Starter System Troubleshooting; Starter Motor Service; Voltage Drop Test - Polaris 2005 SPORTSMAN 500 Servise Manual

ELECTRICAL
STARTER SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Turn
GBattery discharged.
gravity
GLoose or faulty battery cables or
corroded connections (see Voltage
Drop Tests)
GRelated wiring loose, disconnected, or
corroded
GPoor ground connections at battery
cable, starter motor or starter
solenoid (see Voltage Drop Tests)
GFaulty key switch
GFaulty kill switch
GFaulty starter solenoid or starter motor.
GEngine problem - seized or binding (Can
engine be rotated easily with recoil
starter?)
Starter Motor Turns Over Slowly
GBattery discharged - low specific
gravity
GExcessive circuit resistance - poor
connections (see Voltage Drop Test
below)
GEngine problem - seized or binding
(Can engine be rotated easily?)
GFaulty or worn brushes in starter
motor
GAutomatic compression release
inoperative
Starter Motor Turns - Engine Does Not Rotate
GFaulty starter drive
GFaulty starter drive gears or starter
motor gear
GFaulty 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 .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 chart on 10.27 to perform voltage
10.38
Low specific
drop tests on the starter system.
Voltage should not exceed
.1 DC volts per connection
STARTER MOTOR
DISASSEMBLY
*NOTE: 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.