Kit Stator + Flywheel Rotor for Polaris Sportsman 600 2003 2004 | Sportsman 700 Carb 2002-2004 OEM# 4060152 2202602
This kit only replaces the AC ignition system by Ducati. You can identify this system by the combined CDI/ignition coil unit mounted in front of the headlight. It will have 2 spark plug wires exiting the unit, with the stator plugged directly into it.
Stator
Dimensions :Interior diameter : 40 mm
Exterior diameter : 108 mm
Thickness : 25 mm
Length of wires stator to grommet: 85 mm
Length of wires grommet to plug: 930, 960 and 1400 mm
Length of pickup coil's wire to grommet: 160 mm
Other specifications :
Number of wires : 10
Number of plugs : 7
Number of pins : 10
Wire to wire resistance :
Alternator : Yellow to Yellow/Red = 0.4 ohms +/-20%
Alternator : Yellow to Ground = 0.L on display
Pickup : Red to Black = 360 ohms +/-20%
Source : Brown to Yellow = 5.8 ohms +/-20%
Flywheel
Dimensions:
Exterior Diameter: 168 mm
Interior Diameter: 109 mm
Interior Diameter Center Housing: 28 mm
Exterior Diameter Center Housing: 38 mm
Thickness (exterior): 52 mm
Thickness (interior): 42 mm
- 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 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".
Brand new aftermarket Stator
- Direct replacement to your original unit
- Plug-and-play, direct fit, easy installation
- Highest grade of lamination materials
- Highest grade of copper winding, resistant to 200 degrees Celsius
- Pick up pulsar coil included
- Connector included
- Rubber grommet included
- All products shipped are tested
All item pictures are accurate; if in doubt, do not hesitate to compare our item to your original part.
Introducing our newest Heavy Duty Flywheel Rotor For Polaris 600 & 700cc ATVs.
Anyone who rides or repairs the Polaris 600 & 700cc ATVs 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 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.
Features
Built to OEM size
Fits precisely in your ride: install it and forget it.Improved epoxy
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.Precise balancing
Eliminates crankshaft vibrations for longer engine longevity.Shop with confidence
One year warranty. 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.
Magnet alignment:
The alignment of magnets around the flywheel is critical for proper stator operation. Even very fine misalignment will reduce stator efficiency significantly.
Magnet spacing:
Excessive epoxy or incorrect magnet spacing around the flywheel can easily affect the flywheel balance. This can cause stator contact or even crankshaft damages.
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.
Oil contamination:
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.