Kawasaki Ninja Service Manual: Starter Motor Disassembly

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

Starter Motor Disassembly

Pull out the armature [A] out of the yoke [B].

Starter Motor Disassembly

NOTE

Do not remove the circlip [C] from the shaft.

Remove the starter motor terminal locknut [A].

Starter Motor Disassembly

Pull out the brushes from the brush holder [A].
Remove: Brush Springs [B] Starter Motor Terminal [C] and O-ring Positive Brush Assy [D] Screw [E] Negative Brush Assy [F] Brush Holder

Starter Motor Disassembly

Starter Motor Installation

NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. Clean the starter motor legs [A] and crankcase where the starter motor is ground. Rep ...

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] Ne ...

Other materials:

Stick Coil Removal
Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Disconnect the stick coil connectors [A]. Pull out the stick coils [B] upward. First, turn the stick coil by 90 degrees, and then pull it out by twisting the coil head to the left and righ ...

Alternator Cover Installation
Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth. Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sea ...

Bolt and Nut Tightening
In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values. 1. Clutch Lever Hol ...