Kit Flywheel + Puller for Polaris Xpress 300 400L | Xplorer 400 / L | Sportsman Scrambler 400 | Big Boss 400L 1994-2002
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: 130 mm
Interior Diameter: 116 mm
Interior Diameter Center Housing: 24.50 mm
Exterior Diameter Center Housing: 22.50 mm
Thickness (exterior): 44.70 mm
Thickness (interior): 40 mm
Main Base Diameter: 105 mm (4.1"")
Thickness: 12 mm (.5"")
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".
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-torquing 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.
Make sure the flame of your torch is focused, and heat only the center of the flywheel. This is due to the fact that some flywheels use adhesive or other fixing compounds to locate the magnets in the rim that can be damaged by concentrated heat. Here again, the wheel might fall off the crank, so be prepared to catch it. And remember that you just heated it, so make sure you can catch it without burning yourself.
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!
Brand new aftermarket Flywheel + Flywheel Puller Kit
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.
Brand New Flywheel Puller
- All products are tested
PLEASE CHECK IF YOUR MAKE/MODEL IS COMPATIBLE IN THE 'FITS MODELS' TAB BEFORE BUYING
All item pictures are accurate; if in doubt, do not hesitate to compare our item to your original part.