Installing Electric start on 2020 tips/advice

[RanOutofTalent]

I bought an electric start for the wife’s 2020 800.

I have it in the trailer and plan on putting the new primary on so I can ride it into the shop.

Is this ok to do??

I have never installed an electric start on a sled and figured before I do I would post and get any tips and tricks people have to offer.

I have the basic instructions that came off the Polaris site.

I should also mention this is a take off from a 2019 800 that was used one season.


Thanks


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[sledhed]

As long as you install it correctly, no reason why not. Clean / dry taper and clutch mating surfaces etc., properly torque clutch bolt. One thing to keep in mind is clutch alignment will be off, almost guaranteed, but for a short run into the shop no harm. There was a change in crank taper in 2019 or 2020 for the 800 to use the same taper as the 850 so I would personally double-check the part number on the primary to make sure it is the right taper for your sled, just in case.

 

[RanOutofTalent]

As long as you install it correctly, no reason why not. Clean / dry taper and clutch mating surfaces etc., properly torque clutch bolt. One thing to keep in mind is clutch alignment will be off, almost guaranteed, but for a short run into the shop no harm. There was a change in crank taper in 2019 or 2020 for the 800 to use the same taper as the 850 so I would personally double-check the part number on the primary to make sure it is the right taper for your sled, just in case.

Thanks. I did go to the dealer with the part number before I bought it and talked with the service manager. He told me it should be an issue. But I would like to know for certain.

Do you happen to know the torque specs for the clutch bolt?

Also, probably a silly question, but will I need clutch alignment tool after I install the new primary?


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[sledhed]

Thanks. I did go to the dealer with the part number before I bought it and talked with the service manager. He told me it should be an issue. But I would like to know for certain.

Do you happen to know the torque specs for the clutch bolt?

Also, probably a silly question, but will I need clutch alignment tool after I install the new primary?


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I check part numbers for the factory e-start clutched sleds in the online parts sites to make sure, just me, I don't take someone's word for it even someone working for the dealership. If they don't know the taper changed in 2019 or 2020, and it is wrong for your sled, not good. Peace of mind, I look it up - part # for the model and year of sled it came off of, compared to your sled's model and year part number.

I don't know the torque off-hand, I am thinking it is 80 ft-lbs then retorque after warmup, but it should say in the install directions for the e-start kit. If you can't find it I can take a look at my directions which should be in the shop (which is chaos due to renovating house).

I basically took my sled by the dealership and had them throw their alignment tool on it. It was way off after replacing the primary with e-start. We eyeballed it to get it close, and I need to take it in there again, if I had it to do over I would buy a bunch of the shims (thicker and thinner ones) for secondary placement, have the belt and sidecover off the sled sitting on the trailer, then when they throw the tool on it you can put in shims to get the right offset and float. Or... drop it off and let them do it and charge you labor. The alignment tool from Polaris isn't cheap and I have heard negative things about aftermarket ones not being correct.

 

[Sheetmetalfab]

I check part numbers for the factory e-start clutched sleds in the online parts sites to make sure, just me, I don't take someone's word for it even someone working for the dealership. If they don't know the taper changed in 2019 or 2020, and it is wrong for your sled, not good. Peace of mind, I look it up - part # for the model and year of sled it came off of, compared to your sled's model and year part number.

I don't know the torque off-hand, I am thinking it is 80 ft-lbs then retorque after warmup, but it should say in the install directions for the e-start kit. If you can't find it I can take a look at my directions which should be in the shop (which is chaos due to renovating house).

I basically took my sled by the dealership and had them throw their alignment tool on it. It was way off after replacing the primary with e-start. We eyeballed it to get it close, and I need to take it in there again, if I had it to do over I would buy a bunch of the shims (thicker and thinner ones) for secondary placement, have the belt and sidecover off the sled sitting on the trailer, then when they throw the tool on it you can put in shims to get the right offset and float. Or... drop it off and let them do it and charge you labor. The alignment tool from Polaris isn't cheap and I have heard negative things about aftermarket ones not being correct.

The Polaris tool is incorrect also.

Only the TRS tool is trustworthy.

 

[volcano buster]

My understanding is the crankshaft end taper is changed on the 800 in 2020 to match the 850. I don't know why, but I'd be careful putting a clutch from an earlier motor on the 2020 800 without knowing for sure that it is compatible.

 

[RanOutofTalent]

My understanding is the crankshaft end taper is changed on the 800 in 2020 to match the 850. I don't know why, but I'd be careful putting a clutch from an earlier motor on the 2020 800 without knowing for sure that it is compatible.

Thanks. I have asked my dealer once back in the spring but will be sure to call Monday and talk with him to see if he can get my positive confirmation.

I am sure glad I posted cuz I wasn’t going to second guess it


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[jedheadsled]

I can tell you with 100% certainty that a 2019 800 clutch will not work on a 2020. I went thru this last February with my wife’s sled. The dealer didn’t know that the 2020 was different either when they sold me the kit. Not till I tried to install it and the 2019 clutch wouldn’t fit. Like others have said the 2020 has the same part number and taper as the 850s. The 2020 800s and 850s list the same part number for the clutches.

 

[RanOutofTalent]

Thank you.

This is good to know. I double checked and I was off by a year. The kit I bought was a take off from a 2018, not a 2019 but it doesn’t make a difference now that I know the 2020s are different. I’ll have to box it up and see if I can sell it


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[sledhed]

You should have no trouble selling it if you go 10 or 20% below dealer retail I would think. New kits aren't horribly expensive and you have a battery already (too hard / expensive to ship with the kit)... throw it on swapmeet and on facebook mountain sledder swapmeet or some similar group and it will sell pretty fast.