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:

Oil and/or Oil Filter Change
To change the engine oil and replace oil filter, the engine oil drain bolt and oil filter must be removed. The oil change and oil filter replacement should be done by an authorized Kawasaki dealer. A. Engine Oil Drain Bolt A. Oil Filter WARNINGEngine oil is a toxic s ...

Brake Hose and Pipe Damage and Installation Condition Inspection
Inspect the brake hoses, pipes and fittings for deterioration, cracks and signs of leakage. The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the ...

Idle Speed Control Valve Actuator Installation
Replace the O-ring [A] with a new one. Apply engine oil to the new O-ring. Install the idle speed control valve [A] as shown in the figure. 10° [B] Tighten: Torque - Idle Speed Control Valve Actuator Retainer Screws: 2.06 N·m (0.21 kgf·m, 18 in·lb) Install th ...