2004 Skidoo ZX Series Service Manual, Page 460Get this manual
Section 09 ELECTRICAL SYSTEM Subsection 05 (ELECTRIC STARTER)
Make sure that starter and engine mating surfaces are free of grimeSerious trouble may arise if starter is not properly alignedCAUTION: Make sure that both starter brackets are well seated against engine crankcase and starter before torquing all retaining boltsTorque all M8 bolts to 24 Nm (17 lbfft)Torque all M5 bolts to Nm (44 lbfin)CAUTION: Before checking engaging depth of starter pinon teeth, make sure that battery cables are disconnected NOTE: Check proper engaging depth of starter pinion teeth to ring gear teeth (see illustration)Install hardened washers (PN 503 007 900) between engine and starter supports accordinglyCAUTION: Always install new self-locking fastenersMake sure that starter and engine mating surfaces are free of grimeSerious trouble may arise if starter is not properly alignedConnect the RED battery cable and the RED wire to the large terminal of the starter
WARNING
Always disconnect ground cable first and connect lastTorque large terminal nut to Nm (62 lbfin)Connect ground cable to the starter with star washer in betweenTorque ground cable connecting bolt to 11 Nm (97 lbfin)4-TEC Engines The installation is the reverse of removal procedurePay attention to the following detailsNOTE: During assembly replace the O-ring of the starterGrease the drive gear and the O-ring before assembly using multi purpose greaseThis will simplify assembly and prevent displacement of the O-ring during installationIf it is not possible to move the starter into the guide, this is due to the position of the drive gearPull the starter out once more, slightly rotate the drive gear and try again2 1