I did this ignition swap out a couple of weeks ago now. I just want to add for those I saw on the forums that struggled with removing the flywheel nut some advice- if you don't have an impact gun you can look through the 3 holes around the flywheel shaft with a flashlight and slowly turn the flywheel to line up the holes with the Allen head bolts that are behind the flywheel that hold the stator. Stick a good 5 mm Allen wrench through it into the bolt and turn the flywheel until it's tightly against the wrench in the correct direction (counter clockwise when removing the nut vice versa when putting the new one in) then you can CAREFULLY loosen the flywheel nut. I actually used 2 of the 5 mm in 2 holes just to give it more stability. No one mentions this anywhere I could find and it worked like a charm. Give my comment a like if this helps anyone and like this guys video because it's a big help to the first timers. I'm happy to help if anyone has any questions too! Good luck
Thank you for sharing this. I just did mine yesterday. I could not have done it with the directions alone. The electrical part I'm not very good at. Your video made it a lot easier. Thank you!! It started right up.
Thanks for this. I am in the middle of doing this on my 700. While I was at it I also replace the plugs, did an oil change and checked my belt :) Kit arrives tomorrow. It sure took me a while to figure out how to remove the front body stuff. Having a winch up front kind of threw me a bit.. A couple of the bolts for the front rack were also hidden under the plastic top part of the rack too. Had to loosen it a bit to move it enough to use a hand wrench to get those two top bolts out. :)
Yes had to put this kit on both my 2003, 600 and 700 sportsman. Within a week both of them would not start. Scary! Anyway the old system is not reliable and really a piece of junk compared to the new one. It is really unreliable and will quit at anytime. I really can't believe polaris put this system on the machines in the first place. Machines run and start fantastic now, better than new. A Lot of work to install these systems. They are expensive too. Plan on buying a fly wheel puller tool too. You will need a good torque wrench as well. The first system was the hardest. Second one was much faster to install. Presured wash your quad thoughly bebore you install the system
Was this done because of complete fail to start issue or just when it gets hot it died constantly? It was hot yesterday 90° and after a little riding mine died and wouldn't start until after sitting 30 mins. Then it died again. Had to walk home then go early morning and it started right up and drove home. Wondering if it's this issue or just the ignition coil maybe? Any cool gents out there with knowledge or advice? Thanks!
I did this ignition swap out a couple of weeks ago now. I just want to add for those I saw on the forums that struggled with removing the flywheel nut some advice- if you don't have an impact gun you can look through the 3 holes around the flywheel shaft with a flashlight and slowly turn the flywheel to line up the holes with the Allen head bolts that are behind the flywheel that hold the stator. Stick a good 5 mm Allen wrench through it into the bolt and turn the flywheel until it's tightly against the wrench in the correct direction (counter clockwise when removing the nut vice versa when putting the new one in) then you can CAREFULLY loosen the flywheel nut. I actually used 2 of the 5 mm in 2 holes just to give it more stability. No one mentions this anywhere I could find and it worked like a charm. Give my comment a like if this helps anyone and like this guys video because it's a big help to the first timers. I'm happy to help if anyone has any questions too! Good luck
Thank you for sharing this. I just did mine yesterday. I could not have done it with the directions alone. The electrical part I'm not very good at. Your video made it a lot easier. Thank you!! It started right up.
Thanks for this. I am in the middle of doing this on my 700. While I was at it I also replace the plugs, did an oil change and checked my belt :) Kit arrives tomorrow. It sure took me a while to figure out how to remove the front body stuff. Having a winch up front kind of threw me a bit.. A couple of the bolts for the front rack were also hidden under the plastic top part of the rack too. Had to loosen it a bit to move it enough to use a hand wrench to get those two top bolts out. :)
Yes had to put this kit on both my 2003, 600 and 700 sportsman. Within a week both of them would not start. Scary! Anyway the old system is not reliable and really a piece of junk compared to the new one. It is really unreliable and will quit at anytime. I really can't believe polaris put this system on the machines in the first place. Machines run and start fantastic now, better than new. A Lot of work to install these systems. They are expensive too. Plan on buying a fly wheel puller tool too. You will need a good torque wrench as well. The first system was the hardest. Second one was much faster to install. Presured wash your quad thoughly bebore you install the system
well this video really help me out on putting the ignition system kit 2202602 after all put back together hit the key fired right up.
I bought this same upgrade kit. Do you know what the red wire tucked in the wiring harness is on the wiring schematic?
Was this done because of complete fail to start issue or just when it gets hot it died constantly? It was hot yesterday 90° and after a little riding mine died and wouldn't start until after sitting 30 mins. Then it died again. Had to walk home then go early morning and it started right up and drove home. Wondering if it's this issue or just the ignition coil maybe? Any cool gents out there with knowledge or advice? Thanks!
What issue where u having to do update
I need to buy all those parts to make the upgrade or you decided to upgrade all the parts just cause?
Cristian Haire-Foster à
Hi - did you ever sell your old flywheel?
Yes I sold the good used parts already
@@davidsalmons9012 Ok - thanks for responding!
Any chance you want to sell the old flywheel?
If you are still looking, I've got my original.
Rite on...thanks