2003 Ski-Doo ZX Series Factory Shop Manual, Page 278Get this manual
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER)
Inspect connections and clean as necessaryRelay condition can be checked with an ohmmeterInstall test probes on large connectors of relay when it is activated (+ on REDGREEN wire and on relay body for the fan cooled models and on the BLACK wire for liquid cooled models)IMPORTANT: No current must be present on large cables when using ohmmeter, otherwise meter could be damaged
A03E05A
ASSEMBLY
Fan Cooled ZX Series Prior to assembling, coat sliding surfaces and moving parts on armature shaft splines, overrunning clutch, relay plunger, drive lever and bushings with synthetic grease (PN 413 711 500)Proceed as follows for assemblingSecure drive housing in viseCAUTION: Do not overtighten since housing might be damagedInstall overrunning clutch onto armature shaftInsert inner collar onto shaftInstall new circlipCAUTION: Always install new circlip when servicingInsert outer collar being careful to match protrusions with notches of collarsUsing pair of pliers on each side of stop collars, squeeze evenly until collars sit over circlip