1999 Ski-Doo Factory Shop Manual Volume Two, Page 275Get this manual
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER)
Install bushing cover no19 then, using punch, stake bushing cover in placeA19E05A
1Cut close to connector
A19E02A
Remove burrs with file on the remaining welded portion
1Stake bushing cover 2Support
CAUTION
3, Bushing (end frame)
Check the wear on bushing no3 by measuring the amount of radial play between the armature shaft and the bushingThe radial play should not exceed 0.20 mm (.008 in)If greater, replace bushing as follows: Using 12 mm tap, cut threads into bushing so that the tap contacts the end frameContinue to rotate tap until the bushing comes free1
Be careful not to damage plastic portion of yokePlace spare brush plate edge against yoke connector edge (welded portion)Crimp plate over yoke connector with pair of pliers