Starter System Testing Flow Chart - Polaris 2007 Sportsman 500 EF Service Manual

ELECTRICAL

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. This flow chart assumes that the starter lockout system is functional.
With the tester on the VDC position, place the
tester'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. Tester should
read battery voltage.
Yes
Voltage Drop
Testing
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.
Depress starter button. Reading should be less than
.1 V D.C.
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.
Depress 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.
10.50
Test starter solenoid coil by connecting an ohmmeter between the solenoid
wire and the solenoid mounting plate. Check solenoid ground path by
measuring resistance between mounting plate and battery negative terminal
(-). There should be no continuity.
Yes
Remove battery and properly service. Install
No
fully charged shop battery to continue test.
Check voltage on both sides of circuit
breaker, ignition switch/engine stop switch.
The voltage on both sides should be the same.
No
NOTE: The ignition switch and engine stop
switch must be 'on'. Replace component if
failed .
No Clean the battery-to-solenoid cable ends
or replace the cable.
No
Replace the starter solenoid.
Clean the solenoid-to-starter cable ends or
No
replace the cable.