12.60
9850067 R01 - 2020-2021
GENERAL
/
GENERAL XP
Service Manual
© Copyright Polaris Inc.
STARTER MOTOR INSTALLATION
1. Inspect and replace starter motor O-ring if needed.
2. Lubricate starter motor O-ring with fresh engine oil.
3. Install the starter motor onto the engine case.
4. Hand tighten the upper starter mounting bolt / stud.
5. Install and torque the lower mounting bolt to
specification.
NOTICE
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.
6. Torque upper starter mount screw to specification.
7. Install (-) negative battery cable to the upper starter
mounting bolt / stud. Torque nut to specification.
TORQUE
Starter Mounting Bolts and Nut:
7 lb-ft (10 Nm)
STARTER SOLENOID SERVICE
Starter Solenoid Bench Test
Test the start solenoid by powering the solenoid using
battery voltage for a
maximum of 5 seconds.
With the
solenoid energized at room temperature (77 °F),
resistance should read within specification between
terminals. If resistance measurement is out of
specification, replace the starter solenoid
Starter Solenoid Terminal Resistance (77 °F)
0 - 0.5 Ω
Starter Solenoid Operation
To energize the Starter Solenoid the following must
occur:
• The brake must be applied to provide a ground path
via the orange wire.
• The key switch must be turned to the “start” position to
provide 12V power via the Green / White wire.
• Once the pull-in coil is energized, the solenoid
provides a current path for 12V power to reach the
starter motor.
NOTICE
See “
Starting System Breakout page
” for starter
solenoid operation.
STARTING SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Run
• Battery discharged
• Loose or faulty battery cables or corroded connections
(Refer to page 12.59)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor, or starter solenoid (Refer to page 12.59)
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
Starter Motor Turns Over Slowly
• Battery discharged
• Excessive circuit resistance - poor connections (Refer
to page 12.59)
• 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
