I have a 1999 sportsman 500 I am trying to locate a flywheel for. Purchased a stator due to no voltage but while removing flywheel with puller it broke off the magnets from the inner portion of the flywheel. Paid $800 for the bike two years ago and have put multiple parts to keep it running. Lowest price flywheel I have located is $389 and honestly that would put me past my cost to use ratio. If anyone may have a dealer or parts store that may be a bit less please let me know. Thank you!




Polaris Part #: 3085558

 

Parts been upgrade to #3086983. Sometime hard to find a good older one. Best I've found is one at Partzilla.3086983 FLYWHEEL-W/RING GEAR $327.59 Or a used one on ebay for $289 that I'm not sure about.http://www.ebay.com/itm/Polaris-Sportsman-500-98-02-Flywheel-FF97-9683-/361347037229?fits=Make%3APolaris&hash=item5421f6382d&vxp=mtr On repairing used machines sometimes hard to get within that "cost to use ratio" including purchase price.

 

Those are about the same prices i have found. So i have a second question. I notice the magnets are not cast in but glued in. Do you know of an adhesive that would work to reset them without effecting the continuity between the stator and ingiton system? I am a heavy diesel mechanic so these smaller engines are a bit new me. Thanks for all your help!

 

I've heard of people trying to use a strong epoxy(what they're glued down with to begin with from the factory) to reset thrown magnets that have destroyed stators on the old exposed magnet flywheels,but I wouldn't trust one at all.. That's the main reason they updated the flywheels to an enclosed magnet style to stop this. Heat and age causes the epoxy to give out and magnets get thrown. I don't know how many that came into the shop over the years that I had to replace the stator and flywheels on that were trashed.

 

I would try JB Weld High Heat epoxy , strong and rated for high temps , any auto strore should have it .

 

Had people try this and some strong 3M type stuff. Most didn't work and they just came in and ordered new flywheels.