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 ...

Other materials:

Brake Disc Warp Inspection
Raise the wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 For front disc inspection, turn the handlebar fully to one side. Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the ...

Oil Level Inspection
If the oil has just been changed, start the engine and run it for severalminutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles. NOTICE Racing the engine before the oil reaches every part can cause engine seizure. ...

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 ...