Starter motor disassembly
Remove:
- Starter Motor (see Starter motor removal)
Take off the starter motor through bolts [A] and remove both end covers [B] and pull the armature out of the yoke [C].
![](https://motoinstruction.ru/img/kawasaki/13/119540.jpg)
Remove:
- Terminal Locknut and Washers
- O-ring
Remove the brush plate assy [A] from the yoke [B].
![](https://motoinstruction.ru/img/kawasaki/13/119541.jpg)
Remove the brush plate [A] from the terminal bolt assembly [B].
![](https://motoinstruction.ru/img/kawasaki/13/119542.jpg)
Note. Do not remove the negative carbon brushes form the brush plate.
Starter motor assembly
Install the terminal assembly [A] to the yoke [B].
Install the brush plate assy to the yoke.
![](https://motoinstruction.ru/img/kawasaki/13/119543.jpg)
Install the brush plate [A] on the terminal bolt assembly.
![](https://motoinstruction.ru/img/kawasaki/13/119544.jpg)
Insert the suitable plates [A] between the springs and brush holders.
Install the armature [B], and pull out the suitable plates to release the springs.
![](https://motoinstruction.ru/img/kawasaki/13/119545.jpg)
Install the new O-ring [A] as shown.
Install:
- Washers [B] and Terminal Locknut [C]
Tighten:
- Torque-Starter Motor Terminal Locknut: 11 N·m (1.1 kgf·m 97 in·lb)
![](https://motoinstruction.ru/img/kawasaki/13/119546.jpg)
Align the lines [A] on the yoke with the end cover lines [B].
Tighten the through bolts.
- Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)
![](https://motoinstruction.ru/img/kawasaki/13/119547.jpg)
Brush inspection
Measure the length of each brush [A].
★ If any is worn down to the service limit, replace the brush plate assy [B] and the terminal bolt assy [C].
Starter motor brush length:
- Standard: 12 mm (0.47 in.)
- Service Limit: 6.0 mm (0.24 in.)
![](https://motoinstruction.ru/img/kawasaki/13/119548.jpg)
Commutator cleaning and inspection
Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.
![](https://motoinstruction.ru/img/kawasaki/13/119549.jpg)
Measure the diameter [A] of the commutator [B].
![](https://motoinstruction.ru/img/kawasaki/13/119550.jpg)
★ If the commutator diameter is less than the service limit, replace the starter motor with a new one .
Commutator diameter:
- Standard: 28 mm (1.10 in.)
- Service Limit: 27 mm (1.06 in.)
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
![](https://motoinstruction.ru/img/kawasaki/13/119551.jpg)
★ 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.
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] Brush Plate and Negative Brushes [B]
- Special Tool - Hand Tester: 57001-1394
![](https://motoinstruction.ru/img/kawasaki/13/119552.jpg)
★ If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assy and/or the brush plate assy.
Brush plate and terminal bolt inspection
Using the highest hand tester range, measure the resistance as shown.
- Terminal Bolt and Brush Plate [A]
- Terminal Bolt and Negative Brush Holders [B]
- Terminal Bolt and Yoke [C]
![](https://motoinstruction.ru/img/kawasaki/13/119553.jpg)
- Special Tool - Hand Tester: 57001-1394
![](https://motoinstruction.ru/img/kawasaki/13/119554.jpg)
★ If there is any reading, the brush plate assy and/or terminal bolt assy have a short. Replace the brush plate assy and the terminal bolt assy.