2003 Ski-Doo ZX Series Factory Shop Manual, Page 90Get this manual
Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM)
7Check engineaEngine seizedOverhaul the engine8Check height of commutator micaaCommutator mica too highUndercut mica9Check field coil resistanceaShorted field coilRepair or replace yoke10Check armature resistanceaShorted armatureRepair or replace armature11Check tension of brush springsaWeak brush spring tensionReplace springs12Check yoke assembly magnetsaWeak magnetsReplace yoke assembly13Check if bushings are wornaWorn bushingsReplace bushingsSYMPTOM CONDITION TESTINSPECTION STARTER TURNS, BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEARNORMAL USE1Check clutch pinion gearaWorn clutch pinion gearReplace clutch2Check clutchaDefective clutchReplace clutch3Check bracketsaWorn or broken bracketsReplace brackets4Check movement of clutch on splinesaPoor movement of clutch on splinesClean and correct5Check clutch bushingaWorn clutch bushingReplace clutch6Check starter bushingsaWorn starter bushing(s)Replace bushing(s)