Kawasaki Ninja Service Manual: Starter Motor Assembly

Kawasaki Ninja Service Manual / Electrical System / Electric Starter System / Starter Motor Assembly

Install the positive brush assy [A] and the starter motor terminal [B] as shown in the figure.
Replace the O-ring [C] with a new one, and install it.

Starter Motor Assembly

Install: Brush Springs [A] Negative Brush Assy [B]

Turn the stopper side [C] to inside.

Tighten: Torque - Brush Holder Screw: 3.8 N·m (0.39 kgf·m, 34 in·lb)
Install the brushes onto the brush springs.

Starter Motor Assembly

Install the following parts to the starter motor terminal [A].
Collar [B] Washer [C] Starter Motor Terminal Locknut [D]

Turn the flange of the collar to the locknut as shown in the figure.

Tighten: Torque - Starter Motor Terminal Locknut: 11 N·m (1.1 kgf·m, 97 in·lb)

Starter Motor Assembly

Apply thin coat of grease to the oil seal [A].

Starter Motor Assembly

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].

Starter Motor Assembly

Assemble the yoke [A] and the end covers [B] as shown in the figure.

“Y” Mark [C] ”I” Mark [D]

Starter Motor Assembly

Tighten: Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51 kgf·m, 44 in·lb)

Starter Motor Assembly

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]. Pull out the armature [A] out of the yoke [B]. ...

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 [B] Standard: 12.05 mm (0.4744 in.) Service Limit: 6.55 mm ...

Other materials:

Intake Air Temperature Sensor Removal
NOTICE Never drop the intake air temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the connector [A] from the intake air temperature sensor. Remove the da ...

Kawasaki Clean Air System
The Kawasaki Clean Air System (KCA) is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn. The KCA System allows extra air into the exhaust system so that the spen ...

Oxygen Sensor Installation (Equipped Models)
NOTICE Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil contact. Oil contamination from hands can reduce sensor performance. Tighten: Torque - Oxygen Sensor: 25 N·m (2.5 kgf·m, 18 ...