Flywheel Rotor Polaris Sportsman 500 1998-2004

2004 Polaris ATP 500 4x4 Carb
2004 Polaris Sportsman 400 4x4 Carb
2004 Polaris Sportsman 500 4x4 Carb
2003 Polaris Magnum 500 4x4
2003 Polaris Scrambler 500 4x4
2003 Polaris Sportsman 400 4x4 Carb
2003 Polaris Sportsman 500 6x6 Carb
2003 Polaris Sportsman 500 HO 4x4 Carb
2002 Polaris Big Boss 500 6x6
2002 Polaris Big Boss 500 6x6 International
2002 Polaris Magnum 500
2002 Polaris Magnum 500 4x4
2002 Polaris Magnum 500 RMK 4x4
2002 Polaris Magnum 500 VL HDS 2x4
2002 Polaris Scrambler 500 2x4
2002 Polaris Scrambler 500 4x4
2002 Polaris Sportsman 500 4x4 Carb
2002 Polaris Sportsman 500 6x6 Carb
2002 Polaris Sportsman 500 RSE Carb
2002 Polaris Sportsman 500 X Carb
2002 Polaris Sportsman 500 HO 4x4 Carb
2002 Polaris Worker 500
2001 Polaris Big Boss 500 6x6
2001 Polaris Big Boss 500 6x6 International
2001 Polaris Magnum 500 4x4
2001 Polaris Magnum 500 HDS 4x4
2001 Polaris Scrambler 500 2x4
2001 Polaris Scrambler 500 4x4
2001 Polaris Sportsman 500 4x4 Carb
2001 Polaris Sportsman 500 6x6 Carb
2001 Polaris Sportsman 500 HO 4x4 Carb
2001 Polaris Sportsman 500 HO RSE Carb
2001 Polaris Worker 500
2000 Polaris Big Boss 500 6x6 International
2000 Polaris Magnum 500 4x4
2000 Polaris Magnum 500 EB
2000 Polaris Magnum 500 HDS 4x4
2000 Polaris Scrambler 500 4x4
2000 Polaris Sportsman 500 4x4 Carb
2000 Polaris Sportsman 500 6x6 Carb
2000 Polaris Sportsman 500 RSE Carb
1999 Polaris Big Boss 500 6x6
1999 Polaris Big Boss 500 6x6 International
1999 Polaris Magnum 500 4x4
1999 Polaris Scrambler 500 4x4
1999 Polaris Sportsman 500 4x4 Carb
1999 Polaris Sportsman 500 RSE Carb
1999 Polaris Worker 500
1998 Polaris Big Boss 500 6x6
1998 Polaris Scrambler 500 4x4
1998 Polaris Sportsman 500 4x4 Carb
1997 Polaris Scrambler 500 4x4
2004 Polaris Ranger 500 Series 11 2x4
2004 Polaris Ranger 500 Series 11 4x4
2004 Polaris Ranger 500 Series 11 6x6
2003 Polaris Ranger 500 Series 10 4x4
2003 Polaris Ranger 500 Series 10 6x6
1999 Polaris Ranger 500

OEM
3085558
3086819
3086983
3087166

Dimensions:

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

Puller

Main Base Diameter: 105 mm (4.1")
Thickness: 12mm (.5")

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’’.

Puller

Removing a Powersport Vehicle's Flywheel / Rotor:

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-torquing 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.