ELECTRIC START KIT P/N APPLICATION BEFORE YOU BEGIN KIT CONTENTS. Instr Rev Page 1 of 6. All Polaris Pro-Ride Snowmobiles
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1 ELECTRIC START KIT P/N APPLICATION All Polaris Pro-Ride Snowmobiles BEFORE YOU BEGIN Read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information. KIT CONTENTS This Kit includes: REF QTY PART DESCRIPTION PART NUMBER 1 1 Stud Plate Assembly Weld Battery Box Battery Box Bracket Assembly-Model: RMK Battery Box Bracket Assembly- Models: Switchback Assault/RMK Stud Plate Assembly, 60.96mm Pinion/Pinion Bracket Assembly Drive Clutch Assembly, ES SP 8 1 Harness ES, DC-SDI Rush Circuit Breaker, 12 amp Cable, Battery/Solenoid Switch, Magnetic Red Cable, 1045mm Black Cable, 1335mm Starter Motor Assembly Hook- "D" Bracket, Electric Start/ Clip Bracket, Electric Start/ UCA Tube Upper Bracket, Electric Start/ UCA Tube Lower Shield-Heat Battery Strap-Rubber Shaft-Flex Starter Cable Tie Clamp-Band, Narrow 70-90mm Nut, ¼-20 Nyloc Instr Rev Page 1 of 6
2 REF QTY PART DESCRIPTION PART NUMBER 25 6 Nut, M6 X 1.0 Flange - Nyloc Olive Rivet, 3/ Tie Cable Press Mount Black Screw HXFL M6 X 1 X Screw M8 X 1.25 X Screw M6 X 1 X Bolt-M6 X 1.0 X 15, PH/TX Foam-Seal, Rear Cooler Strap Panduit 14" Clip Routing Nut 1/4-20 Hex-Y Washer 1/4 Spring Lock-Y Screw-TXTH-M5X 0.8X Screw-HXFL-M8 X Nut, M8 X 1.25 Flange Bracket, Battery Box Front Instructions TOOLS REQUIRED Battery (PN ) Clutch Puller (PN ) Strap Puller (PN ) Spring Puller Flat Screwdriver Metric Socket Set Metric Wrench Set Torque Wrench Side Cutter Large Phillips Screwdriver Rivet Gun 6mm Allen Wrench or Short Allen Socket Master Repair Manual (MRM) IMPORTANT Your ELECTRIC START KIT is exclusively designed for your vehicle. Please read the installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For your safety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown. ASSEMBLY TIME Approximately 90 minutes Instr Rev Page 2 of 6
3 INSTALLATION INSTRUCTIONS WARNING Battery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with the skin, eyes, or clothing. Avoid contact with electrolyte. 10.Route cables d and f on outboard side of coolant bottle and under the recoil housing. Part number labels on battery cables should face towards the battery. Fasten cables with cable tie 2@. 1. Order battery (PN ). 2. Charge battery per instructions included with the battery. 3. Remove hood and both side panels. 4. Remove the exhaust pipe and silencer. 5. Verify unit is not in reverse. NOTE Driven clutch cover will not open if stopped in reverse mode. 6. Apply parking brake and remove drive belt. 7. Remove drive clutch per MRM (Master Repair Manual). 8. Remove Y-pipe from engine using a 6mm Allen socket. 9. Install pinion and pinion bracket assembly y. Torque bolts to below specification. Pro RMK: Fasten cables around white tape marks as shown. TORQUE 15 ft. lbs. (20.3 Nm) Switchback Assault; Base RMK: as shown. Instr Rev Page 3 of 6
4 600 Rush; Switchback 136: as shown. 13.Install flex drive on starter drive assembly. Loosely install band clamp over starter motor. 14.Lay starter motor on e-start bracket. Install two 6mm bolts 3) and nuts 2% through side casting and starter motor bracket with nuts on inside toward starter motor. 15.Install black battery cable (PN ) on rear 6mm starter motor bracket bolt and install nut. Torque both 6mm bolts to below specification. TORQUE 8 ft. lbs. (10.8 Nm) 11. Install upper e-start bracket k and lower e-start bracket l on crosstube. Ensure that the brackets are tight to the tube before installing screws 3!. Install third rivet to hole in steering frog support. Install foam pad 3@ to top of bracket as shown. 12.Install starter motor bracket (Bracket, Electric Start/Clip, j) on end of starter as shown. 16.Tighten band clamp around starter motor and lower e-start bracket. Fasten red battery cable (PN ) using washer 3^ and nut 3% to starter motor terminal. Install protective cover. 17.MY11-12 RMK: Drill out two lower footrest rivets to mount bracket e. Use four rivets 2^ supplied in kit to mount bracket. SWITCHBACK: Mount bracket r to footrest with four rivets 2^. MY13 RMK: Use four screws 3& supplied in kit to mount bracket e. Instr Rev Page 4 of 6
5 18.MY13 RMK Only: Remove and save screw (A) in bulkhead side casting. 21.Install stud plate t. Mount solenoid switch and circuit breaker to stud plate using two nuts 2%. 19.Install mount bracket 4), using the M8 screw 3*, and nut 3( supplied in kit and screws (A) removed at Step Connect e-start harness to connector at top right side of steering post casting. Install cable ties in locations shown. 20.Install battery box w as shown. Using two 6mm nuts 2%, one 6mm screw 2* and stud plate q. Instr Rev Page 5 of 6
6 23.Rush; Switchback 136: Install cable tie 2& in 1/4" hole in right upright tube. Tie both battery cables and e-start harness i to upright tube using cable tie around tape mark. 25.Route cables and wires as shown. Install plastic clamp 3$ in hole located at top inside corner of foot rest. Install both battery cables and e-start harness in clamp and close clamp. 26.Install battery (PN ) into battery box. Install battery heat shield with rubber tie down strap as shown. 24.Connect e-start harness to solenoid switch and circuit breaker. Connect red battery cable to inside terminal of solenoid switch. Install protective cover over terminal. Tie e-start harness to black battery cable directly under solenoid with cable tie 2@. 27.Install short red battery cable a on outside terminal of starter solenoid and to positive terminal of battery as shown Step 21. Install protective covers. Connect end of small gauge wire to circuit breaker. 28.Install new E-start clutch and torque to specifications. Install belt, Y-pipe, exhaust pipe and resonator. 29.Install hood, connect hood electrical harness to chassis harness. Install side panels. Instr Rev Page 6 of 6
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