11.26
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
STARTING SYSTEM
STARTER TROUBLESHOOTING
Starter Motor Does Not Run
• Battery discharged
• Loose or faulty battery cables or corroded connections
(see Chapter 11 – Voltage Drop Test, page )
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor, or starter solenoid (see Chapter 11 – Voltage
Drop Test, page )
• 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
Chapter 11 – Voltage Drop Test, page )
• 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 0.1 volts per connection
STARTER REMOVAL
1. Remove driver side seat and disconnect the battery.
2. Raise and support rear of vehicle.
3. Remove RH rear wheel.
4. Remove (+) positive wire from starter motor terminal.
5. From the RH side wheel well using an 8mm flex
socket, remove the negative battery cable nut and the
two fasteners securing the starter motor to the
engine.
NOTE
The (-) negative battery cable is mounted to the
engine using the upper starter mounting bolt / stud.
6. Remove the starter from the engine.
STARTER 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.
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.
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 ft-lb (10 Nm)
ELECTRICAL
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