Starter Motor; Starter / Starter Lockout System Diagram; Troubleshooting; Starter Motor Removal / Replacement - Polaris Sportsman 850 Service Manual

STARTER MOTOR

STARTER / STARTER LOCKOUT SYSTEM
DIAGRAM
The starter and starter lockout system consists of:
• Battery / Fuse or Circuit Breaker
• Key Switch / Off/Run Switch
• Starter Solenoid
• Brake Switch / Transmission (Neutral) Switch
• Start Diode
• Starter Motor

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 or Off/Run Switch
• Faulty transmission switch
• Faulty Start Diode(s). Use a digital multi-meter to test
diode operation. Locate the diode(s) in the main
harness under the hi-temp conduit and measure
between the diode connections. Continuity should flow
one direction only.
• 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
STARTER MOTOR REMOVAL /
REPLACEMENT
NOTE
The starter motor and solenoid can not be serviced.
Removing the black protective coating from the
components will allow for premature component failure.
Replace the starter motor and solenoid as an assembly.
1. Remove the seat and the upper and lower LH side
panels.
2. Disconnect the battery negative (-) cable.
3. Clean the area around the starter motor.
4. Using an 8 mm allen socket, with an extension,
remove the (2) bolts retaining the starter motor.
5. Remove the engine oil dipstick to allow for starter
motor removal.
6. Remove the starter motor from the crankcase
housing. Reinstall the engine oil dipstick.
7. Remove the key switch energize wire and battery
cable from the starter solenoid. Remove the starter
motor assembly from the chassis.
8. Install the new starter motor assembly by reversing
this procedure.
ELECTRICAL
11
11.71