Starter System Testing Flow Chart - Polaris 2004-2005 Sportsman 6x6 Service Manual

STARTER SYSTEM TESTING FLOW CHART

Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with
dynamic testing of starter system. A digital multitester must be used for this test.
With the tester on the VDC position, place the tes-
ter's black lead on the battery negative and the red
lead on the battery positive.
Reading should be 12.4 V D. C. or greater.
Yes
Disconnect coil engagement wire from the starter
solenoid. Connect tester black wire to battery
ground. Connect red tester lead to harness wire at
solenoid. Turn on ignition switch and depress the
starter button. Tester should read battery voltage.
Voltage Drop Testing
See Page 10.24 for instructions.
Reconnect the solenoid. Connect the tester black
lead to the battery positive and the red lead to the
solenoid end of the battery-to-solenoid wire. De-
press starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to solenoid end of
battery-to-solenoid cable. Connect red tester lead
to solenoid end of solenoid-to-starter cable. De-
press starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to the solenoid end of
the solenoid-to-starter cable. Connect the red tester
lead to the starter end of the same cable. Depress
the starter button. The reading should be less than
.1 V D.C.
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.
Test starter solenoid coil by connecting an ohmmeter between the solenoid
wire and the solenoid mounting plate. Resistance should be 3.4Ω. Check
Yes
solenoid ground path by measuring resistance between mounting plate and
Remove battery and properly service.
Install fully charged shop battery to continue
No
Check voltage on both sides of circuit
breaker, ignition switch/engine stop switch
and starter button. The voltage on both
sides should be the same. NOTE: The igni-
tion switch and engine stop switch must be
No
on and the starter button depressed. Re-
place component if failed .
battery negative terminal (-).
Clean the battery-to-solenoid cable ends or
No
replace the cable.
No Replace the starter solenoid.
Clean the solenoid-to-starter cable ends or
No
replace the cable.
ELECTRICAL
test.
10.47