Flywheel For Polaris Big Boss Magnum Scrambler Sportsman 400 500 1997-2004 FF97

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We are aware our flywheel does not have timing marks on the outer diameter like the OEM part. We are in the process of adding these to our flywheel; they will be on all future production. Until our new production is available, if you need to adjust your timing, please line up our flywheel with your OEM, matching the woodruff keyway orientation. You can then add timing marks in the same location to our flywheel with a permanent marker or paint pen.
Please Note:
There are two possible flywheel for the ranger 500 series 11. This flywheel will only fit if it has been built after 08-09-2002. If your model has been built before this date you must use RMs120-106200.
Two flywheels exist for Polaris 500cc models. This flywheel has the code FF97 stamped on its back. If 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 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.
Vehicle models fitment
Polaris ATP 500 -- 2004
Polaris Big Boss 500 -- 1998-1999
Polaris Intl Big Boss 500 -- 1999-2002
Polaris Magnum 500 4x4 -- 2000-2001
Polaris Magnum 500 EB -- 2000
Polaris Magnum 500 HDS 2x4 -- 2002
Polaris Magnum 500 HDS 4x4 -- 1999-2003
Polaris Magnum 500 RMK -- 2002
Polaris Scrambler 500 2x4 -- 2001-2002
Polaris Scrambler 500 4x4 -- 1997-2003
Polaris Sportsman 400 -- 2003
Polaris Sportsman 400 4x4 F/C Carb -- 2004
Polaris Sportsman 500 4x4 -- 1998-2003
Polaris Sportsman 500 6x6 -- 2000-2002
Polaris Sportsman 500 HO -- 2001-2003
Polaris Worker 500 -- 1999, 2001-2002
OEM part replacement
3085558
3086819
3086983
3087166
Specifications
Dimensions:
Exterior Diameter: 141 mm
Interior Diameter: 117 mm
Interior Diameter Center Housing: 25 mm
Exterior Diameter Center Housing: 23 mm
instructions
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??.
Item Delivery
Our multiple North American locations, from which we ship our products, allows us to deliver 99.7% of our orders within the specified time period. If your item is not available in our main Colorado facility, we still guarantee that your order will be delivered within the specified time period.
If your item is not delivered within this time period, we will offer you a 5.00$ discount on your order. This guarantee applies to shipments delivered in the 48 continental USA states, excluding PO boxes.
Videos
Watch Evan, electrical engineer of RMSTATOR, explaining the installation process behind this product.
Learn more about the great company that is RMSTATOR™.
Learn more why and how to repair melted or corroded connectors.
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International Buyers:
Import duties, taxes, and charges are not included in the item price
or shipping cost. These charges are the buyer's responsibility.
More than 20 years of assisting mechanics around the world resolving the worst electrical problems made us know our stuff. When it comes to vehicle electrics, we definitively are the power in powersports.
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