Two flywheels exist for Polaris 500cc models. This flywheel has the code FF97 stamped on its back. In doubt, please refer to specifications.

 

Polaris Big Boss 500 -- 1998-1999
Polaris Intl Big Boss 500 -- 1999-2001
Polaris Magnum 500 4x4 -- 2000
Polaris Magnum 500 EB -- 2000
Polaris Magnum 500 HDS 4x4 -- 1999-2000
Polaris Scrambler 500 4x4 -- 1997-2000
Polaris Sportsman 500 4x4 -- 1998-2000
Polaris Sportsman 500 6x6 -- 2001
Polaris Worker 500 -- 1999

 

RMS900-102832

 

Flywheel

Dimensions:

Exterior Diameter: 141 mm
Interior Diameter: 117 mm
Interior Diameter Center Housing: 25 mm
Exterior Diameter Center Housing: 23 mm

Flywheel Puller

Main Base Diameter: 105 mm (4.1")
Thickness: 12mm (0.5")

Stator

Dimensions:
Interior diameter: 51 mm
Exterior diameter: 114 mm
Thickness: 20 mm

Other specifications:
Number of wires: 9
Number of plugs: 7
Number of pins: 10

Wire to wire resistance:
Alternator: Yellow to Yellow/Red = 0.6 ohms +/-20%
Pickup: White to White/Red = 100 ohms =+/-20%

Source Green to Red/Black = 450 ohms =+/-20%
Source 2: Green to Black = 3.8 ohms =+/-20%

 

Before installing your new stator

• 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 of 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".

Flywheel

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".

Flywheel Puller

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:

Torque Wrench

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.

Propane Torch

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!

Warning:

Risk of electric shock. Disconnect the battery before servicing.
Ensure proper installation by a qualified technician to avoid malfunction.

 

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.

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.