ELECTRIC START KIT KIT P/N

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1 ELECTRIC START KIT 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. This Kit Includes: Qty...Description... Part Number 1...Asm Stud Plate Weld Battery Box Asm-Battery Box Bracket-Model: RMK Asm-Battery Box Bracket- Models: SwitchbackAssault/RMK Asm Stud Plate mm Asm-Pinion/Pinion Bracket Asm Drive Clutch ES SP 1...Harness ES, DC-SDI Rush Circuit Breaker, 12 amp Cable, Battery/Solenoid Switch, Magnetic Cable, 1045 mm, Red Cable, 1335 mm, Black Asm-Starter Motor Hook- D Brkt, Elec Start/ Clip Brkt, Elec Start/ UCA Tube Upper Brkt, Elec Start/ UCA Tube Lower Shield-Heat Battery Strap-Rubber Shaft-Flex Starter Cable Tie Clamp-Band, Narrow mm Nut, ¼-20 Nyloc Nut, M6 x 1.0 FLG-NYLOC Olive Rivet, 3/ Tie Cable Press Mnt Blk Screw HXFL M6 x 1 x Screw M8 x 1.25 x Screw M6 x 1 x Bolt-M6x1.0x15, PH/TX Foam-Seal, Rear Cooler Strap Panduit Clip Routing Nut 1/4-20 Hex-Y Washer 1/4 Spring Lock-Y Rivet, 3/ Screw-Txth-M5x0.8x Screw-Hxfl-M8x Nut, M8x1.25 Flg Bracket, Battery Box Front Instructions

2 You Will Need To Supply: 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 6 mm Allen Wrench or Short Allen Socket Master Repair Manual (MRM) IMPORTANT: Perform all items correctly and completely. 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. 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 6 mm Allen socket. 9. Install pinion and pinion bracket assembly (PN ). Figure 1. Torque bolts to 15 ft. lbs. (20.3 Nm). Figure 1-2-

3 10. Route cables (PN and PN ) 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 (PN ). Figure 2. Cable Tie Figure 2 Pro RMK: Fasten cables around white tape marks as shown in Figure 2a. Pro RMK Figure 2a Switchback Assault; Base RMK: Shown in Figure 2b. Switchback Assault; Base RMK Figure 2b 600 Rush; Switchback 136: Shown in Figure 2c. Rush; Switchback 136 Figure 2c -3-

4 11. Install upper e-start bracket (PN ) and lower e-start bracket (PN ) on crosstube. Ensure that the brackets are tight to the tube before installing screws (PN ). Install third rivet to hole in steering frog support. Install foam pad (PN ) to top of bracket as shown in Figure 3. Foam Pad PN Figure Install starter motor bracket (Bracket, Electric Start/Clip, PN ) on end of starter as shown in Figure Install flex drive on starter drive assembly. Loosely install band clamp over starter motor. 14. Lay starter motor on e-start bracket. Install two 6 mm bolts (PN ) and nuts (PN ) through side casting and starter motor bracket with nuts on inside toward starter motor. Figure Install black battery cable (PN ) on rear 6 mm starter motor bracket bolt and install nut. Torque both 6 mm bolts to 8 ft. lbs. (10.8 Nm). Figure Tighten band clamp around starter motor and lower e-start bracket. Fasten red battery cable (PN ) using washer (PN ) and nut (PN ) to starter motor terminal. Install protective cover. Figure 4 Step 16 Figure 5 Steps 14 and 15-4-

5 17. MY11-12 RMK: Drill out two lower footrest rivets to mount bracket (PN ). Use four rivets (PN ) supplied in kit to mount bracket. SWITCHBACK: Mount bracket (PN ) to footrest with four rivets (PN ). MY13 RMK: Use four screws (PN ) supplied in kit to mount bracket (PN ). Figure MY13 RMK Only: Remove and save screw in bulkhead side casting. Figure 7. Remove Screw (PN ) Figure Install mount bracket (PN ), using the M8 screw (PN ), and nut (PN ) supplied in kit and screw (PN ) removed at Step 19. Figure 8. Add Bracket (PN ) Reuse Screw (PN ) 20. Install battery box (PN ) as shown in Figure 10 using two 6 mm nuts (PN ), one 6 mm screw (PN ) and stud plate (PN ). Figure 9. Figure 8 6mm Nuts 6mm Screw Figure 9-5-

6 21. Install stud plate (PN ). Mount solenoid switch and circuit breaker to stud plate using two nuts (PN ). Figure 10. Note Circuit Breaker Orientation Figure Connect e-start harness to connector at top right side of steering post casting. Install cable ties in locations shown in Figure 11. Connect Here All Models Figure 11 Base RMK; Switchback Assault Only 23. Rush; Switchback 136: Install cable tie (PN ) in 1/4 hole in right upright tube. Tie both battery cables and e-start harness (PN ) to upright tube using cable tie around tape mark. Figure 12. Install plastic clamp (PN ) in hole located at top inside corner of foot rest. Install both battery cables and e-start harness in clamp and close clamp. Figure 12. Cable Tie Plastic Clamp PN Figure 12-6-

7 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 (). Figure 13. Cable Tie Figure Route cables and wires as shown in Figure 14. All Rush Models Route Wires Over Top of Solenoid 26. Install battery (PN ) into battery box. Install battery heat shield with rubber tie down strap and screw (PN ) as shown in Figure Install short red battery cable (PN ) on outside terminal of starter solenoid and to positive terminal of battery as shown in Figure 10. Install protective covers. Connect end of small gauge wire to circuit breaker. 28. Install new e-start clutch and torque to spec. Install belt, Y-pipe, exhaust pipe and resonator. 29. Install hood, connect hood electrical harness to chassis harness. Install side panels. Figure 14 Figure 15 Screw PN P/N Rev01 5/12 Printed in U.S.A. -7-

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