bringing an 02 back and adding RER (and elec Start)

[AKwelder]

Over a year ago we went on a great spring ride, and an unmentioned person married to me forgot a parking brake, the fire that hit my 02 summit highmark was just like losing a member of the family. So in true sledneck fashion we pushed the old girl back into the weeds and started looking for an organ donar.

I found a 03 summit with RER and a wrecked bottom end. This sled has been ridden HARD, and was never put away. The track (144") is junk, the cowling is scratched and ugly, and the flywheel was robbed to support someone else's machine. When i picked up the old gal 3 boxes of parts and an engine came with her, time for a moment of silence for one no longer standing on top of the mountian

So this week I drug the trailer in and started to sort out my options. After a couple strong drinks and some long thoughts here is the plan.

The 03 had RER, so i want to add RER to my 02. The method may become extreme, I plan on swapping the entire electrical system from the 03 to the 02. MPEM, handle bar switches and all. anybody done this? What are the glitches i will see? I know the whole 800 versus 800HO deal, but what are the real differences?

I like to ride, not pull start the sleds of the ladies in my life, so the thought of adding electric start has been really attractive. What are the differences between the 02 and 03 electric start kits? anyone tried this? anyone have any parts? A ring gear would be great. What REV parts would work? Anyone know the part numbers beside the kit one of 561506900?

thank you everyone

 

[Summit8]

Shouldn't be that hard to swap over to rer, my 02 has it. MPEM, wiring harness and driven clutch, same with elec. start.
Ebay has a ton of parts for sale, just narrow your search down to Skidoo parts. Good luck.

 

[AKwelder]

Update

after some research and pulling my recoil off the 02, this is the plan

- the 02 has both pickup bosses for the stator, two are used on the RER system
- The oil pump must be swapped, mine doesn't work in reverse
- The wiring harness from the handle bars on down will be swapped, and since my wiring is burned in a couple spots, so i am swapping the entire harness.
- The MPEM off the 02 may not support RER, but the 03 does, and the wiring harness goes with
- Ski-Doo was kind enough to sell me a complete electric starter kit, ouch
- The donor sled had a 144 track, If i can find a good track i will swap the 151 skid frame in, better for my wife
- A friend had a flywheel for sale
- The donor sled had a team secondary clutch, the 02 does not, this may be the hardest part, the gears are missing from this sled and i don't know the effect this will have on the clutches tuning
- my 02 had a stock exhaust that had vibrated to junk, swap it in, Y-pipe and all
- The next problem is that there is snow "over the handle bars" reported at summit lake, time to ride

pictures to follow

 

[Alberta Boy]

a few things...
Swap the ENTIRE electrical including the stator... 03 was much better than the 02 electrical...

when you get the 151" slide the skid back a bit to better the attack angle... use the same 144" rails

 

[AKwelder]

well i did it

It worked, I had a local mechanic do it while i was at work for 4 weeks, but it worked. here is the story

-the head had to be switched out to fit the 03 coolant sensor
-The complete steering should have been switched, but we got the 03 handle bars to fit the 02
-The ring gear only fit the 03, so the clutch had to be swapped
-The tach has issues, it only engages above idle, and falls flat after idling for just a short time
-After a couple short rides the battery has died, and wont stay charged, so more work awaits
-the misses handled it great and the 151 wasn't to much to side hill, so scratch the 144 idea (i had less than 100 miles on the new track anyway)

All in all i am happy with the sled and so is my wife, she now has "HER SLED", and that is a good thing

 

[AKwelder]

and most important

she had electric start and it BACKED OFF the trailer! this is great