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Starter Motor Assembly - Kawasaki KLX110 Service Manual

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Table of Contents
Electrical Starter System

Starter Motor Assembly

Smooth the commutator surface if necessary with fine
emery paper (more than #600).
Blow or wipe the parts of the starter motor to clean the
dust or any carbon particles.
Replace the oil seal with a new one.
Apply engine oil to the oil seal outer circumference.
Press in the oil seal [A].
Install the oil seal so that the marked side faces yoke side.
Install the insulator plates [B] and the brush holder plate
Install the terminal [D] trough the grommet [E] from inside
to outside.
Tighten the brush holder plate screws [F] (one screw
should be tightened with the carbon brush lead).
Torque - Brush Holder Plate Screws: 0.9 N·m (0.09 kgf·m,
8 in·lb)
Apply adhesive cement [A] to the terminal [B] as shown.
Install the terminal cover plate so that the flat side faces
Torque - Terminal Cover Plate Screws: 2.0 N·m (0.20 kgf·m,
18 in·lb)
Replace the bearing with a new one.
Press in the bearing [A] with a suitable tool.
Install the bearing with the marked side toward the pin-
ion gear.
Spin the bearing by hand to check its condition. If it is
noisy or does not spin smoothly, replace it.
Insert the (–) carbon brush spring into the brush holder
Insert the (–) carbon brush [B] into the brush holder until
it is bottomed.


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