Kawasaki Ninja Service Manual: Commutator Cleaning and Inspection

Kawasaki Ninja Service Manual / Electrical System / Electric Starter System / 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.

Commutator Cleaning and Inspection

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.

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 ...

Armature Inspection

Using the × 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 readin ...

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Drive Chain Lubrication Condition Inspection
If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. NOTICE The O-rings between the side plates seal ...

Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. Special Tool - Inside Circlip Pliers: 57001-143 Unscrew the locknut [E] and pivot bolt ...

Camshaft, Camshaft Cap Wear Inspection
Remove the camshaft caps (see Camshaft Removal). Cut the strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Tighten the camshaft cap bolts and upper camshaft chain guide bolts to the specified ...