Flywheel for Polaris Magnum 425 | Sportsman 335 / 400 / 500 | Xplorer 500 | Worker 335 1995-2002

KEY FEATURES
 

Brand new Magneto Flywheel Rotor

All products are tested

All item pictures are accurate; if in doubt, do not hesitate to compare our item to your original part

DESCRIPTION

 

Please Note: There are two possible flywheel for the ranger 500 series 11. This flywheel will only fit if it has been built before 08-09-2002. If your model has been built after this date you must use RM11512.

Introducing our newest Heavy Duty Flywheel Rotor For Polaris 400 & 500cc ATVs.

Anyone who rides or repairs the Polaris 400 & 500cc 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.

Vehicle models fitment

 

Polaris Magnum 425 2x4 -- 1995-1998
Polaris Magnum 425 4x4 -- 1995-1999
Polaris Magnum 425 6x6 -- 1996-1997
Polaris Sportsman 335 -- 1999-2000
Polaris Sportsman 400 -- 2001-2002
Polaris Sportsman 500 4x4 -- 1996-1997
Polaris Worker 335 -- 1999
Polaris Xplorer 500 -- 1997

OEM part replacement

 

3084969
3086857
3086858

Specifications

 

Dimensions:
Exterior Diameter: 132 mm & 174 mm
Interior Diameter: 106 mm
Height Total: 65 mm
Height Inside: 37 mm
Taper Depth: 28 mm
Taper Widest: 25 mm
Taper Narrowest : 22.30 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".