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:

Chain Slack Inspection
Set the motorcycle up on its side stand. Rotate the rear wheel to find the position where the chain is tightest, and measure the maximum chain slack by pulling up and pushing down the chain midway between the engine sprocket and rear wheel sprocket. A. Chain Slack If the ...

Intake Air Pressure Sensor #1 Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Disconnect the intake air pressure sensor #1 connector and connect the measuring adapter [A] between these con ...

Alternator Rotor Removal
Remove the alternator cover (see Alternator Cover Removal). Clean off the oil from the outer circumference of the rotor. Hold the alternator rotor steady with the rotor holder [A] and suitable washer or plate [B]. Special Tools - Grip [C]: 57001-1591 Rotor Holder: 57001-1666 Flywheel P ...