Electric start install help needed

[nitris223]

I bought a e-start from a Ty member on here. The e-start was on a 1997 600 or 700 . I want to install it on a 2002 sxr600. Does anyone have a picture or install manual for the electric start kits. It seems like there are a few more wires needed then what the 1997 had. Basically the starter , ring gear and battery boxes are all the same. I think I need a fues box assembly and a wire lead that are not on the 97 . Other then that I think I have it all. Just need to see where everything is routed and connected. Not sure if I need to update the starter relay assembly. Looks like there was a part number change or update.

Any help would be great.

 

[gild]

poor but hope it helps

 

[nitris223]

There is some sort of heat shield or extra thick material on the red lead wire. Does this section go under the motor. What wire connects to the starter switch.

 

[stein700sx]

There is some sort of heat shield or extra thick material on the red lead wire. Does this section go under the motor. What wire connects to the starter switch.

Yep

 

[nitris223]

Guys I did some checking on what parts I might need and this is what I found. 97 600 starter relay # 3EL-81940-00-00 2002 SXR600 starter relay #4BH-81940-00-00 2002 SXR600 Fuse Box assembly #8DS-82170-00-00.

Are the starter relays the same even though the first three letters are different .

Do I need the fuse box even though the starter relay has 2 push in style fuses already there.

What plugs into the starter relay , where is the wire located that plugs into the relay. There are a couple of deadend plug wires on the side near the foot well right hand side, but they do not have a end that would fit the relay.

 

[nitris223]

Gild. Thanks for the info but to hard to read even when I magnified it. I think I seen that in TY tips. Leaves out some much needed info from what I can tell about what plugs into where for the switch unless I missed it. Read it kind of fast.

 

[gild]

pics

I'll take some pics . My Ign wires were in the wire set above the front of the chaincase. I believe it was a 3 wire plug but I'll send pics later tomorrow

 

[nitris223]

Thanks. out in the shop right now trying to find where the plug would be. Nothing on the chaincase side has a 4 prong plug to fit the starter relay. I will take a pic of the relay that I have. If you could do the same that would be great. I also have the CD manual for the 2001 - 2004 600 triples. Would be nice to have the electrical schematic from a 97-98 just to compare and see what is different.

 

[nitris223]

Found a three prong plud below the coolant line. It was capped off. Red, Red/White and a black wire. Looks like I might be getting somewhere. Might have to use jumper wires with different ends to make it work. This might be the difference between the relay part numbers. Does the red lead wire go under the water pump and then over top of the recoil along the water coolant lines.

Still haven't figured out if I need the fuse box yet.

 

[nitris223]

Here is a pic of the starter relay that I have.

 

[Bluenote]

This would make a great sticky if we get some pictures up on the steps that you are doing as I think a lot of us want to install Electric start but are in the same boat as you, confused lol

 

[nitris223]

I plan on taking a few pics . Might need some help with the editing . From what I have seen most of the parts are the same it's just that yamaha changes a letter here and there and then things start getting confusing. The starter off the twin 600 fits the triple 600 . The chaincase are mostly the same so the battery bracket fits fine. It's just the wiring connections that need to be figured out. Fuse box is still up in the air. It shows in 2001 that it is only for the 700 and in 2002 it is on the 600 . Dealership here won't help at all so it up to the guys on the site for added help.

I need to see a 2002 starter relay picture to see if it is different , can a three prong plug be adapted to run on a 4 prong relay with out screwing up the CDI . That's the stuff we need to figure out.

 

[gild]

The 3 prong plug in on my sled has a Red , Red / Blue Stripe and Black. The plug in I used is not OEM. I used my own plug in. the RED TO Red which is the wire on the top in picture, Red / Blue Stripe to Red / Blue Stripe lower wire in Picture and Black to Black . Connect them to the Relay as shown in second picture. The Big B terminal is main wire to Battery, The M is to the Starter Motor. Add battery ground and you should have your starter system which charges your Battery when running

 

[nitris223]

Gild

Where did you get that connector. Mine is black and shaped like a triangle. It is coming out of the harness near the motor. Several other connections are there. Did you remove the black one. Nice pic . Mine the B is worn and actually looks like a M. That is clearin some things up. Any idea what the fuse box is used for on the 2002. Did they seperat the relay and fuse box. I seen somewhere in the schematic that there is a 30 amp somewhere on my sled. Gild what sled is this electric start on.

 

[nitris223]

Gild

Here is the three prong plug that is on my 2002 sxr600.

 

[gild]

E Start

The three prong plug in you found is the ign and crank wires you need. Connect them up to the relay as the 2nd picture shows but using the Red/White in place of my Red/Blue.
The white plugin I used is for an Allison Trans not a Yamaha part, just cut your wires off the plug, add more wire to reach the relay and wire it direct. I cut off my Triangle shaped plugin like yours and added the White one in the picture. You do not need a Plugin you can take the added wire off of the relay if you need to.
The 30 amp fuse is probably the main battery cable to relay.
My sled is an 01 SX700R and I have no fusebox on my sled or I should say I have no knowledge of one

 

[gild]

sorry

The picture shows the red/white wire where it should be

 

[nitris223]

Gild

Here is the fuse box I am talking about. In 2001 it is only listed for the 2001 700. It's number 28 in the picture.

The relay I have has 2 10 amp fuses like the picture you sent. Wish I had a good dealer that I could phone . My local one doesn't even want to work on 2 strokes any more.

 

[gild]

pics

A picture of the plugin I cut off

The beveled ring gear

My Lightweight Battery to Fit SLP pipes & Reverse

Where I mounted My Relay

 

[nitris223]

Gil so the ring gear just has the very top edge or corner knocked off. The one in the e-start install procedure shows a actual bevel to the inside part of the ring gear. Basically from the top of the teeth down to the bottom of the teeth. I will check mine out later.