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:

Intake Air Temperature Meter
Intake air temperature meter indicates temperature of the air in the air cleaner case. The “Intake Air” is displayed if the intake air temperature meter is selected. A. Intake Air Temperature Meter B. “Intake Air” NOTE The intake air temperature meter shift to the coolant temp ...

Balancer Installation
Position the crankshaft at #2, 3 positions TDC or at #1, 4 positions TDC. Install the balancer assembly as follows. Align the punch mark [A] on the weight and the projection [B] on the crankcase. Engage the balancer gear and the crankshaft gear. Insert the balancer shaft until it is bot ...

Spark Plug Condition Inspection
Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. If the spark plug is ...