Iâ€™ve got a 2002 Ski-Doo 800 and Iâ€™m concerned with the durability of the rewind assembly. I know of several riders who had the rewind fail on their 2002s (and 2003s), and weâ€™re wondering if weâ€™re going to have the same thing happen (are we just putting the same parts back in there when we get it fixed) or have their been any changes to address this problem?
Thatâ€™s funny, we just broke the rewind on a 2003 Summit this year and wondered the exact same thing! For 2003, Ski-Doo introduced an â€œimprovedâ€ rewind assembly and rope. While the rope worked very well, the rewindâ€™s aluminum-reinforced (plastic) post occasionally broke. An improved version of the reinforced post was introduced as a running change late in the season with a aluminum insert molded-in, and this improved rewind was standard issue on all 2004 models.
Even with the stronger post, Ski-Doo also found many of the problems were caused by excessive temperatures inside the rewind assembly. On the 2004 models they introduced a ventilated adapter ring (that matches the smaller crankcase to the larger diameter rewind, between the crankcase and rewind) that allows the hot air to escape the rewind assembly. Weâ€™re told this vented ring works excellent at reducing internal rewind temperatures and can be used in conjunction with the latest rewind on older models (like your 2003) to pretty much eliminate heat related problems with the rewind.
When you order rewind parts for your 2003, they will be superseded with the newer parts, but you do have to order the vented adapter ring separately – #420 810 867.