PERC 550 Fan

[Mark's RMK]

I have a 2002 550 Fuji fan. I have the newer flywheel and stator for PERC. Can I install the new stator and flywheel? I think they are from a 2005.

I went to remove the flywheel yesterday and my SLP puller (I see they are now slotted instead of having all the holes) wouldn't line up with the three starter cup holes. So I couldn't remove the flywheel to check.

I set my old starter cup on the other flywheel and it also looks like my starter cup holes are drilled to a smaller diameter off the center but I could file them out a little.

Has anyone ever done this? I've had really good luck doing the Liberty stuff but not as familiar with the Fuji.

 

[Mark's RMK]

Fuji

Should have my new SLP flywheel puller to use this week end. Picture shows slots instead of the many holes.

Hopefully the flywheel will come off easy and I'll be able to verify stator and flywheel fitment.

 

[Mark's RMK]

550 Fuji

Okay, the new stator and flywheel are on. Fit fine but now the starter cup holes are too far in by about 1/2 a hole diameter.

I'll order a different starter cup tomorrow and then we'll see if it runs next Sat.

The new wire harness is installed with the left hand control with the PERC button.

I had to use a jumper for the ground as the voltage regulator/rectifier I'm using doesn't have a brown wire coming out and the old harness just had the brown wires pigtailed to the bolt holding the regulator.

Should work fine. I'll also have to run a wire up the hood harness and add another light to the tach for the blinking reverse light.

 

[Mark's RMK]

PERC

Starter cup is on. New one actually has both sets of hole spacing to work on both sets of flywheels.

Sled started, ran fine and it now goes into reverse with the press of a button.

I have to add an airbox bracket as the airbox is pretty loose and doesn't seem to sit level on the bulkhead to line up at the correct height for the carb boots to hit the carbs just right.

Doesn't seem like the premium setting engages a different curve on these motors like it does the Liberty motors.

I've posted a thread about the newer CDI harness having a red and blue connection coming out of pins 18 and 17 of the CDI and it states "Connect if Electric Start".

The drawing (attached) makes it look like it should be jumpered if you elec start?

I haven't jumpered it, motor seemed to start and run fine but due to lack of snow I can't really find out.

Anyone know what the purpose might be of jumpering those two connectors?

 

[Mark's RMK]

Jumper

I added the jumper and took a spin on the lake. Seemed to run fine.

Had to modify my airbox using the black plate that holds the carb boots from the 02 box.

Seems that the alignment is slightly different on the 550's than the small block liberties that I had the airbox from.

I ordered an airbox from an 04 on e-bay so we'll see how that fits this weekend.

I'll be taking the mechanical reverse off and installing one of the new style chaincases with the Hayes double piston caliper.

Let me know if you want to buy a mechanical reverse set up.

I'm also going to change the top gear to an 18 (39T bottom) from the 19 as It's now a 136 and the specifications for the trail RMK's call for a lower gear ratio.