2. Remove the starter cover and the engine
sprocket cover: see Sprocket Cover Rernoval in
Remove the 2 starter motor mounting bolts
4. Pull the starter free. pull back the rubber
boot and disconnect the starter cable at the
motor (Figure 32).
5. To install, reverse the removal steps. Note
a. Make sure the starter case terminal and
mounting bosses are clean.
b. Oil the O-ring on the end cap ofthe motor
assembly (Figure 33).
c. Make sure the starter terminal is
protected by the rubber cover.
The overhaul of a starter motor is best left to
an expert. T h i s section shows how to
determine if the unit is defective.
1. Remove the long starter motor case screws
and separate the cases.
Write down how many thrust washers
are used at each end ofthe armature and
install the s a m e nutnber when
reassembling the starter.
Clean all grease, dirt and carbon dust from
the armature, case and end covers.
Do not immerse brushes or the wire
windings in solvent or the insulation
might be damaged. Wipe the windings
with a cloth lightly moistened with
solvent and dry thoroughh.
Measure the length of the brushes (Figure
34). If a brush is worn shorter than 1/4 in.
mm). it should be replaced.
4. Inspect the condition of the commutator;
the mica in the normal commutator is cut
below the copper (Figure 35). A worn
commutator is also shown where the copper is
worn to the level of the mica.
commutator can be undercut. but it requires a
specialist. Take the job to your Kawasaki
dealer or auto electrical repair shop.
discoloration. If a pair of bars are discolored,
that indicates grounded armature coils.
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