Improved Flywheel for Polaris 400 L Big Boss Scrambler Sport Sportsman Xplorer Xpress 300 400 L 1994-2003 FF95 1964K01
Our parts is ONLY compatible with the flywheels that have the following codes:
- 2003 Polaris Trail Blazer 400
- 2002 Polaris Xplorer 400
- 2002 Polaris Scrambler 400 4x4
- 2002 Polaris Scrambler 400 2x4
- 2001 Polaris Xplorer 400
- 2001 Polaris Scrambler 400 2x4
- 2000 Polaris Xplorer 400
- 2000 Polaris Scrambler 400 4x4
- 2000 Polaris Scrambler 400 2x4
- 1999 Polaris Xplorer 400
- 1999 Polaris Sport 400
- 1999 Polaris Scrambler 400 4x4
- 1998 Polaris Xplorer 400 L
- 1998 Polaris Xplorer 400
- 1998 Polaris Sport 400
- 1998 Polaris Scrambler 400 4x4
- 1997 Polaris Xpress 400 L
- 1997 Polaris Xpress 300
- 1997 Polaris Xplorer 400 L
- 1997 Polaris Sportsman 400
- 1997 Polaris Sport 400
- 1997 Polaris Scrambler 400 4x4
- 1997 Polaris Big Boss 400 L
- 1996 Polaris Xpress 400 L
- 1996 Polaris Xpress 300
- 1996 Polaris Xplorer 400 L
- 1996 Polaris Sportsman 400
- 1996 Polaris Sport 400
- 1996 Polaris Scrambler 400 4x4
- 1996 Polaris Big Boss 400 L
- 1996 Polaris 400 L
- 1995 Polaris Xplorer 400
- 1995 Polaris Sportsman 400
- 1995 Polaris Sport 400
- 1995 Polaris Scrambler 400 4x4
- 1995 Polaris Big Boss 400 L
- 1995 Polaris 400 L
- 1994 Polaris Swedish 400L 4x4
- 1994 Polaris Sportsman 400
- 1994 Polaris Sport 400
- 1994 Polaris Norwegian 400L 4x4
- 1994 Polaris 400 L
Exterior Diameter: 178 mm
Interior Diameter: 106 mm
Interior Diameter Center Housing: 24.50 mm
Exterior Diameter Center Housing: 22.50 mm
Thickness (exterior): 44.70 mm
Thickness (interior): 40 mm
Before attempting to start your Polaris vehicle 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".
Introducing our newest heavy duty flywheel rotor for Polaris 300, 400 & 500cc ATVs.
Anyone who rides or repairs a Polaris 300, 400 & 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.