AC/DC converter "update" - HCS Snowmobile Forums

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Old 01-10-2018, 10:36 AM   #1 (permalink)
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Default AC/DC converter "update"

Already sent MANY diagrams to HCS members on wiring their own update kit. Guess it is about time to post a how to since I made it thru two seasons without issue with wiring "kit" myself.

I purchased one kit from Polaris at their $240ish price. The wiring from Polaris had one wire in incorrect position but all else has worked perfect. I will reply to each pic in an individual reply. Pics to follow...
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Old 01-10-2018, 10:45 AM   #2 (permalink)
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Join Date: Oct 2007
Posts: 1,720
Current Sled(s): Polaris 2006 600 Fusion Dragon
Previous Sled(s): 74 and counting
Location: NW suburb of water crisis USA...cottage in Boyne City
Favorite Riding Area: Elmira, Michigan
19-20 Mileage: 1
18-19 Mileage: 900
17-18 Mileage: 404
16-17 Mileage: 900
Age: 53
Riding Since: 1970
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...Incorrect actually went from #2 in updated converter to black harness plug for current harness in your sled(note red arrow lower left).One member tells me that wire is for electric start.
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Old 01-10-2018, 10:52 AM   #3 (permalink)
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Join Date: Oct 2007
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Current Sled(s): Polaris 2006 600 Fusion Dragon
Previous Sled(s): 74 and counting
Location: NW suburb of water crisis USA...cottage in Boyne City
Favorite Riding Area: Elmira, Michigan
19-20 Mileage: 1
18-19 Mileage: 900
17-18 Mileage: 404
16-17 Mileage: 900
Age: 53
Riding Since: 1970
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Replacement converter and additional pics. The kit you purchase from Polaris contains the converter found stock in the 2008 RMK 600, a harness that stretches from your original converter to mount updated '08 converter on top of your clutch guard, and plugs to disconnect your existing converter(and abandon) to main wire harness.
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Old 01-10-2018, 11:08 AM   #4 (permalink)
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Join Date: Oct 2007
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Current Sled(s): Polaris 2006 600 Fusion Dragon
Previous Sled(s): 74 and counting
Location: NW suburb of water crisis USA...cottage in Boyne City
Favorite Riding Area: Elmira, Michigan
19-20 Mileage: 1
18-19 Mileage: 900
17-18 Mileage: 404
16-17 Mileage: 900
Age: 53
Riding Since: 1970
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Splicing wires together is your call. I used Sopoby connectors found on eBay.

I mounted mine as follows since I have clutch guard tool bags on my sleds. This mounting position required drilling one hole...the frame already has one hole drilled. I wrapped my harness with foil tape to protect from exhaust heat.
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Old 01-10-2018, 11:18 AM   #5 (permalink)
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Join Date: Oct 2007
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Current Sled(s): Polaris 2006 600 Fusion Dragon
Previous Sled(s): 74 and counting
Location: NW suburb of water crisis USA...cottage in Boyne City
Favorite Riding Area: Elmira, Michigan
19-20 Mileage: 1
18-19 Mileage: 900
17-18 Mileage: 404
16-17 Mileage: 900
Age: 53
Riding Since: 1970
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You ask why I did this. Polaris wants $240ish for the kit which I feel should be a warranty item anyway. Plus, I might have to do this 7 times(3 more to go) as the converters keep crapping out. This update is also for '06 Switchback 600 and '07 IQ 600 carb.

Please feel free to add any input to this...especially if you find any errors. I am no automobile electrician. I can wire a house...automobile type wiring is a different story. My wire rigs have worked perfect on 3 sleds that I have done. It is nice to have handwarmers and lights that work as they should have from the beginning. Good luck!!!
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Last edited by drewma; 01-10-2018 at 01:19 PM.
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Old 01-11-2018, 08:01 PM   #6 (permalink)
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This is how I mounted mine, with the harness extension. Relocated the ignition coil while I was at it. Pay no mind to the sloppy tape job on the wire loom. I need to take a few minutes and clean that up. I was in too big of a hurry to ride when I put this all together to do it as clean as I wanted at that time.
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Old 01-11-2018, 08:17 PM   #7 (permalink)
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Thank you. I'll be doing one soon.
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Old 01-14-2018, 12:28 PM   #8 (permalink)
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Join Date: Oct 2007
Posts: 1,720
Current Sled(s): Polaris 2006 600 Fusion Dragon
Previous Sled(s): 74 and counting
Location: NW suburb of water crisis USA...cottage in Boyne City
Favorite Riding Area: Elmira, Michigan
19-20 Mileage: 1
18-19 Mileage: 900
17-18 Mileage: 404
16-17 Mileage: 900
Age: 53
Riding Since: 1970
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Stock converter, 4th one to go down in my fleet, crapped out on my 17 year old son's sled yesterday. This is his work this morning to get his sled going.
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Old 01-14-2018, 12:33 PM   #9 (permalink)
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What? No soldering? Tisk, tisk.
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Old 01-14-2018, 12:54 PM   #10 (permalink)
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Join Date: Oct 2007
Posts: 1,720
Current Sled(s): Polaris 2006 600 Fusion Dragon
Previous Sled(s): 74 and counting
Location: NW suburb of water crisis USA...cottage in Boyne City
Favorite Riding Area: Elmira, Michigan
19-20 Mileage: 1
18-19 Mileage: 900
17-18 Mileage: 404
16-17 Mileage: 900
Age: 53
Riding Since: 1970
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Quote:
Originally Posted by sayatodaU.P.eh? View Post
What? No soldering? Tisk, tisk.

Look close at connections...they have solder melt when shrinking them with heat. You can see solder thru clear connection sleeve. 33 cents a piece but well worth it.

Connections are Sopoby that I bought thru eBay. I use them for everything and yet to fail.
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