Kit Stator + Flywheel + Puller + AC to DC Ignition Conversion Kit for Polaris Sportsman Big Boss Scrambler 500 2002-2003
Exterior Diameter: 141 mm
Interior Diameter: 117 mm
Interior Diameter Center Housing: 25 mm
Exterior Diameter Center Housing: 23 mm
Flywheel PullerMain Base Diameter: 105 mm (4.1"")
Thickness: 12mm (0.5"")
Generator StatorDimensions :
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%
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".
AC to DC Ignition conversion kit
Removing a Powersport Vehicle's Flywheel / Rotor:
How it Works
Flywheel Pullers are very versatile engine service tools and are a must in every toolbox. Our large selection of best selling rotor and flywheel pullers fit just about any motorcycle or ATV. Flywheel pullers are very simple to use, having only an outer body to hold the flywheel and a screw to push on the crankshaft. Some are even simpler, having only a bolt to thread into the flywheel. A taper holds the flywheel or rotor and the crankshaft together. The flywheel is secured to the shaft by applying torque to the fixing bolt.
An Important Component to use
Many flywheel or rotor puller tools will include a small cap. This is a crankshaft thread protector, and should always be used if it is included with the puller. You slip this cap onto the end of the inner piece of the puller which presses against the tip of the crankshaft. This keeps the fine threads from being stripped or damaged while removing the flywheel or rotor.
Actions to Avoid
Most of the time, removing a flywheel or rotor is painless. But sometimes corrosion, over-torqueing the fixing bolt, or heat-cycling can give you a hard time removing the flywheel. We too often see mechanics use a larger breaker bar or air impact tools to ease the flywheel off. These two techniques will damage the flywheel, the flywheel puller, or the crank. Avoid using them if you want to keep it cheap.
Tips to break a stuck flywheel loose:
How do you know if it's stuck? You simply have to set your torque wrench to 50 ft-lbs and try to ease the flywheel off. If the flywheel is not stuck, you should be able to remove it with even less torque than this. If it is stuck, don't use more torque or you might break your wrench.
Ball Peen Hammer
If 50 ft-lbs does not do the trick, go fetch something like a 12 or 16 oz ball peen hammer. Hit the end of the flywheel puller with a medium blow. Many times, the shock you create will successfully remove your flywheel. Be prepared to catch the flywheel since the shock of the hammer can make the flywheel jump off. Once again, getting into that situation will be pricey. And don't forget your safety glasses.
The hammer is not a be-all, end-all solution. Sometimes, you will have to find something more powerful, and that's where the propane torch comes in. As a last resort solution, the heat should expand the flywheel but not the crank, since it is too massive to expand as fast. That way, the flywheel will become looser and will come off easier.
Important Security Tips: In order to not set fire to your garage, your vehicle, or yourself, certain precautions are necessary prior to heating the flywheel:
- Clean any oil or flammable liquids off the flywheel;
- Make sure your work area is free of any flammable liquids and that you work in a well ventilated area;
- Make sure to remove the gas tank, and set it aside at a safe distance.
With these tips and techniques, you are now equipped to handle any stuck flywheel without throwing your flywheel puller at it; unless you have a habit of working with machines that have been in a lake for months!
Two flywheels exist for Polaris 500cc models. This flywheel has the code FF97 stamped on its back. In doubt, please refer to specifications.
Bring it back to life
Introducing a brand new ACE Ignition System for your Polaris.
Revive your old trusted Polaris and fix it for good with this ignition system that includes :
AC to DC conversion system
Improved magneto flywheel
Universal flywheel puller
Easier diagnosis if a new
Much less expensive than replacing multiple OEM components
Quick and easy installation with
no need to open the engine
The system stabilizes the ignition, especially at low speed
Converts the unreliable AC powered ignition to a more modern and reliable DC powered system
Improves ignition performance, especially in cold weather
There was a run of Sportsman from 1997 to 2002 that were plagued with electrical problems and failure of the ignition system was a matter of when not if.
The AC powered ignition was the Achilles heel of an otherwise stone reliable ATV. Unfortunately, the price to replace with an upgraded Polaris kit was well over $500 and it was your only option.
With our new Ignition Fix Kit, we convert your problematic 2002/2003/2004 Sportsman 700 AC ignition to a much more reliable DC ignition at less than half of the price of the Polaris upgrade kit.
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.
The common repair is using JB Weld© Marine Blue Epoxy to reattach the loose original magnets or to install new ones.
Our new RMSTATOR™ 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.