Hey All,

New here as this is my first 4 wheeler. I'm old school with 2 big reds.
Just purchased an o4 manual eiger that needed a new stater upgrade which i
did myself. When i pulled the side cover the half the gears fell out. Got the manual for the rebuild and the 1st time together it ran fine but no reverse... pulled it back apart and rechecked and realigned everything and voila! all ranges and gears work fine... however i now notice an intermittent rattle/whine when i take off. I know its something i did but would like some advise on where i should focus in on before the third time charm.

Thanks in advance

 

O.k. been checking some more posts here and i keep hearing about a clutch nut that backs off??? Could that be the problem even though i didn't mess with it during the new stater install? any help would be appreciated. If i keep pulling this thing apart i'm gonna get a job with suzuki...

 

Also, its localized in the area of the gear shift lever... don't know if that helps any.

 

O.k. i opened up the shifter side again and looked everything over... seems o.k. Is it possible by doing the stater replace that i loosened something on the foot brake side of the tranny?? Any ideas, anyone listening, anyone here?????

 

Why did you take the alternator off to "upgrade"? the starter? Taking that cover off results in a shower of washers, levers and gears, so it is possible you got them back wrong. There was a modification in 03 which deleted one of the washers, I once spent over an hour looking for a washer shown on the parts drawing, which, it turned out, never was there in the first place.

 

sorry, i meant to say stater upgrade... the old one had a couple of loose magnets so it wouldn't start. Its very possible i put something back wrong as the pictures in the manual aren't very helpful but i seem to have it right. All the gears work, reverse and hi/lo and 4 wheel too. It just sounds like something is not sync and growling when its in gear and moving. I did notice there are two washers in mine, which one was deleted? I opened it back up and have seen no shavings , no wear marks or any sign but i haven't run it much since...

And thanks so much for the reply... beginning to think i was alone here.

 

This loose magnet hing has always baffled me. Yes, I have had it happen, but the magnet jumped onto the stator, jammed between the stator coils and the next magnet and wrecked both flywheel and stator. I can't see any way a magnet is not going to do this if it comes loose. Incidentally had the same bike to pieces yesterday. It had broken a valve and locked it between head and piston. Owner had tried to start it and wrecked the starter clutch. Usual shower of washers shafts and gears when I took the case off. There are a lot more than two washers in that case.

 

Yeah who would have thought that two different materials wouldn't glue together... bathed in oil 24/7 in the hot and cold at high temps and underwater and back braking bottom outs... engineering eggheads that's who.. well at least the retro is good. Any thoughts as to my rattling dilemma? Merryman? Oh and by the way i have 2 washers the same size in mine.

 

Did you have the bike running before you took it to pieces, as a cam rattle is quite common and one of our 400 King Quads has been rattling for over a year, I reckon someone seized it when we lent it out as a courtesy bike, and now has a lot of piston slap, runs fine though.

 

That's the funny thing when i first replaced the stator magnet it started and ran fine but no rattling sound... it just had no reverse. Now after opening it up the second time everything works like it should , hi/lo, all gears and reverse and 4x4...but with the rattle. That's why i asked if it was possible i might have loosened something on the other side with my stator magnet change out. And its a pretty bad rattle too. You said something about suzuki
deleting a washer... where exactly are the washers supposed to be and which one was deleted? I really like this bike and want to keep it but its making me pull out what little hair i have left.

Thanks for everything Merryman