Service manual/wiring diagram for 2005 Eiger 400

KWB · 09-18-2012, 10:53 AM

Hey guys, New to site and new Suzuki owner. I have a 2005 eiger 400 auto I just picked up and was running pretty good after sitting for a year without use. I had driven and tested it out numerous times while I was tweaking and adjusting things. I bought it with a dead battery and used the pull string to start it. I bought and replaced old battery with new fully charged battery. with new battery,the motor would spin but not fire with the electric start, but use the pull start and it fires right off. Wasnt worried about that too much. Planned to go run gas through carb since the more it ran the better it was running. I took it out for its maiden trip for me and drove it 1/2 mile at low speeds and stopped to look around and left it idling, while it was sitting there it died . It fired off again once after numerous tries and tried to run spitting and sputtering then died and now I cant get a spark from the electric start or pull string. Checked fuses and new spark plug still nothing.

I am weak on electrical diagnosing stuff so any ideas will have to be explained in detail.

Where is a good place to get a good quality service manual with a wiring diagram?

I did find 2 "fuses/diodes " in the wiring harness up by the left front shock ( one with three prongs in a row and one with two prongs at 90 degree angle), but dont know what these go to.

Also when the key is turned on the neutral light comes on when selector is in neutral, if it was the neutral safety switch would the light still come on?. I also tried to start in gear by squeezing the brake lever while in gear, still nothing.

Any help or assistance appreciated and thanks in advance.

ajl719 · 09-18-2012, 11:09 AM

Best places to look for a service manual are: (Clymer Home) or (Repair Manual | Owners Manual | Haynes Repair Manual | RepairManual.com.)

Clymer manuals are pretty good and probably run anywhere from $40 and up. The manuals at Repair Manual are OEM factory service manuals and are probably better then the Clymer manuals but are a little more expensive, running you between $70 and $90. Though the saying is you get what you pay for.

As for your problem, are you getting any spark at all..? A no spark issue could be a coil or CDI issue. Also, the Eiger's are known for there magnet's coming unglued which in this case would give you the same issue. And welcome to the forum.

KWB · 09-18-2012, 11:44 AM

Magnets coming unglued from what? The Stator? Is that fixable or replacement of part required?

KWB · 09-18-2012, 03:33 PM

Did some reading on the magnets and stator . Hope thats not the issue! Hoping for the coil but my luck usually doesnt work that way. Thanks for the replies so far.

Anyone have a wiring diagram for this machine?

ajl719 · 09-18-2012, 05:33 PM

Try looking on this site for a diagram. I'm not sure if they have an actual wiring diagram but it's worth a look.

KWB · 09-29-2012, 06:11 PM

Update 5 magnets of the six from the flywheel were stuck to the stator, luckily no damage to stator. Everything tested good electrically and visually no damage to the stator. Just waiting on flywheel to arrive. It is amazing as common as this problem was and they changed the design of the flywheel that no recall was done. I guess they got away with that one.

ajl719 · 09-29-2012, 10:59 PM

As much as I'm sure you were hoping for a simpler cause to your problem at least you know there was no serious damage done to your stator. In the end you found the problem and you'll be able to fix it. And i do find it amazing myself on how common this issue actually is. And like yourself, why there was no recall ever done is beyond me.