till I seen your vidio and knew exactly what was wrong thanks for the help
this saved me lots of time and work trying to figure out what could be wrong. this was exactly what my problem was. thanks!
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
Thanks from Canada! Excellent video. helped a lot.
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.
D Ray, you're my hero. This is probably is what I've been having trouble with. Thanks for the vid man.
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
Awesome info thanks. Just picked up a AC 400 FIS 2005. Saved this video in case I have issues in the future.
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
Thanks for the same of knowledge about these 400 cats been fighting mine for awhile.
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.
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 and thanks for helping me repair my Eiger 400
I think you might have just saved the day. Thanks for the video.
Hey man thanks for the info, exactly the problem I had.... Gettin her fixed now after it has set for a couple of years ...
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
Well spoken and straight to the point!
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!!
thanks. Pulled side cover off, magnets were missing. Must have scared previous owner. Gonna buy a flywheel and hope for the best
This guy is great! Very informative and explains things very well, good job buddy!
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.
Awesome info, that is exactly our problem & you were very thorough, thanks
Great info. At least I understand what my dealer is talking about now.
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
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.
clear an concise info all about the subject matter thank you 2 thumbs up
Bingo, I found what I'm looking for, thank you so much!
Great to see someone explain it .
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.
Excellent info and presentation.
How bout some epoxy? Seems a little cheaper than a new part. I’m sure you could tell where they were glued before.
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.
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, it has given me a direction to go with.
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.
Just brought mine into the shop-diagnosis was the same thing. Replacement flywheel has been re-engineered.
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
THANKS good to know going to let dealer know could be my issue .have no spark
Yeah, forums have saved my butt more than once. Even if they don't provide an answer, they can lead you to check something that you may not have thought about. :)
Yeah it’s a every day thing with them
If you have not changed it just go ahead and get it done ✅
Very good info. May of just found out what I wrong with AC.
great explanation of process to trouble shoot and repair.JW
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..
Thanks for the advice definitely a good spot to start at!
thank you for the info.my dad had an old atv nut came off the end of the crankshaft could not find a nut for it so i made one drilled it out end tapped it out and die nut on end of crankshaft,voila lolo
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 agree, they should make good on all of them, clearly a defect in manufacturing.
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
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.
This was great. Thank you so much. I have a Suzuki Eiger 400 with no spark. Changed spark plug and coil without it fixing the problem. I know where to look next thanks to you.
Appreciate the information.....have to work on one tomorrow that won't start.
I would just like to say thanks much for your vidio saved me much time great deal
Thank for the information. I think that is what is going on with our machine.
I'm hoping someone can explain to me WHY these magnets have anything to do with the coil trigger. The ATV has a battery , and the stator flywheel Carrie's the magnets for charging, 3 phase AC. On the outside of the Flywheel there is a magnetic strip which flys by a PM generator ( pick up ) for triggering ignition timing and spark. How do these magnets even play into the ignition side of things ??
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.
common issue with the suzuki sv bikes as well. Apparently suzuki had some not great epoxy back in the day
really great information.enjoyed
Thanks for the tips on the puller!! Great video!
Agreed man. If this were my personal atv, you bet your ass I would be gluin' those magnets back on! lol I just dont feel safe doin' that to a customer's machine. Have a goodun' bro!
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.
You forgot the bailin' wire.....lol! Thanks man!
good stuff. I have a 2006 5 speed, will be watching for any problems, Thanks.
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’ll have to check this out!
another good use for duct tape ? super glue ? window caulking ? hell just stick some used bubble gum on it yeah thats it bubble gum.... it will hold ...trust me.....lmao good vid dray
I'm working on my neighbor's Arctic Cat, same problem. BUT this one had another problem too, the diode was bad in the left handle bar kill switch. Sure wish somebody made an after market flywheel Suzuki is HIGH priced stuff!!!
Thanks for the information vary helpful
You the man!! Thank you 👍🏼
True, better to be safe than sorry, bein its for a client an all. Not worth the risk, a new stator nowadays would be pretty pricey I reckon