Snowmobile Polaris (2006 year). Manual - part 66

13.6

ELECTRICAL

components of water. Because of the loss of these gases and 
the lowering of the electrolyte level, it will be necessary to 
add pure, clean distilled water to bring the fluid to the proper 
level. After filling, charge the battery to raise the specific 
gravity to1.270 or greater.

OFF SEASON STORAGE

To prevent battery damage during extended periods of non-
use, the following basic maintenance items must be 
performed.

1.

Remove battery from machine and wash the case and
battery tray with a mild solution of baking soda and water.
Rinse with lots of fresh water after cleaning. 

2.

Using a wire brush or knife, remove any corrosion from
the cables and terminals.

3.

Make sure the electrolyte is at the proper level. Add
distilled water if necessary.

4.

Charge at a rate no greater than 1/10 of the battery's amp/
hr. capacity until the electrolyte's specific gravity reaches
1.270 or greater.

5.

The battery may be stored either in the machine with the
cables disconnected, or on a piece of wood in a cool place. 

NOTE: Stored batteries lose their charge at the rate 
of 1% per day. They should be fully recharged every 
30 to 60 days during a non-use period. If stored 
during winter months, the electrolyte will freeze at 
higher temperatures as the battery discharges. The 
chart indicates freezing points by specific gravity.

CHARGING PROCEDURE

Charge battery with a charger no larger than 1/10 of the 
battery's amp/hr. rating and for as many hours as needed to 
raise the specific gravity to 1.270 per cell or greater.

STARTER SYSTEM

DYNAMIC TESTING OF THE ELECTRIC 
STARTER SYSTEM

CONDITION: Starter fails to turn the starter motor or it turns 
the starter motor slowly

NOTE:  Be sure the engine crankshaft is free to turn 
before proceeding. For this test a digital multitester 

CAUTION

D

O

 

NOT

 

ALLOW

 

ANY

 

OF

 

THE

 

BAKING

 

SODA

 

SOLUTION

 

TO

 

ENTER

 

THE

 

BATTERY

 

OR

 

THE

 

ACID

 

WILL

 

BE

 

NEUTRALIZED

.

Table 13-3: Specific Gravity Freezing Point

Specific Gravity of Electrolyte

Freezing Point

1.265

-75_F (-59_C)

1.225

-35_F (-37_C)

1.200

-17_F (-27_C)

1.150

5_F (-15_C)

1.100

18_F (-8_C)

1.050

27_F (-3_C)

WARNING

B

ATTERY

 

ELECTROLYTE

 

IS

 

POISONOUS

. I

T

 

CONTAINS

 

AC

-

ID

!

S

ERIOUS

 

BURNS

 

CAN

 

RESULT

 

FROM

 

CONTACT

 

WITH

 

THE

 

SKIN

, 

EYES

, 

OR

 

CLOTHING

.

ANTIDOTE:

EXTERNAL: F

LUSH

 

WITH

 

WATER

.

INTERNAL: D

RINK

 

LARGE

 

QUANTITIES

 

OF

 

WATER

 

OR

 

MILK

. F

OLLOW

 

WITH

 

MILK

 

OF

 

MAGNESIA

, 

BEATEN

 

EGG

, 

OR

 

VEGETABLE

 

OIL

. C

ALL

 

PHYSICIAN

 

IMMEDIATELY

.

EYES: F

LUSH

 

WITH

 

WATER

 

FOR

 15 

MINUTES

 

AND

 

GET

 

PROMPT

 

MEDICAL

 

ATTENTION

. 

B

ATTERIES

 

PRODUCE

 

EXPLOSIVE

 

GASES

. K

EEP

 

SPARKS

, 

FLAME

, 

CIGARETTES

, 

ETC

. 

AWAY

. V

ENTILATE

 

WHEN

 

CHARGING

 

OR

 

USING

 

IN

 

CLOSED

 

SPACE

. A

LWAYS

 

SHIELD

 

EYES

 

WHEN

 

WORKING

 

NEAR

 

BATTERIES

.

KEEP OUT OF REACH OF CHILDREN.

WARNING

T

HE

 

GASES

 

GIVEN

 

OFF

 

BY

 

A

 

BATTERY

 

ARE

 

EXPLOSIVE

. A

NY

 

SPARK

 

OR

 

OPEN

 

FLAME

 

NEAR

 

A

 

BATTERY

 

CAN

 

CAUSE

 

AN

 

EXPLOSION

 

WHICH

 

WILL

 

SPRAY

 

BATTERY

 

ACID

 

ON

 

ANYONE

 

CLOSE

 

TO

 

IT

. I

F

 

BATTERY

 

ACID

 

GETS

 

ON

 

ANYONE

, 

WASH

 

THE

 

AFFECTED

 

AREA

 

WITH

 

LARGE

 

QUANTITIES

 

OF

 

COOL

 

WATER

 

AND

 

SEEK

 

IMMEDIATE

 

MEDICAL

 

ATTENTION

.

13.7

ELECTRICAL

must be used. Meter connections are shown later in 
this chapter.

Table 13-4: Electric starter troubleshooting

With tester on VDC, place tester black lead on battery 
negative (-) terminal and tester red lead on battery positive (+) 
terminal. (A) Page 13.9. Reading should be 12.6V or greater. 
Is it?

NO

Remove battery, test and/or service. Install a fully 
charged shop battery to continue the test and 
continue with left column

YES

Disconnect red engagement coil wire from start solenoid. 
Connect black tester wire to an appropriate ground and red 
lead to red harness wire at solenoid. Rotate ignition key to the 
start position. Meter should read battery voltage. Does it?

NO

With black tester lead on ground, check for voltage 
at large relay in terminal, circuit breaker in and out 
terminals, and across both sides (red and red/white) 
of the ignition switch with switch on start. Repair or 
replace any defective parts.

YES

Reconnect solenoid, connect tester black lead to battery 
positive terminal and red tester lead to solenoid end of battery 
to solenoid cable. (B) Page 13.9. Turn key to start position. 
The reading must be less than.1V DC. Is it?

NO Clean battery to solenoid cable ends or replace cable.

YES

Connect black tester lead to solenoid end of solenoid to starter 
cable and red tester lead to starter end of same cable. (D) Page 
13.9. Turn key to start position. The reading must be less 
than.1V DC. Is it?

NO Replace starter solenoid.

YES

Connect black tester lead to starter frame. Connect red tester 
lead to battery negative (-) terminal. (E) Page 13.9. Turn key 
to start position. The reading should be less than.1V DC. Is it?

NO

Clean ends of engine to battery negative cable or 
replace cable.

If all these tests indicate a good condition, yet the starter still fails to turn, or turns slowly, the starter must be remove for 
static testing and inspection.

13.8

ELECTRICAL

STARTER MOTOR STATIC TESTING

1.

Remove starter motor and disassemble. (See page 9.14 for
exploded view) Mark end covers and housing for proper
reassembly.

2.

Remove pinion retaining snap ring, spring and pinion
gear.

3.

Remove brush end bushing dust cover.

4.

Remove housing through bolts.

5.

Slide brush end frame off end of starter.

NOTE:  The electrical input post must stay with the 
field coil housing.

6.

Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate.

7.

Clean and inspect starter components.

NOTE:  Some cleaning solvents may damage the 
insulation in the starter. Care should be exercised 
when selecting an appropriate solvent. The brushes 
must slide freely in their holders. If the commutator 
needs cleaning, use only an electrical contact 
cleaner and/or a non-metallic grit sandpaper. 
Replace brush assembly when worn to 5/16, (.8 cm) 
or less.

STARTER HOUSING AND FIELD COIL 
INSPECTION

1.

Using a digital multitester, measure resistance between
starter input terminal and insulated brushes. The reading
should be.3 ohms or less.

2.

Measure resistance between insulated brushes and field
coil housing. The reading should be infinite. 

3.

Inspect insulated brush wire and field coil insulation for
damage. Repair or replace components as required.

ARMATURE TESTING

1.

Using a digital multitester, measure resistance between
each of the segments of the commutator. The reading
should indicate.3 ohms or less. 

2.

Measure resistance between commutator and armature
shaft. Reading should be infinity. 

3.

Place armature in a growler. With the growler on, position
a hacksaw blade lengthwise 1/8, (.03 cm) above armature
coil laminates. Rotate armature 360_. If hacksaw blade is
drawn to the armature on any pole, the armature is shorted
and must be replaced.

13.9

ELECTRICAL

STARTER ASSEMBLY

1.

Slide armature into field coil housing.

2.

Lightly grease drive end bushing and install drive end
frame on armature.

3.

Mount starter vertically in a vice with brush end up.

4.

While holding negative brushes out against their springs,
slide brush plate down onto the commutator.

5.

While holding positive brush springs to the side, slide
positive brushes into their holders and correctly position
the springs on top of the brushes.

6.

Using a non-petroleum grease, lubricate brush end bushing
and slide it onto end of armature.

7.

Align threaded holes in brush plate and install dust cover
and screws.

8.

Reinstall through bolts and properly tighten all screws.

9.

Lightly grease pinion shaft and install pinion, spring
stopper and snap ring.

STARTER SOLINOID BENCH TEST

The only test which can be done on the bench is the pull in coil 
resistance, which should be 3.4 ohms.

STARTER INSTALLATION

1.

Position starter motor so there is no less than.100,
clearance between the ring gear and the starter motor
pinion gear.

2.

Torque through bolt mount bracket nuts to specification.

3.

Torque 8mm (drive end) mount bolts to specification.

4.

Torque 6mm (brush end) bracket to specification.

VOLTAGE

UNREGULATED VOLTAGE

1.

Test resistance of lighting coil and compare to
specifications in the model specific wiring diagram.
Reminder: Meter resistance must be subtracted from
reading.

NOTE:  0.3 to 0.5 ohms may be less than the internal 
resistance of your meter leads or meter. Before 
measuring the stator resistance, short the meter 
leads together and read the display and record this 
measurement. Subtract this reading from the stator 
resistance readings.