2003 Ski-Doo ZX Series Factory Shop Manual, Page 275Get this manual
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER)
To replace brush no6, proceed as follows: Cut brush wire close to connector at the welded portion
A19E05A
1Cut close to connector
Remove burrs with file on the remaining welded portionCAUTION: 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
Liquid Cooled ZX Series Before disassembling, trace index marks on starter housing no10 and starter housing assembly no8 to ease further assemblyRemove starter through bolts no17Separate end frame housing no14 from starter housing no10Withdraw starter housing from armature no11Brush holder no13 can be removed from end frame housing no14 by disconnecting the end frame attached brush from brush holder no13Check the radial play between the armature shaft and end frame bearingReplace the end frame bearing or replace starterIf parts are in good condition then coat with synthetic grease (PN 413 711 500) before reinstalling themPush back the collar no3 using screwdriverRemove snap ring no2Remove collar no3 and spring no4