Polaris RZR 800 2013, Manual

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10.35
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
STARTING SYSTEM
Troubleshooting
Starter Motor Does Not Run
• Battery discharged
• 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 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
(see Voltage Drop Test)
• 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 0.1 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.
Refer to the voltage drop tests on the starter system in
this chapter.
Voltage should not exceed
.1 DC volts per connection
Starter Motor Removal
1. Disconnect the negative (-) battery cable and remove
the seat base.
2. Remove the positive (+) battery cable from the
starter motor.
3. Remove the nut securing the negative (-) battery
cable from the lower starter mounting bolt.
4. Remove the (2) starter motor mounting bolts. The
routing bracket (A) is mounted to the upper starter
motor bolt.
5. Remove starter from the engine. Use a soft, rubber
hammer to aid in starter removal.
Starter Motor Installation
1. Lubricate and install a new O-ring (B) onto the starter
motor.
2. Install the starter motor onto the engine.
3. Install the upper and lower starter mounting bolts by
hand.
4. Torque the upper starter mounting bolt to
specification.
5. Torque the lower starter mounting bolt to
specification.
6. Install the negative (-) battery cable to the lower
mounting bolt. Install battery cable nut and torque to
specification.
7. Install the positive (+) battery cable to the starter
motor.
8. Install seat base and connect the battery.
Starter Motor Mounting Bolts:
7 ft-lbs (9.5 Nm)
ELECTRICAL