Arctic Cat 400 4X4 Ignition Problem (Flywheel Magnets)

[@639Beaver]

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.

[@dlc2838]

i learned more from this guy in 7 min than i did in 2 days of everyone else.........thank u D-RAY

[@josephrodney7941]

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

[@donnydenfeld2394]

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.

[@carlosrobles2048]

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!

[@gawdammitguru]

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.

[@SuperCyril2]

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.

[@jamespayne2677]

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.

[@ryan_riffs]

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!

[@WheelsnThings]

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!

[@helenelalonde7959]

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...

[@nadaone82]

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.

[@rogereads6894]

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.

[@cedarslopestudio974]

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.

[@markswick4504]

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 ‼️🍻

[@dynodon427]

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.

[@philiproark3102]

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

[@nathanieltabbert6782]

Great explanation. Stopped me from tearing into it once he said I needed a special tool.

[@marcdesgagne6636]

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

[@dieterronsberg5970]

Perfect. That`s how explanatory vids should be made- straight to the point with some hints & advices along the way. Keep `em comming dude!

[@kenhulse5191]

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

[@DRaysShop]

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.

[@39knights]

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?

[@39knights]

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.

[@bobstanton6444]

They have a Suzuki engine, not Chinese

[@dg98adams]

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.

[@bitto65]

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

[@coreychapman2921]

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

[@padraiggalvin2807]

Hey. From ireland here. Really appriciate this video. thanks for passing on your knowledge

[@805ROADKING]

You run into the wackiest problems!! Better you than me!! Fine job Bud!!☺

[@DRaysShop]

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.

[@lawnboy81SMS]

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)

[@markhiggs5896]

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.

[@skulledmonte84]

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

[@brandonthekodiak2391]

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.

[@matthewmilam286]

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

[@NLINE7]

Oh man I was hoping Suzuki fixed this problem by 05 because that is the year model Eiger I have.

[@FurryWereWolf93]

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.

[@baconmanbacon303]

I worked on my artic cat for days till I seen your vidio and knew exactly what was wrong thanks for the help

[@SuperTony26]

Thanks from Canada! Excellent video. helped a lot.

[@whitetailization]

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.

[@DRaysShop]

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.

[@tripowar]

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

[@FordMustangGTRocks]

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

[@dustinneal1209]

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

[@camaro69green31]

Awesome info thanks. Just picked up a AC 400 FIS 2005. Saved this video in case I have issues in the future.

[@andrewjunk687]

thanks. Pulled side cover off, magnets were missing. Must have scared previous owner. Gonna buy a flywheel and hope for the best

[@vzvxfy]

this saved me lots of time and work trying to figure out what could be wrong. this was exactly what my problem was. thanks!

[@Treybotoo]

D Ray, you're my hero. This is probably is what I've been having trouble with. Thanks for the vid man.

[@sjones7289]

Hey man thanks for the info, exactly the problem I had.... Gettin her fixed now after it has set for a couple of years ...

[@TheJhine5588]

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!!

[@zummy4429]

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

[@tonyyack9668]

d-ray, your a good guy to mention about pulling the flywheel, had the same problem & learned the hard way. thanks for being honest..

[@melaniekozial2062]

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

[@bobjay9834]

Thanks for the same of knowledge about these 400 cats been fighting mine for awhile.

[@CumminsDriver]

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.

[@JeffOwens-v6n]

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!

[@simpleman6867]

Well spoken and straight to the point!

[@jasonrobinson8488]

This guy is great! Very informative and explains things very well, good job buddy!

[@maryherrin678]

Awesome info, that is exactly our problem & you were very thorough, thanks

[@sunny5rising]

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. :)

[@ClintsTractor]

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...

[@waylonmccrae3546]

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

[@ClintsTractor]

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.

[@gordonparker-e3f]

Great video and thanks for helping me repair my Eiger 400

[@philliphall5198]

I think you just told me what it’s firing out of time but gear timing ok and value clearance ok It’s back firing some time and acts like it’s fixing to start but don’t What do you think ???

[@edwardschneider2716]

Great info. At least I understand what my dealer is talking about now.

[@BlockchainToTheFace]

How bout some epoxy? Seems a little cheaper than a new part. I’m sure you could tell where they were glued before.

[@ELCHACA]

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 :(

[@DRaysShop]

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

[@mikehelmsing501]

I think you might have just saved the day. Thanks for the video.

[@DRaysShop]

I agree, they should make good on all of them, clearly a defect in manufacturing.

[@cuivre2004]

Just brought mine into the shop-diagnosis was the same thing. Replacement flywheel has been re-engineered.

[@peanutblast2709]

D-Ray, I have a 2006, 400 Arctic Cat automatic. Can you do a video on removing the carburetor. It needs to be cleaned.

[@robertbohling4024]

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.

[@DRaysShop]

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.

[@billysessions7583]

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

[@scottfrye5535]

It's the flywheel

[@wmoscati]

common issue with the suzuki sv bikes as well. Apparently suzuki had some not great epoxy back in the day

[@bucklana924]

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

[@johndoeseph6075]

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?

[@Rmstatorinc]

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 : kzbin.info/www/bejne/mIm7qIuknN6Ar5o. 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.

[@markhiggs5896]

Cat started using this engine in 2002 in the 375 model.

[@moocahdasame8812]

Excellent info and presentation.

[@David-ho9mp]

After witching your video, I found the same issue now I'm wonder if I should replace the stator as well?

[@LocalScenery]

Bingo, I found what I'm looking for, thank you so much!

[@sonnyguyah7606]

Sir I u are doing, I have a problem with my Artic cat 700cc 4x4 mud pro I'm getting current going to the coil but no current to the plug what could be the problem.

[@Mrcalisouth2]

Hey man I have a similar problem with an 08 250 2wd model ...its basically the same as the dvx model of those years....only thing I havnt changed was the did ...everythimg else is new and still no fire at all

[@larrylueck2978]

Great to see someone explain it .

[@robertsweigart137]

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.

[@davevanden1]

yes the magnets can slide out and stop the motor fron turning they jam against the stator

[@gregoryjones6714]

Am I the only one who had trouble with the sub trans gears when replacing the stator? I need help bad. I don't know how to line everything up Hi/Lo/Rev. Any suggestions would be appreciated thanks

[@joewellcome8320]

great explanation of process to trouble shoot and repair.JW

[@masterbates7016]

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

[@jesseandrade9561]

sure wish I had seen this video before ruining my crankshaft, i have a 2013 arctic 500 very similar to the model your working on. Do you have any suggestion on where i could another crankshaft?

[@jasoncurtsinger3709]

I have a 2005 suzuki 400 the power wire to coil will spark nonce when unplugged from coil

[@FREDO-x1m]

clear an concise info all about the subject matter thank you 2 thumbs up

[@boumysayavong2856]

When you took off the cover for the stator is there engine oil in these compartments?

[@SteveRobReviews]

good stuff. I have a 2006 5 speed, will be watching for any problems, Thanks.

[@dymondsdad]

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

[@jamessawyer899]

Hello I have an 04 400 and can’t get the gears in the right place. It’s a manual. I can not find diagrams or videos can you help

[@danellsworth3891]

Thanks for the tips on the puller!! Great video!

[@blender_unleashed]

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

[@daddytech]

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

[@DRaysShop]

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.

[@alexeyzoom_zoom8687]

Help me please!!!! My arctic cat 400 2006 flywheel magnets was broken...((( Where can i purchase the magnets???

[@johnspofford2860]

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 ??

[@heaththompson7809]

Thanks man, I have one doing the same thing..I will let you know if that’s the problem after teardown

[@donstem343]

need some help d-ray I have a 2005 400 arctic cat 4x4 auto all I do is plow my driveway with it. shifts great when cold but gets very hard to shift when hot. shifting from H to L or R turn off motor shifts fine.

[@markkoszyk8143]

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