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Discussion Starter · #1 ·
Hello Arctic Chat folks! I'm a hobbyist mechanic and I recently purchased my first ATV - a 2003 AC 400 4x4 FIS Auto.

This AC currently misfires, stalls at idle, and is very sluggish to start. Steps I've taken so far to repair include:
  1. Cleaned fuel tank
  2. Changed fuel filter
  3. Cleaned carb and jets
  4. Adjusted air-fuel mixture
  5. Replaced Spark Plug
  6. Adjusted Valve Clearance
  7. Replaced Stator (w RM Stator)
  8. Replaced Flywheel/Magneto (w/ RM Stator version)
  9. Ohmed out Stator
  10. Confirmed continuity between Stator and CDI
  11. Confirmed continuity between CDI and Ignition Coil
  12. Ohmed out Ignition Coil and Spark Plug Cap
At this point, I believe the CDI maybe faulty.

After an an exhaustive search, I have not found a replacement CDI (AC part 3402-683) that is in stock or less than $1300 USD.

I have contacted https://regulatorrectifier.com about their next repair date, which is 8/10/22. I am concerned that I have not seen any reports back from others on this forum who have had successful CDI repairs.

Therefore, I'm looking for alternatives, and I'm interested in a 2003 Suzuki Eiger 400 CDI (part 32900-38F10) which I found used on eBay for ~$500.

Can anyone please confirm whether these parts (AC 3402-6830 and Suzuki 32900-38F10) are interchangeable?

Thanks in advance!
 

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I believe they are interchangeable. The problem I had was the Zuki and cat are different shapes and sizes, and I couldn't find a wiring diagram for the Zuki to ensure pin layouts match.
Did you check the diaphragm?
Did you check/adjust your valves?
Is it an auto or manual?
Jets in the correct places on reassembly?
Have you checked the belt?
Checked the pilot mixture screw settings on bottom of carb?
Does your new plug come out white or black?
 

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Discussion Starter · #3 ·
I believe they are interchangeable. The problem I had was the Zuki and cat are different shapes and sizes, and I couldn't find a wiring diagram for the Zuki to ensure pin layouts match.
Did you check the diaphragm?
Did you check/adjust your valves?
Is it an auto or manual?
Jets in the correct places on reassembly?
Have you checked the belt?
Checked the pilot mixture screw settings on bottom of carb?
Does your new plug come out white or black?
I ended up sending the CDI to https://regulatorrectifier.com. I'll let you all know how it turns out.

Meanwhile, I've essentially rebuilt the carb and jets, diaphragm, and pilot mixture are all good. Spark plug comes out more black than brown, but I'll adjust it again. I've adjusted the valve clearance and the belt looks good. It's an auto.
 

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Did you check the timing? Fun thing I just went through, if you bought it used you may not know what's been done.

I did the work myself so I have myself to blame for putting my timing out, but if the previous owner was doing something like I did with the service manual I used they likely made the same mistake.

take off both valve covers, pull the spark plug and take the recoil off so you can turn the engine over by hand, and the flywheel timing plug.

put a long skinny stick/screwdriver down the plug hole till it touches the piston, roll the engine over by hand with a finger on-top of the screwdriver to ensure it doesn't bind/hang-up. Watch the rocker arms, as you turn the engine over make sure neither rocker is moving out of sequence prior to the TDC of the correct stroke.

I did my own timing chain a few months ago, and didn't see the timing marks on the end of the cam-shaft in the black and white service manual that I printed off. My intake valves were opening before the top of the exhaust stroke, exhaust valves were opening before the bottom of the power stroke.

It's just a quick easy visual reference to make sure the previous owner didn't do something you aren't aware of without having to tear the rocker box off and deal with the NASTY gasket maker.
 

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Did you check the timing? Fun thing I just went through, if you bought it used you may not know what's been done.

I did the work myself so I have myself to blame for putting my timing out, but if the previous owner was doing something like I did with the service manual I used they likely made the same mistake.

take off both valve covers, pull the spark plug and take the recoil off so you can turn the engine over by hand, and the flywheel timing plug.

put a long skinny stick/screwdriver down the plug hole till it touches the piston, roll the engine over by hand with a finger on-top of the screwdriver to ensure it doesn't bind/hang-up. Watch the rocker arms, as you turn the engine over make sure neither rocker is moving out of sequence prior to the TDC of the correct stroke.

I did my own timing chain a few months ago, and didn't see the timing marks on the end of the cam-shaft in the black and white service manual that I printed off. My intake valves were opening before the top of the exhaust stroke, exhaust valves were opening before the bottom of the power stroke.

It's just a quick easy visual reference to make sure the previous owner didn't do something you aren't aware of without having to tear the rocker box off and deal with the NASTY gasket maker.

I learned i was 22 degrees out of time 1.5 weeks ago. spent since JUNE trying to figure it out. These engines will run with the timing out quite a ways and seem like everything is alright.
 
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Discussion Starter · #6 ·
Got the CDI back and everything tested fine.

I think the next steps for me are to check the timing, as @Farrix recommended, as well as test the grounds and the wiring around the kill/start/stop swtiches.
 

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The easy way I found my issue and to get a rough idea what is going on is to pull the fuel tank, the valve covers, spark plug and flywheel plug to see the tdc mark and the recoil cover

Using a long screwdriver/rod down the plug hole to monitor the piston location.
Rotate the engine over over with the birdcage and watch the rocker arms for the valves. If the valves are opening or closing out of sync with the piston tdc and bdc points then you have an idea something is off.

The hard way is to pull the rocker box and inspect cam marks.

A service manual is available on countrycat.com under technical information.
 
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