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Starter Motor Brush Inspection; Commutator Cleaning/inspection - Kawasaki KLX110 Service Manual

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15-40 ELECTRICAL SYSTEM
Electrical Starter System
Hold the (–) carbon brush in the brush holder so that a
suitable tool [A] could hold the (–) carbon brush lead [B]
as shown.
Install the (+) carbon brush spring.
Hold the (+) carbon brush lead with a suitable tool.
Apply high-temperature grease to the oil seal lip.
Before inserting the armature [A], wrap the pinion gear
portion [B] by the vinyl tape.
Remove the suitable tool.
Check that movement of the carbon brushes is smooth
and they touch the commutator properly.
Raise the lead.
Apply high-temperature grease to the shaft end of the ar-
mature.
Install the gasket and yoke to the end cover.
Tighten:
Torque - End Cover Screws: 4.4 N·m (0.45 kgf·m, 39 in·lb)
Install the starter motor.

Starter Motor Brush Inspection

Measure the overall length [A] of each brush.
Starter Motor Brush Length
Standard:
7.0 mm (0.28 in.)
Service Limit:
3.5 mm (0.14 in.)
If any is worn down to the service limit, replace the carbon
brush.

Commutator Cleaning/Inspection

Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.

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Klx110l

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