Electrict Start Question

[Sage Crusher]

I just bought a used Electrict start for my ladies 05 800 Edge 159.
it was off a 04 Edge that a guy wrecked in the rear and was parting out.
Everything is there except I cannot find where the wiring correctly hooks up to the harness coming across the shock tower.

Can someone assist or take a pic to make sure I hook this up correctly- ther are only 2 wires from the harness but cannot find a Fiche or a dealer that really has good info.

Thanks in advance

MD

 

[Sage Crusher]

No-one?

Can anyone take a picture Most switchbacks cme with the elect start

 

[kirk]

I think there is just one wire that comes out of the harness that you use it just plugs in if I had my sled at home I would take a pic for you. Follow the wiring from the ign switch down to the battery area.

 

[Mark's RMK]

Electric Start

I added electric start to my wife's 550 fan. We were out west riding 6 days in a row. Battery lost it's zip. So I learned that the stator puts out AC and unless you get the regulator with the built in rectifier, you aren't keeping the battery charged. I always hook it to a trickler in the garage here in MN. The rectifier/regulator would have a red wire coming out as well. I haven't installed yet (sleds in trailer) but I'm hoping the harness has a red wire near the regulator harness and there is a matching one by the shock tower. I didn't have any trouble figuring out the wiring connections for the key to work. Red/white from key switch to red wire on starter relay, everything else to ground. There is also a wire from the regulator (charging) through a circuit breaker going to the starter relay. This is how it's shown on the wiring diagram in my service book.

 

[Leardriver]

PM me with an email address and I'll send you a picture of the '04 and '05 e-start wiring on the machine

 

[Sage Crusher]

I added electric start to my wife's 550 fan. We were out west riding 6 days in a row. Battery lost it's zip. So I learned that the stator puts out AC and unless you get the regulator with the built in rectifier, you aren't keeping the battery charged. I always hook it to a trickler in the garage here in MN. The rectifier/regulator would have a red wire coming out as well. I haven't installed yet (sleds in trailer) but I'm hoping the harness has a red wire near the regulator harness and there is a matching one by the shock tower. I didn't have any trouble figuring out the wiring connections for the key to work. Red/white from key switch to red wire on starter relay, everything else to ground. There is also a wire from the regulator (charging) through a circuit breaker going to the starter relay. This is how it's shown on the wiring diagram in my service book.

Could you shoot information from the service book? I found where the two wires hook up but I am thinking that your on the money and don't think that the battery gets charged - from my harness along the shock tower a red wire going to the square box that is mounted to the battery tray, ( voltage regulator?) and the other going to the starter selonid- I cannot see where it can receive a charge from the stator.

You wold think the wiring harness would be the same.

S/C

 

[Sage Crusher]

PM me with an email address and I'll send you a picture of the '04 and '05 e-start wiring on the machine

Sent you a P/M with my contact information
Thanks

S/C

 

[Mark's RMK]

Voltage Regulator

The voltage regulator should be just behind your secondary clutch mounted above the foot rest.

Yellow single lead with brown wire from your harness going to mounting bolt for ground or you could have a two wire (brown/yellow) that plugs into your harness.

The voltage regulator with the rectifier would have a red wire coming out that plugs into the harness and then sends the charging DC current to your battery.

I could send the electronic version of my service manual if you PM me an e-mail.

Too late to just copy from the donor sled as you move it over?

 

[Sage Crusher]

P/M Sent

Sent ya a p/m
I looked at my regulator for the rectifier- as I have a 02 800 Edge and a 2005 800 Edge in my shop to compair Both are snow checked sleds.
The 05 is the one I am putting on the elect start.

The 02 has one yellow wire comming out of the regulator and from the harness there is a brown and a yellow wire with a female plug in. The yellow from the regulartor ( male) plugs into the yellow from the harness.. the brown does nothing and terminated within the female housing.

Now the 05 has a single brown (Male) and a single yellow (Male) coming out of the regulartor, and plugs into a female brown and yellow from the harness and in that harness I can see two red wires but they go nowhere but terminate in the female housing but have a open female slot to connect to but are not used and are avaiable / HOWEVER there is a pig tail off the female harness that has 2 yellow and 1 brown is about 8" long and has a white female connector that goes nowhere it just hangs there sitting behind the hump in the footwell.
Pretty confusing but I wanted to let you know what the obsticales are.

I am sure the manual will assist

The doner sled is not an option- sure wish it was though.
Thanks

S/C

 

[Sage Crusher]

What I found on-line
1st Picture is I think what your refering to/ the second is what I have in there now-
If I get the first one, I can plug it into my harness but the leads in the harness going to the starter assembly only have 2 wires a red one and a red/white one. One goes to the circut breaker and the other to the solenoid. don't know how it will charge the battery?

S/C

 

[Leardriver]

Pics are in your email.

 

[Sage Crusher]

Pics are in your email.

Thanks the hookup for the battery and starter are great Glad we talked about the extra ground wire.
When you have time like to dig deeper in to regular as per my pic's above

Thanks again- this is a BIG help

S/C

 

[Sage Crusher]

a different approach?

View attachment 147506
Found this online today- Is this what your referring to?
I have no piggy back on my current regulator- but this one does make more sense as it will plug into the stock harbess that has two openings.
It is all starting to make sense and I can see why " Marks RMK above " did not charge the battery.
Only thing that will charge the battery is the red wire comming off the circut breaker and that ties back into your battery- the other red lead will come from the rectifyier that plugs into the connector by the regulator by the foot well.
Sounds confusion- but I bet if someone had the directions for the kit it would make life much easier-
I wish I would have take the regulator/rectfyier off the sled- and the guy who sold it to me didn't know that was needed either.

S/C

 

[Sage Crusher]

GRRRRRRRRRRRRRRRRRRRRRR

Well got the rectyfier and it fit well ( thanks to all)

I just found out that the clutch I bought with this and my 01 -09 clutch puller doesn't fit and the stock clutch bolt is very tight ( have to hand pound it in)
I have my dealer looking it up and he said it was a 04 but the tower plate could have been swapped out- so he is calling Team- as they built the clutch for the elec start units.... anyone ever run into a clutch bolt or puller not fitting a 800 Primary
What a pisser

S/C

 

[Mark's RMK]

Clutch Puller

So, you are saying the the puller you used to take the original clutch off doesn't fit well in the new clutch and the actual clutch bolt is tight as well? Is it tight in the black bushing as that's what the washer will fit around when you tighten the bolt.

I know you took the ES clutch off a donor sled with the 800 Liberty in it, right? And the donor clutch is from an Edge series with the raised profile around the clutch bolt, just like the one you took off and have for sale?

I only know that the Liberty and Fuji clutch pullers are different.

 

[Sage Crusher]

The faces are different as the one I have for the E start doesnt have the raised face on the tower cover.
I can fit the clutch bolt 3/4 of the way down inside the clutch and the taper on the bolt ( shoulder) hits something and I have to bang on it to get it past that tight spot.
The clutch puller must hit this sport eariler as the threads will not start on the inside threads of the clutch--- I tried a eariler clutch puller like from the old indy 500 and it it to large for the opening.
I am stumped.

Are all the tapers the same? this will fit on my crank- but I an now wonder if this even came off a 800....I bought it from someone that said it did.

 

[Mark's RMK]

Fjui

I wonder if you have a Fuji clutch instead of a Liberty. The 800 cc Liberty has the raised face (quite pronounced) The Fuji clutch bolt is shaped very different from the Liberty one, it's necked in the middle.

The Fuji clutch puller is shaped differently as well. My clutches are all "up at the lake" so I can't just grab one to look at.

http://www.snowestonline.com/forum/showthread.php?t=219792

I also remember my 2000 Liberty took a different puller. Read this thread.

Try private messaging "clutch man" or "sled_guy" and see if either responds. sled_guy gave me good advice on the 900 fitting on my 800 and he is in Riverton.

I wish I knew if there was a part number on a clutch so that you could do a cross reference for fitment.

 

[Sage Crusher]

I spoke to clutch man ( Thanks) and he is stumped also. He is thinking that this came off a fan cooled sled- but no-one really seems to know or tell me how to find this out. My polaris dealer said he is still waiting on Team to call him back- but I dont think that is going to happe- as this is still not their busy time- it has been 3 weeks already
I don't know about the statement you said about the liberty twins having the raised face clutch. I have a 2002 Edge and the head cober doesn't say liberty but it has the raised face ( longer bushing) but i don't know when they started with the liberty I assume 2000??

Anyhoo- Clutch man told me one way to check is to disamble and check out the spider buttons- larger ones went on the 800's-
I do have part numbers stamped on the back of the clutch- but my dealer said Polaris told him they were Team #;s and that is why we went and call Team, but still waiting

Any help I sure would appreicate... I wished you could buy equipmet and it would fit what peeps say it will and what it relly camoe off..

S/C

A

 

[Sage Crusher]

I contacted Brandon @ Skegs Snow Parts- What a great Guy
He hooked me up with a clutch that will work and willing to buy the clutch I have no use for.... This company goes the extra mile !!!

Thanks to all who assissted

 

[Jay]

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