Polaris TRAIL BOSS 2003 User Manual

ELECTRICAL
10.21
STARTER SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Turn
GBattery discharged - low specific gravity
GLoose or faulty battery cables or corroded
connections (see Voltage Drop Tests)
GRelated wiring loose, disconnected, or
corroded
GPoor ground connections at battery cable,
starter motor or starter solenoid (see
Voltage Drop Tests)
GFaulty starter button
GFaulty ignition switch (Do other syst ems
function?)
GFaulty starter solenoid or starter motor.
GEngine problem - seized or binding (Can
engine be rotated easily with recoil
starter?)
Starter Motor Turns Over Slowly
GBattery discharged - low specific gravity
GExcessive circuit resistance - poor
connections (see Voltage Drop Test
below)
GEngine problem - seized or binding (Can
engine be rotated easily with recoil
starter?)
GFaulty or worn brushes in starter motor
GAutomatic compression release inoperative
Starter Motor Turns - Engine Does Not Rotate
GFaulty starter drive
GFaulty starter drive gears or starter motor
gear
GFaulty 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 .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 chart on next page to perform
voltage drop tests on the starter system.
Voltage should not exceed:
1 DC volts per connection
STARTER MOTOR
DISASSEMBL
Y
NOTE: Use electrical contact cleaner to clean starter
motor parts. Some solvents may leave a residue or
damage internal parts and insulation.
1. Note the alignment marks on both ends of the
starter motor casing. These marks must align
during reassembly.
2. Remove the two bolts, washers, and sealing
O-Rings. Inspect O-Rings and replace if damaged.

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English