Starting System; Starter Troubleshooting; Voltage Drop Test; Starter Removal - Polaris 2015 RZR 900 Service Manual

ELECTRICAL

STARTING SYSTEM

Starter Troubleshooting

Starter Motor Does Not Run
• Battery discharged
• Loose or faulty battery cables or corroded
connections (see Chapter 11 – Voltage Drop Test,
page )
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor, or starter solenoid (see Chapter 11 –
Voltage Drop Test, page
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
Starter Motor Turns Over Slowly
• Battery discharged
• Excessive circuit resistance - poor connections
(see Chapter 11 – Voltage Drop Test, page
• Engine problem - seized or binding (can engine be
rotated easily)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel

Voltage Drop Test

The Voltage Drop Test is used to test for bad
connections. When performing the test, 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 0.1 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.
Refer to the voltage drop tests on the starter system in
this chapter.
Voltage should not exceed 0.1 volts per
connection
11.26
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9925723 R01 - 2015 RZR 900 Service Manual
© Copyright 2014 Polaris Industries Inc.

Starter Removal

1. Remove driver side seat and disconnect the battery.
2. Raise and support rear of vehicle.
3. Remove RH rear wheel.
4. Remove (+) positive wire from starter motor terminal.
5. From the RH side wheel well using an 8mm flex
socket, remove the negative battery cable nut and the
two fasteners securing the starter motor to the
engine.
NOTE: The (-) negative battery cable is mounted
to the engine using the upper starter mounting
bolt / stud.
6. Remove the starter from the engine.

Starter Installation

1. Inspect and replace starter motor O-ring if needed.
2. Lubricate starter motor O-ring with fresh engine oil.
3. Install the starter motor onto the engine case.
4. Hand tighten the upper starter mounting bolt / stud.
5. Install and torque the lower mounting bolt to
specification.
NOTE: Tighten the lower starter bolt first, as the
bottom hole acts as a pilot hole to properly align
the starter drive (bendix) with the flywheel. This
helps prevent binding and starter damage.
6. Torque upper starter mount screw to specification.