Starter Motor Removal
Caution: Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.
- Remove the throttle body assy (See Throttle Body Assy Removal in the Fuel System (DFI) chapter).
- Slide back the rubber cap [A].
- Remove the starter motor cable terminal nut [B].
![](https://motoinstruction.ru/img/kawasaki/23/129171.jpg)
- Remove the mounting bolts [A].
- Pull out the starter motor [B].
![](https://motoinstruction.ru/img/kawasaki/23/129172.jpg)
Starter Motor Installation
Caution: Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.
- When installing the starter motor, clean the starter motor legs [A] and crankcase [B] where the starter motor is grounded.
![](https://motoinstruction.ru/img/kawasaki/23/129173.jpg)
- Replace the O-ring [A] with a new one.
- Apply grease to the O-ring.
- Apply a non-permanent locking agent to the threads of the bolts and tighten the bolts.
Torque - Starter Motor Mounting Bolts: 9.8 Nm (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/129174.jpg)
- Position the starter motor cable [A] as shown.
- About 20° [B]
- Front [C]
Tighten:
Torque - Starter Motor Cable Terminal Nut: 6.0 Nm (0.61 kgf·m, 53 in·lb)
- Slide back the rubber cap to the original position.
![](https://motoinstruction.ru/img/kawasaki/23/129175.jpg)
Starter Motor Disassembly
- Remove the starter motor (See Starter Motor Removal).
- Take off the starter motor through bolts [A] and remove the both end covers [B].
![](https://motoinstruction.ru/img/kawasaki/23/129176.jpg)
- Pull out the armature [A] out of the yoke [B].
Note: Do not remove the circlip [C] from the shaft.
![](https://motoinstruction.ru/img/kawasaki/23/129177.jpg)
- Remove the starter motor terminal locknut [A].
![](https://motoinstruction.ru/img/kawasaki/23/129178.jpg)
- Pull out the brushes from the brush holder [A].
Remove:
- Brush Springs [B]
- Starter Motor Terminal [C]
- Positive Brush Assy [D]
- Screw [E]
- Negative Brush Assy [F]
Brush Holder
![](https://motoinstruction.ru/img/kawasaki/23/129179.jpg)
Starter Motor Assembly
- Be sure that the stopper [A] is in position.
- Align the hole [B] of the brush holder [C] to the boss [D] of the right-hand end cover [E].
![](https://motoinstruction.ru/img/kawasaki/23/129180.jpg)
- Align the stoppers [A] of the negative brush assy [B] to the grooves [C] of the brush holder [D].
- Tighten the screw securely.
![](https://motoinstruction.ru/img/kawasaki/23/129181.jpg)
- Align the stoppers [A] of the positive brush assy [B] to the grooves [C] of the brush holder [D].
Install the starter motor terminal.
![](https://motoinstruction.ru/img/kawasaki/23/129182.jpg)
- Replace the O-ring [A] with a new one.
- Install the following parts to the starter motor terminal [B].
- New O-ring
- Collar [C]
- Washer [D]
- Starter Motor Terminal Locknut [E]
lnstall the collar so that stepped side faces outward.
Tighten:
Torque - Starter Motor Terminal Locknut: 11 Nm (1.1 kgf·m, 97 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/129183.jpg)
- Install the brush springs [A] and insert the brushes [B].
![](https://motoinstruction.ru/img/kawasaki/23/129184.jpg)
- Apply thin coat of grease to the oil seal [A].
![](https://motoinstruction.ru/img/kawasaki/23/129185.jpg)
- Replace the O-rings [A] with new ones.
- Insert the armature [B] so that commutator side [C] faces hollow side [D] of the yoke [E].
![](https://motoinstruction.ru/img/kawasaki/23/129186.jpg)
- Align the marks [A] to assembly the yoke and the end covers [B].
![](https://motoinstruction.ru/img/kawasaki/23/129187.jpg)
- Replace the O-rings [A] with new ones.
- Tighten the through bolts [B].
Torque - Starter Motor Through Bolts: 4.9 Nm (0.50 kgf·m 43 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/129188.jpg)
Brush Inspection
- Measure the length of each brush [A].
If any is worn down to the service limit, replace the brush assy.
Starter Motor Brush Length
Standard: 12 mm (0.47 in.)
Service Limit: 6.5 mm (0.26 in.)
![](https://motoinstruction.ru/img/kawasaki/23/129189.jpg)
Commutator Cleaning and Inspection
- Clean the metallic debris off the between commutator segments [A].
Note: Do not use emery or sand paper on the commutator.
- Check the commutator for damage or abnormal wear.
Replace the starter motor with a new one if there is any damage or wear.
- Visually inspect the commutator segments for discoloration.
Replace the starter motor with a new one if discoloration is noticed.
![](https://motoinstruction.ru/img/kawasaki/23/129190.jpg)
Armature Inspection
- Using the x 1 Ω hand tester range, measure the resistance between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
If there is a high resistance or no reading (~) between any two segments, a winding is open and the starter motor must be replaced.
- Using the highest hand tester range, measure the resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and the starter motor must be replaced.
![](https://motoinstruction.ru/img/kawasaki/23/129191.jpg)
Note: Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
Brush Lead Inspection
- Using the x 1 Ω hand tester range, measure the resistance as shown.
- Terminal Bolt and Positive Brushes [A]
- Right-hand End Cover and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assy.
![](https://motoinstruction.ru/img/kawasaki/23/129192.jpg)
Right-hand End Cover Inspection
- Using the highest hand tester range, measure the resistance as shown.
- Terminal Bolt and Right-hand End Cover [A]
- Terminal Bolt and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is any reading, the brush assy and/or terminal bolt assy have a short. Replace the starter motor.
![](https://motoinstruction.ru/img/kawasaki/23/129193.jpg)
Starter Relay Inspection
- Remove the battery negative (-) cable from the battery negative (-) terminal (see Battery Removal).
Remove:
- Right Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter)
- Bolt [A]
- Cover [B]
![](https://motoinstruction.ru/img/kawasaki/23/129194.jpg)
- Disconnect the connector [A].
- Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D].
![](https://motoinstruction.ru/img/kawasaki/23/129195.jpg)
- Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Tester Range: x 1 Ω range
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
![](https://motoinstruction.ru/img/kawasaki/23/129196.jpg)
Electric Starter Circuit
![](https://motoinstruction.ru/img/kawasaki/23/129197.jpg)
1. Ignition Switch; 2. Water-proof Joint B; 3. Starter Lockout Switch; 4. Ignition Fuse 10 A; 5. Fuse Box; 6. Starter Circuit Relay; 7. Relay Box; 8. Starter Motor; 9. Starter Relay; 10. Main Fuse 30 A; 11. Battery 12 V 10 Ah; 12. Sidestand Switch; 13. Frame Ground; 14. Joint Connector; 15. Neutral Switch; 16. Water-proof Joint C; 17. Starter Button; 18. Engine Stop Switch