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2002 Suzuki Eiger 400 Automatic- no spark!

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Old Jan 17, 2024 | 11:49 AM
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Gixxerjim750's Avatar
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Default 2002 Suzuki Eiger 400 Automatic- no spark!

This machine has been plowing our driveway for 22 years and 1100 miles, and now has no spark. I pulled the plug and checked it in a different bike and it sparks ok. Looking for a recommendation on a good repair manual or recommendations on where/how to begin. I don't have a trailer so taking it to the dealer would be a real hassle, would rather tackle this at home, but needs fixed before the next snowstorm so no time to waste! What's the best manual for testing and getting this resolved?
 
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Old Jan 18, 2024 | 04:46 AM
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From: Lancaster England
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I use the official workshop manual. Suzuki coils and CDIs are pretty reliable though, and the most common reason for lack of sparks is the flywheel magnets come loose, which is an awkward and expensive job, as a new flywheel is required and usually a new stator too. Do the tests, but if it is the flywheel, the big problem with checking is that a shower of gears and washers drops out when you remove the alternator case, and getting them back in the right order, is a challenge. I use the drawing from an on-line parts book, like Babbitts, to get that right. Go for the 2002 drawing, as they changed the case slightly about 2003 and altered how many washers they used.
 
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