10.26
9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual
© Copyright 2013 Polaris Sales Inc.
STARTER SYSTEM
Troubleshooting
Starter Motor Does Not Run
• Battery discharged. Low specific gravity
• Loose` or faulty battery cables or corroded
connections (see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty kill switch
• Faulty starter solenoid or starter motor.
• Engine problem - seized or binding (Can engine
be rotated easily with recoil starter?)
• Starter lockout malfunction
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections
(see Voltage Drop Test below)
• Engine problem - seized or binding (Can engine
be rotated easily?)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty 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.
Voltage should not exceed
.1 Vdc per connection
Starter Motor Removal
1.
Remove the seat, left side panel, and disconnect the
battery.
2.
Remove the (+) positive wire (A) from the starter
motor terminal.
3.
Remove the upper starter motor fastener (1)
securing the starter motor and (-) negative battery
cable to the engine. Completely loosen the lower
starter motor fastener.
NOTE: The (-) negative battery cable is mounted
to the engine using the upper starter mounting
bolt.
4.
Remove the starter from the engine.
Starter Motor Installation
1.
Inspect and replace starter motor O-ring if needed.
2.
Lubricate the starter motor O-ring with fresh engine
oil.
3.
Place the lower starter motor fastener through the
lower mounting boss in the starter motor.
4.
Install the starter motor onto the engine case.
5.
Install the (-) negative battery cable in the upper
starter bolt and hand tighten the upper starter
mounting bolt.
6.
Install and torque the lower mounting bolt to
specification.
NOTE: Tighten the lower starter bolt first, as the
bottom hole acts as a pilot hole to properly align
the starter drive (bendix) with the flywheel. This
helps prevent binding and starter damage.
ELECTRICAL
