Kit Stator + Flywheel for Polaris ATP Big Boss Magnum Ranger Scrambler Sportsman Worker 400 500 2002-2004 FF97
- 2004 Polaris Sportsman 400 4x4 F/C Carb
- 2004 Polaris Ranger 500 Series 11
- 2004 Polaris ATP 500
- 2003 Polaris Sportsman 500 HO
- 2003 Polaris Sportsman 500 4x4
- 2003 Polaris Sportsman 400
- 2003 Polaris Scrambler 500 4x4
- 2003 Polaris Ranger 500 Series 10 4x4
- 2003 Polaris Magnum 500 HDS 4x4
- 2002 Polaris Worker 500
- 2002 Polaris Sportsman 500 HO
- 2002 Polaris Sportsman 500 6x6
- 2002 Polaris Sportsman 500 4x4
- 2002 Polaris Scrambler 500 4x4
- 2002 Polaris Scrambler 500 2x4
- 2002 Polaris Magnum 500 RMK
- 2002 Polaris Magnum 500 HDS 4x4
- 2002 Polaris Magnum 500 HDS 2x4
- 2002 Polaris Intl Big Boss 500
- 1999 Polaris Ranger 500 6x6
Interior diameter : 47 mm
Exterior diameter : 114 mm
Thickness : 20 mm
Length of wires stator to grommet : 155 mm
Length of wires grommet to plug : 900 mm
Length of pickup coil's wire to grommet : 60 mm
Other specifications :
Number of wires : 7
Number of plugs : 9
Number of pins : 12
Wire to wire resistance :
Alternator : Yellow/Red to Yellow = 0.4 ohms +/-20%
Pickup : White/Red to Red = 115 ohms +/-20%
Source : Black to Red = 18 ohms +/-20%
Exterior Diameter: 141 mm
Interior Diameter: 117 mm
Interior Diameter Center Housing: 25 mm
Exterior Diameter Center Housing: 23 mm
Before installing your new stator
- Check the AC output of the stator.
- Replace any burned or corroded connectors on stator and regulator/rectifier
- Check and repair any melted wiring.
- Use hi-temp dielectric grease on all connectors
Our stator may use a different wire color code than your original.
All of the wires are installed in the correct order; please do not change any of the wiring configurations.
This stator is designed as a direct plug-in replacement and should be used as such.
When bolting stator in, always use locking compound.
If our stator includes a pickup coil, always make sure the air gap is correct upon installation; we suggest as close as possible no less than 0.010".
Before attempting to start your Polaris, adjusting the air gap is necessary. Rotate the flywheel so the raised node is lined up with the pick up/pulser coil and adjust as close as possible but no less than 0.010’’.
Two flywheels exist for Polaris 500cc models. This flywheel has the code FF97 stamped on its back. In doubt, please refer to specifications.
Introducing our newest heavy duty flywheel rotor for Polaris 500cc ATVs.
Anyone who rides or repairs the Polaris 500cc ATV's is probably familiar with the flywheel problems common to these models. Most of these bikes will have at least one flywheel failure in their lifetime so far. Low quality epoxy was used on OEM flywheels to secure the magnets to the rotor body. Over time and many heat cycles, the epoxy fails allowing the magnets to come loose and contact the stator, potentially causing catastrophic damage.
For years, service shops & dealerships have offered low cost repairs for Polaris flywheels to save the 400$+ OEM replacement. This sounds like a great idea at first, but there are some serious issues!
The common repair is using JB Weld© Marine Blue Epoxy to reattach the loose original magnets, or to install new ones. Epoxy fixes do repair flywheels in short term, if they are done correctly. However, this kind of repair can easily cause immediate problems, and impact long term reliability of your ATV.
A Heavy Duty Flywheel to the rescue!
New RMSTATOR&trade heavy-duty flywheel rotor for Polaris ATVs is a well-priced solution to problems with the OEM flywheel, and an excellent alternative to all the mechanical troubles you can encounter with a repair.
Built to OEM size
Fits precisely in your ride: install it and forget it.
Uses high temperature epoxy that is stronger than OEM, eliminating the possibility of magnet detachment.
High grade steel capping
Prevents harsh additives in motor oil from degrading the epoxy attaching the magnets. Though extremely unlikely, if a magnet did ever come loose, it would remain in the sleeve preventing contact with the stator.
Eliminates crankshaft vibrations for longer engine longevity
Shop with confidence
All products are tested.
Don't waste time with temporary solutions, and start fixing your ride like a pro!
Why cheap repairs won't work?
Quick stronger epoxy fixes do repair flywheels in short term. It might however impair long term performance and reliability of your ride.
Remaining OEM magnets:
Original magnets remaining can still come loose at any time.
The alignment of magnets around the flywheel is critical for proper stator operation. Even very fine misalignment will reduce stator efficiency significantly.
Excessive epoxy or incorrect magnet spacing around the flywheel can easily affect the flywheel balance. This can cause stator contact or even crankshaft damage.
Incorrect replacement magnets:
The magnetic field strength of new magnets MUST match the originals. Stator failure can occur quickly with stronger magnets and stator output can be decreased significantly using weaker magnets.
Wrong epoxy properties:
Epoxy that is not rated to permanently handle high temperatures and oil immersion can quickly cause a serious failure.
Wrong epoxy for the application can also contaminate the crankcase oil, damaging the motor.
All these reasons make us strongly recommend that you replace your broken flywheel with a new 400+ OEM one or our new heavy duty flywheel.