2005 400 4x4 FIS-Multiple Problems - ArcticChat.com - Arctic Cat Forum
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post #1 of 16 Old 04-13-2019, 02:26 PM Thread Starter
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2005 400 4x4 FIS-Multiple Problems

Hi all,
This is my first post. I have a machine with multiple mysteries to me. I'm not a great mechanic, but I get by. The 4-wheeler ran fine through the fall, then one winter day started backfiring, then quit. Could not get spark when testing the plug like I do on my lawnmower (removed, connected, and grounded to case). Plug works fine on tester at my aircraft shop. I could get it to fire occasionally but not stay running. Carb has been cleaned and checked, and all is reassembled. I can now get it to start, but will not accelerate or run under load (high RPM or going up hill). Also having some backfiring. Have tried adjusting mixture to no avail. New plug, coil, and air filter installed.
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post #2 of 16 Old 04-13-2019, 02:43 PM
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Your magnets let loose as this is an issue with 400's 03-07. Replacements are updated and you can use parts from a Suzuki Eiger. Read the link below.

https://www.arcticchat.com/forum/pin...et-issues.html
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post #3 of 16 Old 04-13-2019, 06:42 PM Thread Starter
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You are correct. I got the cover off, and the magnets are loose. But the stator is still intact. I will decide whether to try the JB Weld repair or order a new one. Any luck with the eBay flywheels? Magnets are sealed on those, and only $200.
Also, any link with guidance for putting it all back together? Some gears and springs came off with the cover, and I think orientation is important for timing.
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post #4 of 16 Old 04-13-2019, 07:01 PM
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Download a service manual from Country Cat.com under technical information. In that link there are pictures showing washer placement in both auto and manual atvís. They are important to get correct. Not sure of quality of flywheels off eBay but I have never heard of issues, only stator issues.
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Current Sled rides
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Past Sled rides
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Current ATV rides
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RTR Bushings & shock bushings
Motobatt Battery


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt Battery
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Past ATV rides
2003 A/C 400 manual ACT 4x4
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post #5 of 16 Old 04-15-2019, 04:44 PM Thread Starter
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Thanks. You're a great help. One more question: I am going to try re-gluing the magnets. Other than spacing and north-south orientation, does position on the flywheel matter? Would a few degrees out either way make a difference?
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post #6 of 16 Old 04-15-2019, 05:02 PM
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I'm going to say no as updated flywheel you can't see magnets anyways.

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings
Motobatt Battery


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt Battery
26" Kenda Bearclaw HTR's


Past ATV rides
2003 A/C 400 manual ACT 4x4
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post #7 of 16 Old 04-15-2019, 08:36 PM
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post #8 of 16 Old 05-13-2019, 06:01 PM Thread Starter
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Thanks to all for the help. I have re-glued the flywheel magnets. Spacing is equal at 5/16 inch. Cover is re-installed, and now I am getting consistent spark, and the engine starts easily every time. This is a great improvement, but it still backfires/bogs down at high RPM. I can ride it, and even get into 3rd gear, so long as I don't hit high RPM. Any ideas?
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post #9 of 16 Old 05-13-2019, 06:33 PM
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ATV: 03 400 4x4 auto FIS, 05 300 4x4
Thoroughly clean the carb and make sure diaphragm is not ripped and seated properly when you install it after cleaning.

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings
Motobatt Battery


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt Battery
26" Kenda Bearclaw HTR's


Past ATV rides
2003 A/C 400 manual ACT 4x4
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post #10 of 16 Old 05-13-2019, 07:17 PM Thread Starter
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That has been done as part of the troubleshooting before I decided to go ahead and pull the side cover. The diaphragm was torn, but has been replaced. I am wondering if timing might be out, but it doesn't look like that's adjustable.
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