Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Instruction - part 63

 

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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Instruction - part 63

 

 

10.12

Battery and Electrical Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Battery Box

BATTERY BOX

SOLENOID

CIRCUIT BREAKER

RED LEAD TO STARTER

RED LEAD FROM BATTERY

GROUND WIRE

10.13

Battery and Electrical Systems

10

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Dynamic Testing

NOTE: Be sure the engine crankshaft turns freely
before proceeding. Use a digital multimeter during
tests.

Static Testing

1.

Remove starter motor and disassemble. (See page
11.11 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.

Test battery voltage. Is the battery voltage equal to or greater 
than 12.8 Vdc?

NO

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

YES

Disconnect two-pin harness from starter solenoid. Connect 
black multimeter probe to the engine or ground, then the red 
probe to the 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 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 the solenoid harness. Connect black probe to 
battery positive terminal and red probe to solenoid end of 
battery to solenoid cable. 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. 
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. 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.

10.14

Battery and Electrical Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Starter Housing / Field Coil Testing

1.

Using a digital multimeter, 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 multimeter, 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.

10.15

Battery and Electrical Systems

10

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

CARBURETED ELECTRICAL 
SYSTEMS

EC50PL Stator Specifications

NOTE: Use a multimeter to test the stator circuits.
Remember to test the circuits when the engine is cold
and after the engine has been running for some time.

EC34 / EC55 Stator Specifications

500EV Stator Specifications

Ignition Coil Packs

NOTE: Specifications listed for all models except
EC50PL (488cc) as this model features a CDI / coil
pack.

Oil Level Sender

To test the oil level sender, position the sender as it would
be in the oil tank. Allow the float to drop in the direction it
would if the oil tank were empty. Continuity should be
present when using a multimeter to test the sender with
the float in the “empty” position. 

No continuity should be present when the float is moved
away from the “empty” position.

500 EV Coolant Temperature Sensor

Specifications 

BRN / WHT TO BLK / RED 164 

YELLOW TO YEL / RED

0.2 - 0.5

YEL / RED, WHT, BRN TO 
GROUND

0

Specifications

YEL TO BRN

0.16

BRN TO ENGINE

0

BLK / RED TO GRN

13

RED TO GRN

13

RED TO ENGINE

OPEN

BLK TO ENGINE

0

WHT / RED TO WHT

185

WHT TO ENGINE

OPEN

Specifications

YEL TO BRN

0.15

BRN TO ENGINE

0

BLK / RED TO GRN

15

RED TO GRN

15

BLK or WHT TO ENGINE 0

WHT / RED TO WHT

185

Specifications

BLK TO WHT (Primary)

0.3

BLK or WHT TO 
SECONDARY LEAD

OPEN

SECONDARY LEAD TO 
LEAD

5K

PLUG CAPS

10K

Sensor Specifications

Temperature (F / C)

Resistance (OHMS)

-22_F / -30_C

22914 - 28006

32_F / 0_C

5085 - 6215

68_F / 20_C

2189 - 2675

149_F / 6_C

455 - 556.2

221_F / 105_C

152.8 - 186.8

 

 

 

 

 

 

 

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