2004 Suzuki Eiger 400 No Spark (ATV)

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  • BRIAN617
    Senior Member
    • Dec 2016
    • 153

    2004 Suzuki Eiger 400 No Spark (ATV)

    These particular engines are known for the magnets on the flywheel coming unglued and moving around even sometimes coming apart. So I got this thing in and suspected flywheel problem right away but thought it would be fun to scope it first just to get a look at the pattern and be able to identify this with out couple hours worth of labor pulling side cover. The magnets are supposed to be evenly spaced inside the flywheel which should reveal an even AC wave.
    Attached Files
  • greasybob
    Senior Member
    • May 2008
    • 1590

    #2
    Cool !!!

    Comment

    • Steve6911
      Moderator
      • Feb 2007
      • 2206

      #3
      Nice job!

      Comment

      • Witsend
        Banned
        • Nov 2012
        • 2942

        #4
        I imagine the headlights were wavering quite a bit at idle. What were the symptoms?

        Comment

        • BRIAN617
          Senior Member
          • Dec 2016
          • 153

          #5
          Originally posted by Witsend
          I imagine the headlights were wavering quite a bit at idle. What were the symptoms?
          Intially, rough running and stalling, then eventually no start.

          Comment

          • tech25
            Senior Member
            • Oct 2017
            • 172

            #6
            good write up, and good pictures.. I like this

            Comment

            • BRIAN617
              Senior Member
              • Dec 2016
              • 153

              #7
              Finally got around to fixing this thing after fighting with the removal of old flywheel. Couple pictures first of the updated flywheel to fix the magnet movement issue and second of the corrected AC pattern.
              Attached Files

              Comment

              • BMW JEDI
                Senior Member
                • Feb 2012
                • 422

                #8
                So..... where are the magnets for the new flywheel?

                Comment

                • Witsend
                  Banned
                  • Nov 2012
                  • 2942

                  #9
                  So..... where are the magnets for the new flywheel?
                  Reply With Quote
                  Moved to the brake shoes of the new Regenerative Braking drums
                  I've seen the tone rings for ABS speed sensors integrated under the rubber compound of dust seals , but not sure what type of non ferrous metal the magnets must be spaced and pressed or epoxied between the inner and outer surfaces of that flywheel. My guess is the flywheel weighs a little more, and not rev as responsively, but could actually dampen engine vibration better?

                  Comment

                  • BRIAN617
                    Senior Member
                    • Dec 2016
                    • 153

                    #10
                    Originally posted by BMW JEDI
                    So..... where are the magnets for the new flywheel?
                    They are in the same spot, but covered with a thin layer of metal/tin now.

                    Comment

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