2005 Polaris Sportsman 700/800 EFI Service Manual, Page 293Get this manual
ELECTRICAL
STARTER SYSTEM TROUBLESHOOTING
Starter Motor Does Not Turn
G Battery dischargedLow specific gravity 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 kill switch Faulty starter solenoid or starter motorEngine problemseized or binding (Can engine be rotated easily with recoil starter?) Battery dischargedlow specific gravity Excessive circuit resistancepoor connections (see Voltage Drop Test below) Engine problemseized or binding (Can engine be rotated easily?) Faulty or worn brushes in starter motor Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel
drop tests on the starter systemVoltage should not exceed .1 DC volts per connection
STARTER MOTOR REMOVAL DISASSEMBLY
NOTE: Use electrical contact cleaner to clean starter motor partsSome solvents may leave residue or damage internal parts and insulation