Polaris Outlaw 500, Service Manual

Page: 194 / 202

7.21
ELECTRICAL
7
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.
With the tester on the VDC position, place the tes-
ter’s black lead on the battery negative and the red
lead on the battery positive.
Reading should be 12.5 VDC or greater.
Disconnect White/Red engagement coil wire from
the starter solenoid. Connect tester black wire to
battery ground. Connect red tester lead to White/
Red harness wire at solenoid.Turn on ignition
switch and depress the starter button.Tester
should read battery voltage.
No
Yes
Remove battery and properly service.
Install fully charged shop battery to conti-
nue test.
Check voltage on both sides of circuit break-
er, ignition switch/engine stop switch and
starter button. The voltage on both sides
should be the same.
NOTE: The ignition
switch must be on and the engine switch
turned to “RUN”. Check the clutch and neu-
tral safety start circuits, as they supply the
ground path for solenoid operation. Replace
the defective component(s) or wiring.
No
Test starter solenoid coil by connecting an ohmmeter between the solenoid
red wire and the solenoid mounting plate. Resistance should be 3.4
Ω.
Check solenoid ground path by measuring resistance between mounting
plate and battery negative terminal (-).
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.Depr-
ess starter button. Reading should be less than
.1 V D.C.
Voltage Drop Testing
See Page 7.16 for information
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. Depre-
ss starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to solenoid end of
the solenoid-to-starter cable. Connect red tester
lead to the starter end of the same cable. Depress
the starter button. The reading should be less than
Yes
Yes
.1 V D.C.
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
Clean the battery-to-solenoid cable ends or
replace the cables.
No
Replace the starter solenoid.
No
Clean the solenoid-to-starter cable ends or
replace the cable.
No