Flywheel + Ignition Conversion Kit fits Polaris Sportsman Ranger 500 2002 2003

  

ATV / UTV / SXS. Flywheel + Ignition Conversion Kit for Polaris Big Boss Int'l / Sportsman / Magnum / Scrambler 500 2002 2003. Two flywheels exist for Polaris 500cc models. Improves ignition performance, especially in cold weather. There was a run of Sportsman from 1997 to 2002 that were plagued with electrical problems and failure of the ignition system was a matter of when not if. The AC powered ignition was the Achilles heel of an otherwise stone reliable ATV. With our new Ignition Fix Kit, we convert your problematic 2002/2003/2004 Sportsman 700 AC ignition to a much more reliable DC ignition at less than half of the price of the Polaris upgrade kit. 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. The common repair is using JB Weld? Marine Blue Epoxy to reattach the loose original magnets or to install new ones.

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. Polaris Intl Big Boss 500 -- 2002 Polaris Magnum 500 HDS 2x4 -- 2002 Polaris Magnum 500 HDS 4x4 -- 2003 Polaris Scrambler 500 2x4 -- 2002 Polaris Scrambler 500 4x4 -- 2002 Polaris Sportsman 500 6x6 -- 2002. Dimensions: Exterior Diameter: 141 mm Interior Diameter: 117 mm Interior Diameter Center Housing: 25 mm Exterior Diameter Center Housing: 23 mm. Main Base Diameter: 105 mm (4.1") Thickness: 12mm (0.5").

Before attempting to start your Polaris, adjusting the air gap is necessary. AC to DC Ignition conversion kit. Watch our AC to CD Ignition conversion kit installation video. Download our complete installation instruction (PDF 15Mo). Removing a Powersport Vehicle's Flywheel / Rotor. Flywheel Pullers are very versatile engine service tools and are a must in every toolbox. 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. 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. 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. 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.

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. 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! We deliver 99.4% 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. RaceTech Electric was founded in 2011 by three motorcycle industry veterans in San Diego, CA. The group has over 20 years combined in the Motorcycle industry.