1996 Ski-Doo Shop Manual, Volume 1, Page 243Get this manual
Se ion ELECT RI CAL Sub-Section 05 (ELECTRIC STARTER)
REMOVAL Disconnect BLACK ground cable from battery Disconnect RED positive cable from batteiy, WARNINGAlways disconnect ground cablefirst and connect last Disconnect RED cable and RED GREEN wire from starter solenoid switch Remove stafler from engine
Insert and twist
DISASSEMBLY
Disconnect bare wire linking starter and solenoid
10,15,16, Solenoid Switch, Drive Lever and Nut
Remove nuts then solenoid switch by lifting and pulling to disengage from drive lever
AO19 004001
Twist screwdriver to separate stop collars thus giving access to circlipRemove outer collar, circlip then inner collarRemove overrunning clutch
1,2,8,17, Screw, End Frame, Yoke and Drive Housing
Unscrew starter longer screws then pull yoke with end frame to separate from drive housing
18,19, Bushing (drive housing) and Cover
Check the wear on bushing by measuring the amount of radial play between the armature shaft and the bushingThe radial play should not exceed 0.20 mm (0.008 in)If greater, replace the bushingTo replace, press out the old one toward bushing cover and press in new one with bushing pusherThe correct size of the bushing pusher to use is given on next illustration