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Discussion Starter · #1 ·
i want to install Electric start on my 2004 summit 550 fan, i already have the starter but now i need to know what wiring is needed or if it is even possible to have electric start, but since the legend model of the same year and same engine can have one and zx are all the same why not.
can some one help me?
 

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I've always gotten the kits from Doo. They had the starter, ring gear, starter wiring, etc in them. You might even need a different voltage regulator?? (don't quote me on that but I have done 2 of them that came with a different reg.)
 

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Very possible but I cannot speak to your exact sled. ZX's get a little funny after 2002, as they are "parts bin engineering" machines.

Aside from a starter, starter relay, start button, battery box, battery, primary clutch ring gear and associated wiring...

The sled (rope start) currently puts out AC voltage.
You need a Voltage regulator+Rectifier in the system to convert to a DC voltage to charge your battery.

The factory E-start kits are probably a long ways out of production at this point. I'd refer to the parts diagram on partzilla to get a look at what parts were used on the E-start models. You may be best served to find a fan cooled legend or grand touring as a donor for your project.

Also you might find that RMstator has the V-reg you need.
 

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Discussion Starter · #5 ·
Very possible but I cannot speak to your exact sled. ZX's get a little funny after 2002, as they are "parts bin engineering" machines.

Aside from a starter, starter relay, start button, battery box, battery, primary clutch ring gear and associated wiring...

The sled (rope start) currently puts out AC voltage.
You need a Voltage regulator+Rectifier in the system to convert to a DC voltage to charge your battery.

The factory E-start kits are probably a long ways out of production at this point. I'd refer to the parts diagram on partzilla to get a look at what parts were used on the E-start models. You may be best served to find a fan cooled legend or grand touring as a donor for your project.

Also you might find that RMstator has the V-reg you need.
ok have done some research and i do have a regulator rectifier, and i have the wiring from the starter thru the key switch but the only thing missing is the charging system, so i wonder what is this regulator doing there
 

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Discussion Starter · #6 ·
ok from the starter i have a smal red wire going from the positive side of the starter relay, this wire passes thru the key swich then a fuse and finally to the positive terminal of the batterie.
the negative of the starter is grownded on the frame.
so this is the relay activation sircuit am i right?
but for the starter power sircuit the only diagram i could find is from the legend and it shows a big red cable going from the positive side of the batterie to the high power positive terminal of the relay so my question is were is the ground for this sircuit, is the starter itself grounding on the engine block and if so would those tow sircuit short together no?
 

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ok from the starter i have a smal red wire going from the positive side of the starter relay, this wire passes thru the key swich then a fuse and finally to the positive terminal of the batterie.
the negative of the starter is grownded on the frame.
so this is the relay activation sircuit am i right?
but for the starter power sircuit the only diagram i could find is from the legend and it shows a big red cable going from the positive side of the batterie to the high power positive terminal of the relay so my question is were is the ground for this sircuit, is the starter itself grounding on the engine block and if so would those tow sircuit short together no?
YES GROUND THRU BLOCK
 

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I just put electric start on a 1998 Formula 500 (S-Chassis). I can't get too much into the ZX Chassis, but I'll tell you what I needed for mine.
-Starter
-Starter brackets to mount starter to engine (they are engine-specific in some cases, you'd have to research that one)
-Ring gear (be careful as some years have different bolt diameters). And don't tap the clutch holes, get the proper bolts/screws, they will be self-tapping, you have to carefully put them in with loctite.
-Battery box (and battery)
-Large cables for positive and ground
-Fuse holder with 30A fuse
-Rectifier/regulator. This is what allows your machine to convert the AC power generated by the engine to DC to charge the battery.

As for wiring diagrams, the one you have should work for you, same basic principal.

I've attached a parts diagram for a 2004 Legend 550F, that shows all of the parts that you should need. I can't guarantee it, but it's my best effort to help you. Good luck.

 

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Discussion Starter · #13 ·
I just put electric start on a 1998 Formula 500 (S-Chassis). I can't get too much into the ZX Chassis, but I'll tell you what I needed for mine.
-Starter
-Starter brackets to mount starter to engine (they are engine-specific in some cases, you'd have to research that one)
-Ring gear (be careful as some years have different bolt diameters). And don't tap the clutch holes, get the proper bolts/screws, they will be self-tapping, you have to carefully put them in with loctite.
-Battery box (and battery)
-Large cables for positive and ground
-Fuse holder with 30A fuse
-Rectifier/regulator. This is what allows your machine to convert the AC power generated by the engine to DC to charge the battery.

As for wiring diagrams, the one you have should work for you, same basic principal.

I've attached a parts diagram for a 2004 Legend 550F, that shows all of the parts that you should need. I can't guarantee it, but it's my best effort to help you. Good luck.

great that helps alot, but after the rectifier is there supposed to wiring going to the batterie can you explain to me how it works
 

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Looks much like the diagram I had. You have to add a wire to the ignition switch. This is the red wire in the diagram provided by Daag44, include the 30A fuse in that wire. Then you have to put a ring terminal on the other end of the wire and that connects to the positive terminal on the battery. Looks like it goes in position 7 on the ignition switch. On my machine, the Red/GN wire from the key switch (ignition switch) to the starter solenoid was there, tye wrapped to the harness right where the starter solenoid will be when the starter is mounted to the engine. I did cut the ring terminal off as it was pretty green, and crimped on a new one. If it's there and in good shape use it, if it's green, either clean it up, or cut it off and crimp on a new one.
 

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Discussion Starter · #19 ·
i think i found it, connect the small red wire to the positve and on the selenoid connect the big red wire to the positive of the batterie and the starter connect negative terminal of both batterie and starter to the frame??
 

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The small wire to connect to the solenoid should already be there, tye wrapped to the main harness, at least that's how it is on an S-chassis. The small red wire from the positive terminal goes to the ignition switch, that's the wire you have to add to the ignition switch, this same wire has the 30A fuse in it. Again, that's all from my S-chassis experience.

Your explanation of the negative wires sounds correct.
 
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