Engine Cranks But Does Not Start - Polaris RZR XP Service Manual

DIAGNOSTIC

ENGINE CRANKS BUT DOES NOT START

1. Check battery voltage while cranking. If voltage is
below 10.8V, vehicle may not start.
• Perform Voltage Drop Test on Starter Circuit. Refer
toTesting Voltage Drop page 10.35. Acceptable
drop is 0.1V per connection, if too much drop is
detected concern may be caused by faulty starter,
or solenoid.
• Charge battery.
• Check battery electrolyte level. Fill following
procedure if low.
• If battery voltage is not ~12.6 V charge battery at
recommended rate. Refer to Charging Procedure
page 12.27. Attempt starting after charging.
• If battery still does not reach ~12.6 V, battery may
require replacement. Refer toBattery Installation
page 12.25.
2. Visually inspect vehicle for any electrical connectors
or wiring that may be loose or damaged. Check
connectors for water intrusion or corrosion.
• If connections are found to be loose, repair
connector as necessary.
• If connector is found to have corrosion or water
within connectors, clean, dry, and reconnect.
• Repair any damage to wiring.
3. Check vehicle for trouble codes. Refer to Digital
Wrench® Diagnostic.
• If codes are present proceed with testing per Digital
Wrench®.
4. Check air box and filter for debris or moisture.
• If debris is found clear debris and recheck for
concern.
• If water is found within air box, dry box and filter. It
is possible that engine may have ingested water.
This could cause engine failure, refer to Engine
Troubleshooting page 10.13
5. Check for fuel shut off/res position.
• If applicable, verify that fuel is turned on before any
further diagnosis.
6. Check fuel level and condition in vehicle.
• Possible to have incorrect reading from fuel gauge.
Using a flashlight, check for fuel in tank. If no fuel is
visible, fill with fuel before further diagnostic.
• If filled with fuel, vehicle starts, and gauge still is not
reading refer to Fuel Sender Test page 4.37.
10.8
7. Check fuses or fuel system relays (where applicable).
• If any fuel related system fuses are blown, replace
fuses and recheck. Wiring concern or faulty parts may
cause fuse to blow.
• It is advisable to try swapping a relay with a known
good relay to check operation. Swap relay with like
relay and see if vehicle starts.
8. Check fuel lines and fittings for leaks or damage.
• If leak or damage is found repair, replace as
necessary and recheck concern.
• If no concerns are found proceed with fuel pressure
testing.
9. Check fuel pressure. Refer to Fuel Pressure Test
page 4.32
• Check using fuel pressure gauge to see that fuel
pressure is within specification.
• If not within specification, check fuel filter for
restriction and/or replace filter.
• If no concern is found with filter or pressure is still
low after filter replacement, suspect weak or faulty
fuel pump.
10. Inspect spark plug wiring, spark plug, and check for
spark.
• Check to make sure that spark plug is tight.
• Inspect spark plug for fouling. Inspect plug gap
using feeler gauge or similar tool. Adjust to
specification if needed.
• Disconnect plug wire and remove spark plug. With
spark plug removed check for spark using inline
spark tester. If spark tester is not available, reinstall
wire to plug connection. Using caution crank
engine while watching spark plug for spark.
CAUTION
DO NOT TOUCH SPARK PLUG DURING TEST.
TOUCHING SPARK PLUG COULD RESULT IN
ELECTRIC SHOCK.
• If plug does not spark in previous test, check
connections at ignition coil. Concern may be
caused by faulty ignition coil.
11. Listen for unusual noises while cranking.
• Broken or damaged flywheel, starter motor gear, or
starter motor drive could sound like engine
cranking but crankshaft may not be turning.
• Unusual noise could suggest that there may be a
mechanical engine concern. Proceed to step
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
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