2003 Bombardier Outlander 400 Factory Service Manual, Page 223Get this manual
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)
STARTING SYSTEM TROUBLESHOOTING
REMEDY Turn switch to the ON positionCheck main fuse and wiring conditionSet transmission to PARK or Neutral or squeeze the brake lever or press on brake pedalPoor contact of battery terminal(s) or Clean and tighten terminal(s)ground cable connectionsWeak batteryRecharge batteryCheck and replace defective partPoor contact or open circuit of: start button, engine stop switch, ignition switch or starting solenoidPark andor Neutral switch(es) is(are) Check park andor neutral switch(es) defectiveand wiring conditionCheck and replace defective partEngine mechanical problem (ensure that other electric components are good)Starter turns, but does not Poor contact of battery terminal(s)Clean and tighten terminal(s)crank the enginePoor battery ground cable connectionClean and tightenBurnt or poor contact of solenoid Replace starting solenoidswitch contact discPoor contact of brushClean, verify or straighten commutator and brush or replace electric starterBurnt commutatorTurn commutator in lathe or replace electric starterWorn commutator segmentsUndercut mica or replace electric starterShorted armatureReplace electric starterWeak brush spring tensionReplace electric starterWeak magnetReplace electric starterWorn bushingsReplace electric starterWeak batteryRecharge or replace batteryReplace electric starterStarter turns, but overrunning Worn clutch pinion gearclutch pinion does not mesh Defective clutchReplace electric starterwith ring gearPoor movement of clutch on splinesReplace electric starterWorn clutch bushingReplace electric starterWorn ring gearReplace ring gearStarter motor keeps runningShorted starting solenoid switch wind- Replace starter solenoidingMelted solenoid contactsReplace starter solenoidSticking or defective starter clutchLubricate or replace electric starterSYMPTOM Starter does not turnCAUSE Ignition switch is in the OFF positionBurnt fuseTransmission is not set to Park or Neutral position