ATV Starting System Technical Manual

Page 1

Subsection 05 (STARTING SYSTEM)

STARTING SYSTEM

SERVICE TOOLS

Description Part Number Page

ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 4

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 5

GENERAL

STARTING SYSTEM OPERATION

When the START button is pressed, 12 Vdc is applied through the start switch (MG1) to the starter solenoid coil. If the engine cranking conditions are met, the ECM completes the starter solenoid control circuit by providing a ground. The starter solenoid then closes its contacts and battery power is applied to the starter for cranking the engine.

Engine Cranking Conditions

The following conditions must be met to allow engine cranking.

– Ignition switch turned ON – EnginestopswitchtoRUN – Transmission in Park, Neutral or a brake

pedal/lever is applied

– Start button is pressed and held.

TROUBLESHOOTING

Check for fault codes. Refer to:

AND FAULT CODES

subsection.

DIAGNOSTIC

ENGINE WILL NOT TURN

4. Starter (refer to subsection)

5. Wiring and connections.

MAGNETO AND STARTER

ENGINE TURNS

Starting system is OK.

1. Verify ignition system. Refer to

subsection.

TEM

2. Verify EFI systems. Refer to

FUEL INJECTION (EFI)

3. Verify mechanical condition of engine. Refer to

subsection.

ENGINE, CVT AND GEARBOX

IGNITION SYS-

ELECTRONIC

section.

PROCEDURES

Ensure battery is fully charged. Refer to applicable

NECTORS

tions on vehicle. Refer to applicable

tional information.

Ensure vehicle is in PARK when performing starting system tests.

for harness layout and connector loca-

WIRING HARNESS AND CON-

WIRING DIAGRAM

for addi-

WARNING

If the starter cranks over the engine with the brakes applied, check the following:

1. Shifter rod adjustment, (refer to appropriate

SHIFTER

2. Gearbox position indicator switches or the gearbox position sensor (GBPS), (refer to appropriate

UNIT

3. Switches or sensor wires a nd connectors, (refer to appropriate

If the “Engine cranking conditions” are met and the starter will not crank the engine, check the following:

1. Battery and connections (refer to

SYSTEM

2. Starter solenoid

3. Start button switch

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subsection

GEARBOX AND 4X4 COUPLING

subsection

WIRING DIAGRAM

CHARGING

)

Page 2

Subsection 05 (STARTING SYSTEM)

STARTING SYSTEM TESTS

Starter Solenoid

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1. Disconnect SS1 and SS2

4. If starter does not turn, verify

NOID CONTINUITY

STARTER SOLE-

Starter Solenoid Control Circuit

ECM

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TEST CONDITION

Engine stop switch RUN

Ignition switch

Start button

Pressed

5 A

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1. SS1

2. Activate the starter solenoid.

2.1 Apply 12Vdc to SS1

2.2 Ground SS2

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SS1 IS ON THE RIGHT

3. If starter turns, verify

CONTROL CIRCUIT

STARTER SOLENOID

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SS1 IS ON THE RIGHT

PROBE PROBE SPECIF

SS1 SS2

SS1

BAT +

BAT - Battery voltage

SS2

Battery voltage

ICATION

If voltage is as per specification replace starter solenoid.

If volt ify

CIRCUI GROUND

age is not as per specification, ver-

RTER SOLENOID CONTROL POWER

STA

STARTER SOLENOID CONTROL

CIRCUIT

as applicable.

Starter Solenoid Control Power Circuit

NOTE: T

his procedure also tests the start button.

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Page 3

Subsection 05 (STARTING SYSTEM)

ECM

STOP

RUN

FREE

START

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1. Disconnect MG2 connector.

ON/

OFF

ON/

WO LIGHT

W LIGHT

If start switch tests as specified, repair wire to starter solenoid SS1 terminal.

Starter Power Circuit Voltage Drop

NOTE: Engine must be in starting condition for

this test. Do not perform on a «No Start» vehicle.

TEST CONDITION

Fuse F5 Removed‡

Engine stop s

Ignition switch

Start button

Engine

witch

RUN

Pressed

Cranking

‡ Will prevent engine from starting

tage drop.

1. Measure vol

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TYPICAL - MG2 STEERING HARNESS CONNECTOR PIN-OUT

TEST CONDITION

Engine s

PROBE PROBE SPECIFICATION

MG2-1

top switch

Ignition switch

RUN

BAT - Batter

yvoltage.

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PROBE PROBE SPECIFICATION

BAT1

Starter B+

terminal

Below 0.4 Vdc

2. If voltage is not as per specification:

1. Check fuse(s)

2. Test engine stop switch. Refer to

SYSTEM

3. Test ignition switch Refer to

TEM

subsection

IGNITION SYS-

subsection.

IGNITION

If voltage drop is above specification, repair or replace sources of high resistance in circuit.

3. Test start button.

TEST CONDITION

Start

button

Pressed

PROBE PROBE SPECIFICATION

MG2-1 MG2-6 Close to 0

If start button does not test as specified, replace the multifunction switch assembly.

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Page 4

Subsection 05 (STARTING SYSTEM)

BAT1

BAT2

Starter Solenoid Control Ground Circuit

SS2-

HIC1-J

ECM

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1. Disconnect SS2.

2. Install the ECM connector onto the

ADAPTER TOOL (P/N 529 036 166)

SS1-

ECM

Starter Solenoid Continuity

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1. Disconnect the BLACK (-) negative battery cable.

2. Disconnect SS1 and SS2

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1. ECM connector

2. ECM ada

pter tool

PROBE PROBE SPECIFICATION

SS2 ECM-L3 Close to 0

If resistance is not as specified, repair or replace wiring/connections.

If solenoid power control c ircuit and ground control circuit both test good, test ECM ground circuits. Refer to

subsection.

(EFI)

ELECTRONIC FUEL INJECTION

NOTE: Supply a ground with a jumper wire if you suspect that the ECM is not supplying a ground to the solenoid.

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1. SS1

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PROB

SPECIFICATION

@ 20°C (68°F)

SS1 SS2 Close to 6

If resistance is not as per specification, replace the solenoid.

3. Disconnect BP3.

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Page 5

Subsection 05 (STARTING SYSTEM)

Solenoid Diode Test

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PROBE PROBE SPECIFICAT

BP3

Ter m in a l t o

starter mo

tor

4. Jump starter solenoid.

O.L.

ION

SS2-

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SS1-

1. Disconnect SS1 and SS2 from starter solenoid.

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1. SS1

2. Use the FLUKE 115 MULTIMETER (P/N 529 035

868)

and set it to the diode symbol as shown.

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SS1 IS ON THE RIGHT

PROBE PROBE SPECI

BP3

Ter m in a l t o

er motor

start

FICATION

Closeto0

If resistance is not as per specification, replace the solenoid.

arter power and ground circuits are good, re-

If st

fer t star

MAGNETO AND STARTER

ter diagnosis and replacement.

subsection for

vmr2006-020-005

3. Probe wires w hile paying attention to the diode polarity.

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Page 6

Subsection 05 (STARTING SYSTEM)

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FORWARD POLARITY, MUST BE AROUND 0.5 V

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REVERSE POLARITY, MUST BE OPEN CIRCUIT

1. SS1

If test failed, replace diode. Refer to

HARNESS AND CONNECTORS

for diode loca-

WIRING

tion. NOTE: The diode is integrated in the harness near

the starter solenoid.

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