Flywheel and Flywheel Puller Kit for Polaris Magnum, Scrambler & Sportsman 400 500 1997-2004
Flywheel and Flywheel Puller Kit for Polaris Magnum, Scrambler & Sportsman 400 500 1997-2004
SKU:RMS900-102191
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Heavy Duty Flywheel and Puller Kit
Polaris ATP, Big Boss, Magnum, Scrambler, Sportsman HO and Worker 400 500 - 1997-2004 - FF97
A heavy duty flywheel rotor for Polaris 500cc ATVs, supplied together with the puller needed to fit it. Two flywheels exist for the Polaris 500cc models, and this is the one with the code FF97 stamped on its back. Check the back of your existing rotor for that code before ordering, because the two are not interchangeable.
The reason these flywheels fail is well known. Low quality epoxy was used on the OEM flywheels to secure the magnets to the rotor body, and over time and many heat cycles the epoxy fails, allowing the magnets to come loose. A magnet that breaks free will destroy the stator underneath it, so a flywheel in this condition takes the charging system with it. This replacement is built to OEM size but uses an improved high temperature epoxy that is stronger than OEM, high grade steel capping over the magnets, and precise balancing. The kit also includes the flywheel puller, an essential tool to remove magneto flywheels without causing damage to crankshaft threads, complete with its crankshaft thread protector cap.
Key Features
- Heavy duty flywheel rotor supplied with the correct puller tool
- For the FF97 coded flywheel - check the code on the back of your rotor
- Built to OEM size
- Improved high temperature epoxy, stronger than OEM, to hold the magnets
- High grade steel capping over the magnets
- Precise balancing
- Puller removes the flywheel without damaging the crankshaft threads
- Crankshaft thread protector cap included with the puller
Technical Specs
| Specification | Detail |
|---|---|
| Flywheel code | FF97 (stamped on the back) |
| Flywheel exterior diameter | 141 mm |
| Flywheel interior diameter | 117 mm |
| Interior diameter, centre housing | 25 mm |
| Exterior diameter, centre housing | 23 mm |
| Puller main base diameter | 105 mm (4.1 in) |
| Puller thickness | 12 mm (0.5 in) |
| Our part number | RMS900-102191 |
Vehicle Fitment Guide
Years shown are the overall coverage span for this part. Please confirm against the OEM part number on your original unit before ordering.
| Make & Model | Years |
|---|---|
| Polaris ATP 400 500 | 1997-2004 |
| Polaris Big Boss 400 500 | 1997-2004 |
| Polaris Magnum 400 500 | 1997-2004 |
| Polaris Scrambler 400 500 | 1997-2004 |
| Polaris Sportsman 400 500 HO | 1997-2004 |
| Polaris Worker 400 500 | 1997-2004 |
OEM Part Number Cross Reference
Aftermarket replacement. OEM part numbers are listed for reference only.
| Part Number | Manufacturer / Brand |
|---|---|
| 3085558 | Polaris |
| 3086819 | Polaris |
| 3086983 | Polaris |
| 3087166 | Polaris |
Frequently Asked Questions
How do I know this is the right flywheel for my machine?
Two flywheels exist for the Polaris 500cc models. This one carries the code FF97 stamped on the back of the rotor. Check the back of your existing flywheel for that code, and cross check the OEM number against the table above, before ordering.
What is in the kit?
One heavy duty flywheel rotor and one flywheel puller tool with its crankshaft thread protector cap.
How do I tell whether my flywheel has failed?
The failure mode is the epoxy letting go of the magnets. Signs are a rattle or grinding from the stator cover, charging output that drops or disappears, metal debris and magnet fragments inside the cover, and scoring on the stator windings. If a magnet has come loose it will normally have damaged the stator as well, so inspect both while the cover is off.
Why is this better than the original flywheel?
It is built to OEM size, but the magnets are secured with a high temperature epoxy that is stronger than the OEM material, and they are retained by high grade steel capping. The rotor is precisely balanced. Those changes address the exact weakness that causes the original flywheels to shed magnets.
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