Starter System Troubleshooting; Starter Motor; Voltage Drop Test - Polaris Trail Boss 330 2003 Service Manual

ELECTRICAL
STARTER SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Turn
GBattery discharged - low specific 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 starter button
GFaulty ignition switch (Do other systems
function?)
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
connections (see Voltage Drop Test
below)
GEngine problem - seized or binding (Can
engine be rotated easily with recoil
starter?)
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 next page to perform
resistance - poor
voltage drop tests on the starter system.
Voltage should not exceed:
1 DC volts per connection

STARTER MOTOR

DISASSEMBLY
NOTE: Use 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.
10.21