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:

Stator Coil Installation
Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) 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 clea ...

Intake Air Temperature Sensor Resistance Inspection
Remove the intake air temperature sensor (see Intake Air Temperature Sensor Removal). Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with ...

Starter Clutch Assembly
Install the one-way clutch [A] to the driven gear. Face the circlip side of the one-way clutch to inside. Install the new snap ring [B] to the one-way clutch. Install the drive gear [C] while turn it counterclockwise [D]. Apply molybdenum disulfide oil solution to the needle bearing ...