Clutch Switch Test; Neutral Start Diode Test; Starter Voltage Drop Testing; Starter Motor Disassembly - Polaris Outlaw 500 Service Manual

ELECTRICAL

Clutch Switch Test

Refer to "Clutch Switch Test" under the "Lighting and
Controls" section of this chapter. Problems with the clutch
switch will cause the starter circuit to not operate.

Neutral Start Diode Test

1. Disconnect diode from harness.
2. Using an ohm meter, test for continuity each way. The diode
should only read continuity one direction if it is working
properly.
3. Should the diode test good and there is still a problem,
check the clutch switch, wiring, and harness connections.

Starter Voltage Drop Testing

A Voltage Drop Test tests for bad connections. When
performing the procedure, you are testing the amount of voltage
drop through the connection. A poor or corroded connection
will appear as a high voltage reading.
Voltage shown on the meter when testing connections should
not exceed .1 VDC per connection or component.
To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested.
Voltage should not exceed
.1 DC volts per connection
7.18

Starter Motor Disassembly

Use only electrical contact cleaner to clean starter motor parts.
Some solvents may leave a residue or damage internal parts and
insulation.
1. Note the alignment marks on both ends of the starter motor
casing. These marks must align during reassembly.
2. Remove the two bolts, washers, and sealing O–Rings.
Inspect O–Rings and replace if damaged.
3. Remove brush terminal end of housing while holding other
two sections together.
4. Remove shims from armature shaft.
NOTE: All shims must be replaced during reassembly.
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