Replacing the stator in your Polaris Big Boss, Sportsman, Magnum, or Scrambler 500 is a critical maintenance task to ensure the proper functioning of your ATV's electrical system.
Here's what you need to know about the stator replacement process:
1. Diagnostic Testing: Before replacing the stator, it's essential to diagnose the issue accurately. If you're experiencing electrical problems such as no spark, dim headlights, or erratic engine behavior, the stator may be the culprit. However, it's advisable to perform thorough diagnostic testing to rule out other potential causes.
2. Gather Necessary Tools: To replace the stator, you'll need a set of basic hand tools, including wrenches, sockets, screwdrivers, and pliers. Additionally, you may require a service manual specific to your ATV model for guidance on disassembly and reassembly procedures.
3. Locate the Stator: The stator is typically located on the side of the ATV engine, underneath the flywheel cover. You'll need to remove the cover to access the stator assembly.
4. Disconnect Battery: Before starting any work on your ATV's electrical system, disconnect the battery to prevent the risk of electrical shock or damage to sensitive components.
5. Remove Flywheel: Once the flywheel cover is removed, you'll need to loosen the flywheel nut and use a flywheel puller tool to remove the flywheel from the crankshaft. This step requires caution to avoid damaging the flywheel or crankshaft threads.
6. Access Stator Assembly: With the flywheel removed, you'll have access to the stator assembly. Depending on your ATV model, the stator may be secured in place with bolts or screws. Carefully remove these fasteners to detach the stator from the engine casing.
7. Disconnect Wiring: Before fully removing the stator, disconnect the wiring harness connected to it. Take note of the wire routing and connections to ensure proper reinstallation later.
8. Install New Stator: Once the old stator is removed, carefully position the new stator in its place, ensuring that it aligns correctly with the engine casing. Secure the stator in place using the appropriate fasteners, and reconnect the wiring harness.
9. Reassemble Components: With the new stator installed, reassemble the flywheel, flywheel cover, and any other components that were removed during the disassembly process. Torque the flywheel nut to the manufacturer's specifications to ensure proper tension.
10. Test Operation: After reassembly, reconnect the battery and perform a thorough test of the ATV's electrical system. Check for proper spark, battery charging voltage, and overall performance to verify that the stator replacement was successful.