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:

Spring Tension Inspection
Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining s ...

Nozzle Assy Assembly
Before assembling, blow away dirt or dust from the delivery pipes [A] by applying compressed air [B]. Replace the O-rings [A] of the joint pipe [B] with new ones. Apply engine oil to the new O-rings, and insert it to the delivery pipes [C] Insert the joint pipe so that the step ...

Brake Pedal Installation
Apply grease to the brake pedal pivot shaft [A]. Install: Washers [B] Brake Pedal [C] Apply a non-permanent locking agent to the threads of the brake pedal mounting bolt [D], and tighten it. Torque - Brake Pedal Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) Install the re ...