Table of Contents
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
3. Remove the nut securing the negative (-) battery
4. Remove the (2) starter motor mounting bolts. The
5. Remove starter from the engine. Use a soft, rubber
Starter Motor Installation
1. Lubricate and install a new O-ring (B) onto the starter
2. Install the starter motor onto the engine.
3. Install the upper and lower starter mounting bolts by
4. Torque
5. Torque
6. Install the negative (-) battery cable to the lower
7. Install the positive (+) battery cable to the starter
8. Install seat base and connect the battery.
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
starter motor.
cable from the lower starter mounting bolt.
routing bracket (A) is mounted to the upper starter
motor bolt.
hammer to aid in starter removal.
motor.
hand.
the
upper
starter
specification.
the
lower
starter
specification.
mounting bolt. Install battery cable nut and torque to
specification.
motor.
Starter Motor Mounting Bolts:
7 ft-lbs (9.5 Nm)
ELECTRICAL
mounting
bolt
to
mounting
bolt
to
10
10.35
Chapters
Table of Contents
Troubleshooting
