Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 368 / 406

10.50
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.
Remove battery and properly service. Install
fully charged shop battery to continue test.
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.
Check voltage on both sides of circuit
breaker, ignition switch/engine stop switch.
The voltage on both sides should be the same.
NOTE: The ignition switch and engine stop
switch must be ‘on’. Replace component if
failed .
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.
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.
Clean the battery-to-solenoid cable ends
or replace the cable.
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.
Replace the starter solenoid.
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.
Clean the solenoid-to-starter cable ends or
replace the cable.
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.
Yes
Yes
Yes
Yes
No
No
No
Yes
No
No
Voltage Drop
Testing