Brad you are correct you pull off the pull rope side. It is not that hard. Just drain oil before you get start. If you carfull you should be able to reuse the seal. Just pull shift lever, pull rope and metal cup on shaft for pull start and I think you have to pull off one of the oil lines on front corner. I also might had to take off the foot rest. If you have a shifter, I'm sure that would have to come off. Mine is an auto so I did not have a shifter to take off. The stator is attached to the housing that comes off so you might want to is connect the wires at the connector. When mine was bad and pulled off the housing all the mangnets was sticking to the stator and not the flywheel.. I'll send the photo's now. If you need more let me know.

 

Hey scott,
I took it apart sat. night and found that 3 of the magnets were loose but still sitting on the flywheel. just like you said looks like the epoxy just failed! Looks like nothing else was damaged though so thats good. Any thoughts on talking to suzuki on replacing the parts?Thanks so much for all your help!!!!!

 

Brad I had no luck with suzuki replacing my flywheel. It can not hurt to try. But to save money (if you are not replacing it yourself), I only put 2 bolts back in side cover and keep everything else off when I took it in to have them remove the old flywheel and install the need one. It saved me a lot of shop labor. If you plan to take it to a shop I would call ahead and see what kind of quote they'll give you. Remind them you have it apart and they just need to remove and install new one. I know the flywheel itself is not cheap.

 

Thanks Scott I didnt have any luck with suzuki either.You would think that they might help their customers out a little!The guy I talked to was a little rude!He said that "some time during this atv's life it has gotten very hot and that is why the epoxy failed" thats when I told him NOT! My forewheeler only has 500 miles on it and has been pampered all 500.Still he insisted it has so to make a long story short do you know where the best place to get a replacement flywheel? He also said they had redone the flywheel and attached the mags. a different way on the new design and I guess I would rather get the new type so I dont have the same problem again down the road.Is that what you did?Anyway if you could let me know where you got your flywheel I would appreicate it.Again thanks for all your help!!!!!!!!!

 

Don't feel bad. They were a little rude to me also about Suzuki paying for it. But I got a great deal on the installation. He is correct on Suzuki redesigning how the magnets are attached. They changed them in 05 that is way only 02-04 models have that problem. I want with Suzuki. I don't know of any other unless you go with Articat witch is Suzuki part. If you are going to do it yourself I would just surch the web for the cheapest price. I would only buy from a dealer because the redesigned ones are good and I just would not trust a afermaket one (in this case). If you live where it get cold, that puts a big temp. swing each time you start it up in the winter.

I hope that helps. BTW: they are on there very very very tight, oh did I say very!

 

10-4. thanks !!!!!!!!!

 

Did you get it fixed? Did you replace flywheel or dealer?

 

Havent gotten it fixed yet! Ran into a problem getting the flywheel off. Talked to a guy at the local atv shop he has a tool to take it off and said I could borrow it "after he gets finished with the eiger he is putting a flywheel on now"(think of that another one that the mags let go) man looks like suzuki would fess up to thier boo-boo!Any way still working on it and I will let you know how it goes.

 

Hey scott,
Got it together late last night and man was it good to hear it start up again! Only one problem when I start it it will run while on choke but if I take it off choke it dies or if I try to give it gas while the choke is on it dies. Took the carb off took it apart and cleaned it and it was gummed up some but put it back on and still the same thing. Any ideals? Thanks for all your help!

 

Hey all,
just got my eiger 400 put back together I had a little trouble with the carb Iguess it sitting around for awhile it gummed up pretty bad but after a second really good cleaning it fired up and ran perfect.Putting on the flywheel wasn't to bad as long as you have one of the flywheel pulleys its a breeze.I would like to thank all who have helped guide me along on this adventure.Now lets RIDE !