Kawasaki Ninja Service Manual: 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.

• 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.

• 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)

• Apply thin coat of grease to the oil seal [A].

• 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].

• Assemble the yoke [A] and the end covers [B] as shown in the figure.

  “Y” Mark [C] ”I” Mark [D]

• Tighten: Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51 kgf·m, 44 in·lb)