Snowmobile Ski Doo REV SERIES (2006 year). Instruction - part 76

Section 07 ELECTRICAL SYSTEM

Subsection 03 (STARTING SYSTEM)

TROUBLESHOOTING

When the ignition switch is turned on or the start
button is pressed, a signal is sent to the starting
solenoid. The battery then supplies current to the
starter through the starting solenoid to turn the
engine.

In case of problems, first ensure the problem is
not related to engine mechanical components. If
not, test the starting system.

Causes of problems are not necessarily related to
starter but may be due to a burnt fuse, faulty bat-
tery, start button or ignition switch, engine cut-
out switch, starting solenoid, electrical cables and
connections or the electronic module.

Check these components before removing starter.

Fuses

Make sure the charging fuse (30 A) on battery and
the MPEM fuse (5 A) on electrical harness are in
good condition. If the fuses test good, continue
with the next tests.

Battery

Refer to CHARGING SYSTEM to check battery
condition. If the test is good, continue with the
next tests.

Start/RER Button

Liquid-Cooled Engines Models

Check if the start/RER button works perfectly.

START/RER BUTTON ON VEHICLES WITH

ELECTRIC STARTER

All engines except SDI

TEST

Continuity from

start/RER button

to MPEM

Voltage

from voltage

regulator/rectifier

WIRE COLOR

RED/GREY and

BEIGE

RED/GREY and

BEIGE

RESISTANCE

1.0

—

VOLTAGE

—

Above battery

voltage and

below 15 volts

NOTE

—

SDI engines

TEST

Continuity from

start/RER button

to MPEM

Voltage

from voltage

regulator/rectifier

WIRE COLOR

BLACK and

BLACK/BLUE

BLACK and

BLACK/BLUE

RESISTANCE

1.0

—

VOLTAGE

—

Above battery

voltage and

below 15 volts

NOTE

—

If the switch functions correctly, continue with the
next tests.

Ignition Switch

Fan-Cooled Engines Models

Disconnect switch housing. Using the multimeter
FLUKE 111 (P/N 529 035 868), check between
MAG and GRD terminals if the circuit is open (O.L.)
in operating position and if it is closed (0

) in off

position.

Engine Cut-Out Switch

Check the condition of engine cut-out switch.

mmr2005-084

301

Section 07 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

ENGINE CUT-OUT SWITCH ON VEHICLE

WITH ELECTRIC STARTER

TEST

Running

insulation

Continuity in

STOP position

WIRE COLOR

BLACK/YELLOW

and BLACK

BLACK/YELLOW

and BLACK

RESISTANCE

O.L.

00.0 to 00.5

VOLTAGE

—

NOTE

Engine cut-out

switch must be

in run position.

Engine cut-out

switch must be

in stop position.

Starting Solenoid

Ensure the solenoid receives electric current
as follows. Using the multimeter FLUKE 111
(P/N 529 035 868), measure the voltage between
the wires, indicate in the following table, when
starting the vehicle. The tether cord must be
installed.

ENGINE TYPES

COLOR OF WIRES

ALL SDI ENGINES

RED/GREY and

ORANGE/BLACK

ALL POWER TEK
ENGINES

RED/GREEN and
ORANGE/BLACK

ALL OTHER ENGINES

RED/GREEN and BLACK

If the solenoid does not properly receive current,
the electronic module can be suspected.

If the solenoid receives current, test it as follows.

– Disconnect battery and starter cables from so-

lenoid.

– Inspect connections and clean as necessary.
– Solenoid condition can be checked with an

ohmmeter. Install probes on large connectors
of solenoid.

– Measure the resistance when current is applied

to small connectors; if it is more than a few
ohms, replace solenoid.

If solenoid tests good, check the electric starter. If
electric starter tests good, the electronic module
can be suspected.

Electrical Cables and Connections

Check all connections, harnesses and wires.

Tighten any loose connections.

Replace any chafed wires.

If wires, harnesses and connections are good,
check the electric starter.

Electric Starter

Remove the tuned pipe and disconnect spark plug
cables.

Using booster cable, carefully supply current from
the battery directly to the starter. Connect the
BLACK cable first. Connect the remaining boost-
er cable from the battery then to the starter.

If the starter turns, ensure wiring harness and con-
nectors between battery and starter are in good
condition. If they test good, the electronic mod-
ule can be suspected.

If the starter does not turn, check for mechanical
problem in the starter.

Electronic Module

Check the MPEM condition, refer to IGNITION
SYSTEM. For SDI and Power TEK engines, re-
fer to ENGINE MANAGEMENT.

STARTER REMOVAL

– Disconnect BLACK (-) cable from battery.
– Disconnect RED (+) cable from battery.



WARNING

Always disconnect BLACK (-) cable first and
connect last.

– Remove tuned pipe.
– Disconnect RED cable from starter.
– Disconnect ground cable from starter.
– Remove stabilizer bar clamp to access the low-

er starter retaining bolt.

302

mmr2005-084

Section 07 ELECTRICAL SYSTEM

Subsection 03 (STARTING SYSTEM)

A33F27B

1. Clamp

– Unbolt and remove starter from engine.

A33E0VA

1. Bolts to be removed

STARTER DISASSEMBLY

Before disassembling, trace index marks on
starter housing no. 10 and starter housing assem-
bly no. 8 to ease further assembly.

Remove starter through bolts no. 17. Separate
end frame housing no. 14 from starter housing
no. 10. Withdraw starter housing from armature
no. 11.

Brush holder no. 13 can be removed from end
frame housing no. 14 by disconnecting the end
frame attached brush from brush holder no. 13.

Check the radial play between the armature shaft
and end frame bearing. Replace the end frame
bearing or replace starter. If parts are in good con-
dition then coat with synthetic grease (P/N 413
711 500) before reinstalling them.

Push back the collar no. 3 using a screwdriver.

Remove snap ring no. 2. Remove collar no. 3 and
spring no. 4.

A32E20A

1. Collar
2. Snap ring

Turn starter clutch no. 6 clockwise to remove it
from armature assembly no. 11.

Pull housing from armature.

STARTER CLEANING

CAUTION: Yoke assembly and drive unit as-
sembly must not be immersed in cleaning sol-
vent.

Clean brushes and holders with a clean cloth
soaked in solvent. Brushes must be dried thor-
oughly with a clean cloth.

Blow brush holders clean using compressed air.



WARNING

Always wear safety glasses when using com-
pressed air.

Remove dirt, oil or grease from commutator using
a clean cloth soaked in suitable solvent. Dry well
using a clean and dry cloth.

Clean engine ring gear teeth and drive unit (clutch).

mmr2005-084

303

Section 07 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

NOTE: Bushings or bearings must not be cleaned
with grease dissolving agents.

Immerse all metal components in cleaning solu-
tion. Dry using a clean and dry cloth.

STARTER INSPECTION

Armature

NOTE: An ohmmeter may be used for the follow-
ing testing procedures, except for the one con-
cerning the shorted windings in the armature.

Check the commutator for roughness, burnt or
scored surface. If necessary, turn the commuta-
tor on a lathe, enough to remove grime only.

Check the commutator for mica depth. If the
depth is less than 0.20 mm (.008 in), undercut
the mica. Be sure that no burrs are left and no
copper dust remains between the segments after
the undercutting operation is completed.

F01H0RA

1. Commutator undercut 0.20 mm (.008 in)

Check the commutator out-of-round condition
with V Blocks and an indicator. If the commutator
out-of-round is more than 0.40 mm (.016 in), the
commutator should be turned on a lathe.

Check commutator outer diameter. If less than
specified value, replace.

A03E06A

MODEL

WEAR LIMIT

All models

27 mm (1.063 in)

Test for Ground Circuit in the Armature

Use growler test probes. Check between arma-
ture core and the commutator bars. If growler
lamp turns on, bars are grounded. If so, replace
armature.

A09E08A

1. Test probes
2. Commutator bars

Test Armature for Shorted Winding

When the armature is rotated in the growler with a
steel strip (hacksaw blade) held above it, the strip
will vibrate over that area of the armature which
has short circuit. Replace armature if so.

A09E09A

1. Steel strip (hack-saw blade)
2. Growler

304

mmr2005-084

Content .. 74 75 76 77 ..