04 Suzuki Eiger 400 Won't move

[alexwv1863]

I've been working on this 4 wheeler for a buddy of mine. I got it running yesterday and went to ride it around the yard on a test drive. Well, it backed out of the garage fine, but when I went to move forward, it wouldn't move at all. While giving it throttle, the bike would lurch forward as if I had the brake on holding it back. Then it died died on me and wouldn't crank. That sounded like the starter was bound up. It's a new starter that I put on not long ago. It's an aftermarket. Also, when I would rev the engine up trying to get it to move, it sounded like it didn't have much, if any, power. It just wasn't revving right. Anybody have any thoughts as to what could be my problem now? The guy doesn't know what was done to the 4 wheeler by a family member. So anything could be wrong with it. Also, it rolls just fine when I had to push it back in the building. I couldn't hear any clanking or rattling in the rear end.

[Gwbarm]

There are many things it could be, clutch, shift linkage, carb issues, but from your description it sound like maybe a flywheel problem, the only reason i say that is because the Eiger was known for the magnets coming unglued from the flywheel and binding, they seem to stay in place but can move around causing intermittant firing problems and can move to a point where it is binding the engine, and eventually destroy the stator, like you stated felt like the brake was on, the only problem is to know for sure you have to get to it and inspect them. Even if thats not the issue i would go ahead and replace the flywheel while in there because it will happen eventually. You can also check the shift linkage when running and make sure it shifts through all the gears if not then there is a tiny spring on the clutch side that can come loose and then it wont shift.

[alexwv1863]

I tore into the side and the flywheel has been updated to the fixed magnet. When I drained the oil, there was a lot of gas mixed in with it. At first, a couple of quarts or so of oil drained out, then nothing but gas mixed with oil. In total, I got just a little over a gallon of oil/gas out. The magneto and flywheel look fine. All of the gears are good upon visual inspection. 

Could the rings broke, or something? How could so much gas get into the oil? 

[Gwbarm]

When i see that much gas in the oil i suspect  the carb needle is not closing off all the way letting gas get into the sump. If you still have the original working vaccum petcock that wont happen while not running exceppt for what is in the carb unless you leave it on prime while sitting. Glad to hear your flywheel has been updated hate you had to tear it apart to find that out. Oil that thin was not getting proper lubrication so i would do a compression check to rule out rings.

I got a 2007 that i have to tear into to see if the flywheel has been replaced hard starting issues, but i need to replace the neutral switch anyway , so not a wasted venture.