2003 rmk w/99 700 has any one else done it?

[derekrmkak]

I put My 99 700 into 03 edge. works great. the only problems so far are how to hook up the temp gauge and the head lights did not work. Any one know how to fix these?

 

[BB454]

99

Your temp gauge should just plug into the same 2 pin connector on the edge chassis that it did on the gen II. No headlight is a chassis problem not motor swap. The connectors down by the pull starter are the same on both sleds and power the lights and CDI. I would check all light bulbs, you may have a bad voltage reg in the edge chassis that burned all of them out. At an idle with a good reg you should see 12-14v AC if more than that the the reg is bad. If less then you have a short some where. Check again after replacing the reg. if low then a short killed the first reg.

 

[derekrmkak]

The head light turned out to just be the switch on the handle bars. the temp gauge on the 99 is a single wire. If I just put a two wire temp gauge in it should be good? The 03 has a two wire plug black w/ white strip and a red w/ black strip.

 

[BB454]

99

The 99 temp sending unit is a simple switch. When it gets hot it closes causing a ground and the light comes on. The 2 wire is a resistance set up for the cdi. As the motor approaches hot the edge cdi starts retarding the ignition to cool the motor if it contines to get hot the light comes on.
Before you change the sending unit, try just grounding one of the wires in the harnes plug while the motor is running. If the light comes on then just plug in the 99 sender into that lead and you should be good. Leave the other empty. I assume you are using the 99 CDI.

I'll try to send you the wiring diagrams.

 

[BB454]

Wiring

Notice on the 99, Blk/w runs from the sender to the light in the tach. That light gets power in the tach on the yellow line.
On the 02 it goes through the large CDI connector but is bassically the same if you have plugged in your 99 CDI to the chassis main harness you won't have that large connector that is on the 02. At the gauge you have the same yellow for power and a blk/w going down to the plug where that large connector for the edge is. In that connector the temp gauge wires are brown and black, that being the difference in the 2 lead sending unit. That shouldn't matter if you are using the 99 CDI because you won't have that large connector.
I guess if you are using the 02 connector you can either switch to the 2 lead sending unit or pull the Blk/w out of the large connector and plug it into the single wire on the 99 sending unit. Note if you do that and are trying to run an edge CDI it will not run. It will think the sending unit is bad and not start or miss while running.

You will notice the test specs on the temp unit are listed with the 02 wiring diagram. Again a resistance unit instead of simple on/off.

 

[TaylorSledWorks]

Are you running the rack mikuni's or the keihins? I have done that swap 4 times now , we used a 99 700 in both 02 and 03 chassis , using the edge motor mounts(rear of mount redrilled and lowered, front of mount washered up to roll the engine a bit), we used on 3 of them the original 99 carb boots and the keihin carbs but found that on some keihins there is a brass "stop" in the float bowl that has to be removed and the floats need adjusted a bit lower due to the angle they sit at in that chassis or they will drool at idle and load the takeoff, the other swap we used 01 700 rack carbs and edge boots...much better in the end as the air box fits better and the carbs need no tinkering. a couple we used edge exhaust and a couple wanted to run thier older slp twins so an orange slice was cut from the flanges and rewelded to allow fitment and a new outlet hole made in the pan.

 

[derekrmkak]

99 CDI

Notice on the 99, Blk/w runs from the sender to the light in the tach. That light gets power in the tach on the yellow line.
On the 02 it goes through the large CDI connector but is bassically the same if you have plugged in your 99 CDI to the chassis main harness you won't have that large connector that is on the 02. At the gauge you have the same yellow for power and a blk/w going down to the plug where that large connector for the edge is. In that connector the temp gauge wires are brown and black, that being the difference in the 2 lead sending unit. That shouldn't matter if you are using the 99 CDI because you won't have that large connector.
I guess if you are using the 02 connector you can either switch to the 2 lead sending unit or pull the Blk/w out of the large connector and plug it into the single wire on the 99 sending unit. Note if you do that and are trying to run an edge CDI it will not run. It will think the sending unit is bad and not start or miss while running.

You will notice the test specs on the temp unit are listed with the 02 wiring diagram. Again a resistance unit instead of simple on/off.

Thanks I'll ground the black/w and see if the temp lights up. THANKS

 

[derekrmkak]

Mikuni's, edge carb and exhaust

Are you running the rack mikuni's or the keihins? I have done that swap 4 times now , we used a 99 700 in both 02 and 03 chassis , using the edge motor mounts(rear of mount redrilled and lowered, front of mount washered up to roll the engine a bit), we used on 3 of them the original 99 carb boots and the keihin carbs but found that on some keihins there is a brass "stop" in the float bowl that has to be removed and the floats need adjusted a bit lower due to the angle they sit at in that chassis or they will drool at idle and load the takeoff, the other swap we used 01 700 rack carbs and edge boots...much better in the end as the air box fits better and the carbs need no tinkering. a couple we used edge exhaust and a couple wanted to run thier older slp twins so an orange slice was cut from the flanges and rewelded to allow fitment and a new outlet hole made in the pan.

Mikuni's with the edge boots and exhaust. It is set up with SLP air box mods, SLP boost bottle, and SLP can. I ride from 500-5000 feet from My house what jets would you run and needle setting?