1986 Formula MX Attempting to add Electric Start

548 Views 17 Replies 6 Participants Last post by chriswy27, 5 d ago

chriswy27

Discussion Starter · 18 d ago

I'm attempting to perform an electric start retrofit on my '86 PRS sled. The parts seem very hard to come by but at this point I think I've collected most of them. Mostly want to ask, is there anything I am completely overlooking? Below is the parts I've acquired. I think I have pretty much everything minus the battery. My only question is which ring gear to use.

From a couple different '91 PRS Sleds:

* Clutch Part# 417202100 : My '87 clutch didn't have the posts to mount a ring gear. Looks like despite having the posts that this one never had a ring gear installed either as the holes are not tapped. I was worried at first but then read the screws are self tapping.

* Ring Gears Part #414807500 & Other Part# 414604300 (maybe)?: Below are two different styles and I'm not sure which one I should use. The right one looks like images I've seen online and comes with the Phillips head self-tapping screws which I believe are part# 309903100. The left one I think was the newer replacement once the right was marked NLA by skidoo and looks to use hex head screws part# 732601120. Any idea which gear I should go with?

* Startor & Engine mounting bracket:

* Wire Harness from a 91 sled with E-start: I believe the missing "pins" marked 1, 3, etc. from the large 8-pin connector are the ones coming from my stator but I'll have to compare my'87 harness there.

* Ignition w/ E-Start

* Voltage Rectifier

Just want to say that I wouldn't have been able to get this far without Hudson's Sled Salvage awesome parts diagrams w/ oem numbers. Anyhow, am I nuts to attempt this? Will something I've purchased not work the way I think it will? Thanks!

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chriswy27

Discussion Starter · #3 · 17 d ago

alainm said:
Obviously you will need the battery and battery tray.
Do you have the shop manual and wiring diagram that also could help you?

I have a shop manual on the way!

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chriswy27

Discussion Starter · #7 · 15 d ago

David H said:
Got it. Missed that part.

Yep I was going to mention that. Now just have to decide which ring gear I should be using.

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chriswy27

Discussion Starter · #12 · 11 d ago

TheBearAk said:
Once you put the ring gear on, you should check the balance. Any local machine shop should be able to do it.

You thinking similar to balancing a tire that they'd just mount the clutch on a spinning shaft and check balance?

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chriswy27

Discussion Starter · #14 · 7 d ago

TheBearAk said:
They balance them at the factory. I've only done two and both times had a shop spin them up and test for balance. Doesn't have to be perfect, but the better it is, the less wear and tear on the crank bearings and seals.

If it's found to be off balance what do they do? Try to mount the ring gear by rotating it to the next set of screw holes? It's not like a tire where they can add weights, right?

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chriswy27

Discussion Starter · #18 · 5 d ago

alainm said:
Yes try to rotate the ring, they can't add weight but they can remove weight from the whole assembly by drilling some off on the opposite side.

Perhaps that's why the clutch I picked up has those 3 drill marks on it in the first place.

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